Glaze Slurry Viscosity Control in the Ceramic Tiles Industry

Defects like color differences, coating thickness variation and even cracks are driven by variation in glaze viscosity. Inline viscosity meter or monitor enable intelligent management of glaze density or viscosity while reducing repetitive manual sampling.

The ceramic tile industry has witnessed dramatic changes over the past decades. More and more manufacturers of sanitaryware, ceramic tiles, and tableware/pottery import fully automated manufacturing process to keep consistent quality and productivity. Then those manufacturers are able to figure out common defect in the manufacturing process. 

Benefits of Glaze Slurry Control

Precise control of glaze slurry viscosity is a game-changer for the ceramic tiles industry. Maintaining optimal viscosity ensures uniform glaze coating thickness, which directly impacts the final product’s quality. Automated viscosity monitoring eliminates manual inconsistencies, reducing waste and improving efficiency in sanitaryware plants and ceramic tiles factories. Key benefits include:

• Enhanced Product Quality: Consistent viscosity minimizes defects like pinhole defects in coating and bubble defects in coating, ensuring a smooth, durable finish.
• Increased Productivity: Automation reduces downtime caused by manual adjustments, allowing tableware/pottery factories to scale production.
• Cost Savings: By minimizing glaze wastage and rework, manufacturers can lower material and labor costs.
• Compliance with Standards: Precise control ensures tiles meet aesthetic and functional requirements, critical for high-end applications.

With inline viscosity monitors, manufacturers gain real-time insights, enabling proactive adjustments to maintain coating consistency throughout production.

Common Defects Caused by Inconsistent Viscosity

Inconsistent viscosity in glaze slurry is a primary cause of defects in ceramic tile production. These defects not only affect the visual appeal but also reduce the service life of tiles. Below are the most common issues:

• Pinhole Defects in Coating: Caused by gases from the tile body escaping through insufficiently liquid glaze, pinholes create small, visible holes on the surface, compromising impermeability.)
• Bubble Defects in Coating: Large bubbles that fail to heal during firing result in surface imperfections. Adjusting viscosity—either higher to trap bubbles below the surface or lower to allow quick escape—can mitigate this issue.
• Orange Peel Coating Defect: High viscosity and surface tension prevent bubbles from escaping, leaving depressions on the glaze surface during cooling.
• Color Variations: Viscosity fluctuations lead to uneven glaze application, causing inconsistent color across tiles, a frequent issue in ceramic tiles factories.

These defects highlight the need for robust viscosity monitoring to ensure coating consistency and reduce reject rates.

Application in Glaze Feeding Systems

Modern glaze feeding systems, such as bell glaze feed systems, rely on precise control to deliver consistent glaze application. These systems use a metallic pipe with a pumping mechanism to maintain a constant glaze height, controlled by a valve and nozzle. However, manual adjustments often fail to account for viscosity variations caused by temperature changes or material inconsistencies. Integrating an inline viscosity monitor into these systems allows real-time measurement and adjustment of glaze viscosity. This ensures a steady flow rate, reducing defects like pinhole defects in coating and bubble defects in coating. For sanitaryware plants and tableware/pottery factories, automated viscosity control streamlines glaze application, enhancing throughput and quality.

Outcomes of Varying Viscosity in Glazing Operations

Variations in glaze viscosity directly impact the quality and efficiency of glazing operations. High viscosity can lead to orange peel coating defects and uneven glaze distribution, while low viscosity may cause excessive flow, resulting in thin coatings and pinhole defects in coating. These inconsistencies increase reject rates, raise production costs, and delay delivery schedules. By implementing viscosity monitoring, manufacturers can stabilize glaze flow, ensuring uniform glaze coating thickness and minimizing defects. Real-time data from inline viscosity monitors enables operators to adjust parameters instantly, maintaining coating consistency even under fluctuating conditions like temperature or humidity changes. This results in higher-quality tiles and improved operational efficiency across ceramic tiles factories and sanitaryware plants.

Parameters

• Viscosity Range:1 – 1,000,000 cP

• Accuracy:±3.0%

• Repeatability:±1%

• Temperature Accuracy:1.0%

• Sensor Pressure Range:< 6.4 MPa (Customized for pressures above 10 MPa)

• Environmental Grade: IP68

• Power Supply:24 VDC

• Output:Viscosity 4 – 20 mADC

• Temperature:4 – 20 mADC Modbus

• Protection Level:IP67

• Explosion-proof Standard:ExdIIBT4

• Temperature Resistance Range:< 450℃

• Signal Response Time:5s

• Material:316 Stainless Steel (Standard Configuration)

• Calibration:Standard sample liquid

• Connection:Flange DN4.0, PN4.0

• Threaded Connection:M50*2

• Flange Standard:HG20592

Product Solution for Viscosity Monitoring

Lonnmeter offers cutting-edge inline viscosity monitors designed to address the challenges of glaze slurry management in the ceramic tiles industry. Our solutions provide real-time viscosity and temperature measurements, enabling precise control of glaze properties. Key features include:

• High Accuracy: Lonnmeter sensors deliver repeatable measurements for both Newtonian and non-Newtonian fluids, ensuring reliable data for complex glaze slurries.
• Easy Integration: Plug-and-play installation in mixing tanks or pipelines takes less than 30 minutes, minimizing downtime in ceramic tiles factories.
• Robust Design: Hermetically sealed, 316L stainless steel sensors are resistant to particulate matter and require no maintenance, ideal for harsh industrial environments.
• Temperature Compensation: Built-in temperature sensors ensure accurate viscosity readings, critical for maintaining coating consistency under varying conditions.

The on-line process viscometer, an on-line viscometer designed for real-time measurement, oscillates at a certain frequency along its axial direction. The conical sensor shears fluids when fluids flow over the sensor, then the lost energy is calculated according to the change in viscosity. The energy is detected by the electronic circuit and converted to displayable readings by the in-line process viscometer. Since fluid shearing is realized by vibration, it could withstand pressure for its simple mechanical structure — no moving parts, seals and bearings.

By automating viscosity control, Lonnmeter solutions reduce defects like bubble defects in coating and orange peel coating defects, enhancing product quality and operational efficiency in sanitaryware plants and tableware/pottery factories.

Common Questions About Glaze Viscosity Monitoring

Why is viscosity monitoring critical in the ceramic tiles industry?

Viscosity monitoring ensures consistent glaze coating thickness, reducing defects like pinhole defects in coating and bubble defects in coating. It improves product quality and minimizes waste in ceramic tiles factories.

How does an inline viscosity monitor improve coating consistency?

An inline viscosity monitor provides real-time data, allowing automated adjustments to glaze flow. This maintains coating consistency, preventing issues like orange peel coating defects and ensuring uniform tile appearance.

Can viscosity monitoring reduce production costs?

Yes, by minimizing glaze wastage and reducing reject rates caused by defects, viscosity monitoring lowers material and labor costs, boosting efficiency in sanitaryware plants and tableware/pottery factories.

Conclusion

In the ceramic tiles industry, achieving flawless glaze coating thickness and coating consistency is essential for producing high-quality tiles free from pinhole defects in coating, bubble defects in coating, and orange peel coating defects. By adopting advanced viscosity monitoring with inline viscosity monitors, manufacturers in sanitaryware plants, ceramic tiles factories, and tableware/pottery factories can enhance product quality, reduce waste, and improve operational efficiency. Lonnmeter’s innovative solutions offer real-time control, ensuring consistent glaze application and minimizing costly defects. Ready to optimize your ceramic production? Request a quote today to discover how Lonnmeter can transform your glazing process!