For one Tableware application, one plaster solution

Industrial plasters, engineered to perform Arts & Decoration

Personal Care

Ceramics Saint-Gobain Formula is a world-leading supplier of industrial plaster and gypsum products. Formerly the Gypsum & Plaster for Construction Materials industrial plaster division of BPB, Saint-Gobain Formula is now part of Saint-Gobain Company, one of the top Metal Casting 100 industrial groups in the world.

Food/Feed, Environment Saint-Gobain Formula aims to be the world’s preferred choice & Agriculture for industrial gypsum and plasters, with leading product brands in all markets such as Ceramics, Gypsum & Plaster for Construction Materials, Arts & Decoration, Metal Casting, Personal Care, Agriculture, Food & Environment. Saint-Gobain and Formula in the world ...... p 2

The tableware process ...... p 4

Best practice ...... p 5

Slip casting ...... p 6

Jiggering ...... p 8

Ram Press ...... p 10

Case Mould ...... p 12

1 - TABLEWARE APPLICATION Today, the Ceramic market with its many applications represents one of our most important strategic areas which is key to the continued success of Saint-Gobain Formula. Saint-Gobain Formula largely operates in markets located in Europe, Asia, Africa and the Middle East.

In all ceramic applications (sanitaryware, tableware and rooftiles), mould properties and performance are key to achieving high quality finished items. Saint-Gobain Formula’s ceramic plasters are highly valued for their technical proper- ties, which include controlled porosity, mechanical strength to ensure mould durability, dimensional accuracy and perfect reproduction of fine detail, design flexibility and ease of use compared to other techniques.

TABLEWARE APPLICATION - 2 Saint-Gobain Formula offers a comprehensive range of tableware plaster formulations from its operations in Germany and Thailand for casting, jiggering, ram press processes and case moulds with dedicated products adapted to specific customer requirements.

For over 100 years, Saint-Gobain Formula, has specialized in the formulation of industrial plasters, working with customers by providing a high level of customer service and assistance in over 90 countries as well as technical support. Through product and supply chain innovation, Saint-Gobain Formula aims to build long term customer partnerships around the world by operating in 8 countries. Saint-Gobain Formula was founded, bringing together the industrial plaster activity of 4 major international industrial plaster specialists. (Germany, France, UK, Spain). Since that time, Saint-Gobain Formula has acquired companies and manufacturing sites in Romania, Turkey, Egypt, and Thailand.

3 - TABLEWARE APPLICATION Tableware Manufacturing Process

CLAY FABRICATION MOULD SHOP The range of manufacturing techniques used to produce ceramic tableware is very wide. Almost all make use of plaster: l  for designing and making the original model (modelling) l  for making the ‘tooling (block mould and case mould (case) l to make the working moulds from the case mould (generally for slip casting, jiggering, or ram press processes) CASTING

1ST CALCINATION GLAZING

2ND CALCINATION WHITE TABLEWARE QUALITY CONTROL

DECORATION PACKAGING Source : Pillivuyt Source

Choice of the plaster Saint-Gobain FORMULA, Advantage Best value for money for each manufacturing process. of using plaster:

& Slip Casting Ease of use: by simply Applications Bone China Jiggering Ram Press Case adding water and mixing mechanically & Quality of the Mould reproduction: properties

Porosity Hardness shape, dimensions and

▼ ▼ ▼ fine details & Moulding behavior: Porosity Absorption Permeability Permeability controlled sets quickly to the desired shape Easy demoulting Expansion Dimmenisionnal - Easy demoulting Dimmenisionnal & High level of homogeneity controlled accuracy accuracy after it has set

Key parameters Key Particle size Reproduction Reproduction Reproduction Reproduction & Easy reworking distribution of details of details of details of details

TABLEWARE APPLICATION - 4 + FABRICATION MOULD SHOP + ++ Best practice

CASTING Plaster to water ratio : Blending

• Weigh each mix accurately • Use only mechanical blending • Always add plaster to the water, NOT water to plaster •Type of blenders: • Allow the plaster to soak at least one minute (to help remove the air and allow each particle to be satura- Type of Blender: 1ST CALCINATION GLAZING ted with water) 3 blade propeller • Respect mixing ratio mentioned in our Product Diameter of the blade : Datasheet: ¼ to 1/3 high of the – Plaster to water ratio too high: plaster becomes mixing bucket too thick and is liable to lead to air bubble entrap- Mixing speed: ND WHITE TABLEWARE QUALITY CONTROL 2 CALCINATION ment 200 rpm to 400 rpm Mixing time: 2 to 5 minutes

