How Ceramic Tiles are Made : From Raw Clay to Shining Surface

Step 5 - Controlled Drying

Freshly pressed green tiles still contain moisture from the spray-dried powder. If they are fired in this state, the water would turn into steam and cause cracks or even break the tile apart. To prevent this, the tiles go through controlled drying.

In large drying chambers, warm air is circulated around the tiles to remove the moisture slowly and evenly. The process is carefully monitored, because drying too fast can make the tile warp, while drying too slow wastes time and energy.

By the end of this stage, the tiles are strong enough to handle the next steps without damage. They now have a stable shape and are ready for glazing and firing.

Step 6 - Glazing Digital Decoration

Once the dried tiles are ready, they move on to glazing. A thin liquid layer of glaze is applied on the tile surface. This glaze works like a glassy coat that seals the tile body, adds strength, and prepares it for decoration. It also gives the tile its final glossy, matte, or textured finish.

After glazing, the tiles enter the digital decoration stage. Modern factories use high-tech digital printers to spray designs directly onto the glazed surface. Just like printing on paper, these machines can create anything from marble and stone effects to wood patterns or even custom graphics. This technology allows every tile to look natural, stylish, and unique.

By the end of this step, the tiles have both protection and beauty—the plain clay body has started to transform into something visually appealing and durable.

Step 7 - Firing (Sintering)

This is the stage where the tile truly becomes a tile. The glazed and decorated green tiles are placed into a long tunnel kiln. Inside, the temperature rises gradually, often reaching over 1,200°C.

fuses the raw materials together. This process is called sintering. The clay hardens, the feldspar melts slightly to act like a glue, and the glaze turns into a smooth, glassy layer on the surface.

The result is a tile that is strong, dense, and durable. Its final strength, color, and finish all come from this firing stage. Without it, the tile would remain weak and breakable.

Step 8 - Finishing Edge Work

After firing, the tiles are strong and durable, but they still need some finishing touches. In this stage, the edges are trimmed and polished to make sure each tile has the correct size and shape. Some tiles also go through grinding machines to achieve perfectly straight edges, a process often called rectification.

This edge work makes it easier to install the tiles with thin, even grout lines. For certain designs, the surface may also be polished or given a matte finish to match the desired look.

By the end of this step, the tiles are not only strong but also refined, ready to be checked for quality before reaching the showroom.

Step 9 - Quality Control Performance Ratings

Before the tiles reach the market, they go through strict quality control checks. Each batch is carefully inspected for cracks, color consistency, surface smoothness, and edge accuracy. Any tiles with visible defects are separated and discarded.

Beyond appearance, the tiles are also tested for performance ratings. This includes measuring water absorption, checking surface hardness, slip resistance, and strength under pressure. These tests ensure the tiles can handle real-life conditions - whether thats heavy foot traffic in a shopping mall or constant cleaning in a bathroom.

Only the tiles that meet international and local standards are approved. This step guarantees that customers get tiles that are not just beautiful but also reliable and long-lasting.

Ending Note

Even though ceramic tiles come with different designs, patterns, and textures, the core process of manufacturing tiles is almost the same. Some tiles such as porcelain, mirror finished tiles etc might require some extra steps to get the expected output. If you are more curious, you can check out our video on how DBL Ceramics manufacture ceramic tiles provided in the middle of this discussion.