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Testing custom colors according to customer's requirements and preparing copper divider molds as well as pressing molds based on order requests. This step determines the pattern accuracy, tile dimensions, and surface quality.
Step 2: Pattern Filling
The copper pattern divider is placed into the pressing mold. Pre-mixed colored cement is carefully poured into each compartment according to the design.
Step 3: Base Layer Application
After removing the pattern divider, the colored face layer is covered with the required cement mortar backing layers. The materials are carefully leveled and compacted to ensure consistent thickness across all the tiles.
Step 4: Hydraulic Pressing
The assembled mold is placed into a hydraulic press and compressed under controlled pressure to form the tile.
Step 5: Demolding & Inspection
The tiles are carefully demolded by skilled craftsmen and individually inspected for pattern accuracy, surface quality, dimensions, and visible defects before curing.
Step 6: Curing
The freshly demolded tiles are initially air-cured under controlled conditions, followed by water curing in curing tanks to achieve the required strength and durability.
Step 7: Final Inspection & Finishing
After curing, the tiles are cleaned and dried on racks for 3-4 days until the moisture content is below 17%. Each tile undergoes final quality inspection before waxing, packing, and loading.