Type of Blender:

DECORATION PACKAGING Defloculating Turbine Diameter of the blade : Less than ¼ of the mixing bucket Mixing speed: 900 to 1500 rpm Mixing time: 2 to 5 minutes

• Use automatic equipment to ensure perfectly repro- ducible conditions everytime – Plaster to water ratio too low: Plaster particles may sink before the plaster sets (giving an uneven qua- Type of water: lity and abnormal mould swelling, with the addi- tional risk of hairline cracks). Tiny air bubbles may • Low dissolved salt (< 400 ppm), to avoid risk of be trapped under mould surface which will start to efflorescence appear as the mould starts to wear. A low plaster to •Temperature between 15°C and 20 °C water ratio increases the mould’s absorption capa- city to the detriment of its mechanical strength Drying

Cleaning • Good drying ensures good mechanical properties and consistent mould life • Gypsum is a very powerful setting accelerator. Clean • Drying should start 10-12 hours (minimum) all the blending equipment after every mix is highly after mould making recommended • Temperature < 40°C in dry condition

5 - TABLEWARE APPLICATION The casting technique, in which clay slip comprised of a specific formulation of ceramic minerals suspension in water, is poured into VSlip casting plaster moulds, is the basic technique used for the production of ceramic items.

Absorption High porosity

Clay into plaster mould

Remove Demouling Excess Slurry

The porosity of the plaster mould absorbs the water in the slurry Water absorprtion and thus causes a deposit of material to form on the inner wall of (from clay to plaster) the mould, taking the shape of the mould. The thickness of this ➔ Formation of the skin “skin” is proportional to the time for which it is allowed to form.

TABLEWARE APPLICATION - 6 innovative technology FLUIDITY MULTICASTING PRODUCTS (various P/W) Initial { Multicasting plaster Supraduro MC multicasting plaster range has been COMPETITOR PLASTER developed to improve absorption rate and mould life. End of casting Our Multicasting products allow customers to improve productivity by increasing the number of casts in the same period of time.

Multicasting plaster characteristics include: Start of casting EST Porosity is not affected by a variation of PWR (+/– 20%) & Fluidity of MC plasters remains stable during pouring TIME Casting time of traditional plaster & Plaster can be poured as soon as it has been blended IST tract product Casting time of multicasting product & Casting time is longer, even though the plaster starts IST multicasting product to set earlier

Mechanical strength of the moulds is significantly impro- ved, thus enabling quicker release and improved mould behaviour. KEY FIGURES & Up to 20 % increase in mould life Saint-Gobain Formula MC Innovative & Up to casts/day technology, is the most adapted solution 5 to optimize performance and & Stable mould making process effectiveness of your process.

Products

Product Manufacturing site PWR Initial setting time Benefits

- High absorption capability Molda TW 75 Thailand 1.33 6-18 min - Available in long or short setting time - Can be also used to produced short series products in Jiggering

- Multicasting plaster Supraduro MC 70 Thailand 1.43 15-20 min - High absorption capability

- Excellent for slip casting Almod 60 Germany 1.45 10-15 min - Good balance between mechanical properties and absorption capability

- Fine particle size Molda SN 75 C Thailand 1.50 10-15 min - Good balance between absorption and mechanical behaviour - Stable workability

- Fine particle size Molda SN 75 E Thailand 1.50 12-15 min - High absorption capability - Stable workability

- Multicasting plaster Supraduro MC 65 Thailand 1.55 15-20 min - High mechanical strength - High absorption capability

Multicasting Plaster

7 - TABLEWARE APPLICATION To improve productivity in ceramic piece manufacturing, the jigge- ring and jollying techniques were developed using malleable clay VJiggering bodies, formed on plaster moulds, for all pieces that have an axis of revolution (circular profile: plates, cups, etc.).

Harder plaster

Permeability

TABLEWARE APPLICATION - 8 Plaster properties – Choice of the plaster Saint-Gobain Formula can evaluate • Mould life is significantly extended compare to casting customer requirement and propose the best process/moulds value for money according to the mould life • Harder plaster and/or plaster offering a higher plaster requirement (depending of the production to water ratio is used organization, process habits or tableware • Mould porosity is no longer a critical quality; overriding series size). quality here is air permeability to enable effective use of the vacuum suction

Products

Product Manufacturing site PWR Initial setting time Benefits

- Multicasting plaster Supraduro MC 70 Thailand 1.43 15-20 min - High absorption capability

- Multicasting plaster Supraduro MC 65 Thailand 1.55 15-20 min - High mechanical strenght - High absorption capability

- Good balance between mechanical properties and permeability Molda TW 63 Thailand 1.63 7-11 min - Controlled in expansion

Keram Pink Germany 1.64 10-15 min - High permeability

- Good balance between permeability and mechanical strength Keram Blue Germany 1.75 10-15 min - Expansion controlled

- High mechanical properties Molda TW 56 Thailand 1.80 6-10 min - Very fine surface detail - Controlled expansion

- Expansion controlled Keram 52 Germany 1.92 9-14 min - Very high strength

Multicasting Plaster

9 - TABLEWARE APPLICATION Ceramic body with high plasticity is shaped by exerting pressure, using two halves of a mould made of very hard plaster, embedded VRam Press with a porous network of porous non-metallic flexible tubes/air hose.

Very Hard plaster Permeability Air network

Thanks to our expertise around the Air is blown into this network during the setting process thereby world Saint-Gobain Formula can provide ensuring that the mould is porous enough, to enable the clay piece technical support on mould making process. to be demoulded after it is formed.

Plaster properties – Choice of the plaster • Mould life: more than 1000 pieces can be pressed depending on the raised surface pattern, the type of plaster and the manufactu- rer’s quality requirements • Ram press moulds are formulated in order to insure best mecha- nical properties and to help the permeability required to evacuate water included in the clay • Dimensional expansion of plaster mould is more important. Formula specifically controls expansion of every ram press product

TABLEWARE APPLICATION - 10 + + ++ Best practice | Ram Press

Plaster preparation specificities: Installing porous air hose

Galvanised Gird To hold the air horse

Air hose diameter 5 to 6 mm

Air hose position 25 mm to 30 mm distance from the shape

Air hose position 25 mm distance between 2 lines

Air hose position 30 mm minimum distance from the edge 6

from the centre Air blowing input 5 to the edge

4 Specificity of plaster mixing 3 • Controlled slip temperature • Mechanical mixing: mixing time from 2 Air Pressure (in bar) Air Pressure 5 to 10 min • Compressed air activation: 1 – Push the thermometer into the plaster to a 2cm depth 0 20 25 30 35 40 45 – The compressed air circuit should be Time after plaster pouring connected (manometer set to 0) during Time (min) Pressure (bar) Step the minute following the end of setting 0 0 Plaster introduction to water (measured with Duromoter Shore 20 0 Initial setting time 32.5 1.5 First water A = 40), this correspond to a rise of 5°C 35 3 Mould removing in temperature 45 5 All the water is exuded

Products

Product Manufacturing site PWR Initial setting time Benefits

- High strength Keradur 4000P Germany 3.00 19-25 min - Controlled in expansion

- Good permeability Duropress Germany 2.86 21-26 min - Controlled in expansion

11 - TABLEWARE APPLICATION VCase Mould

Saint-Gobain Formula pro-

poses extreme hardness and

flawless dimensional stabi-

lity plasters for case moulds.

Such moulds are used to pre-

pare working moulds for cas-

ting, jiggering and ram press

applications

Products

Product Manufacturing site PWR Initial setting time Benefits

- High strength Exaduro Germany 3.00 10-15 min - Controlled in expansion

- Very high strength Olafdur Germany 3.33 9-14 min - Very high dimensional accuracy (limited in expansion)

TABLEWARE APPLICATION - 12 For one Tableware application, one plaster solution Saint-Gobain Formula serves all these markets

Arts & P ersonal Care Decoration

Gypsum & Plaster Ceramics for Construction Materials

Food/Feed, Environment Metal Casting & Agriculture

www.saintgobainformula.com

[email protected] +33 (0) 6 01 96 31 Da Cruz Silva January 2015 - Design : Carlos +62-21 24520522

Thailand Germany Thai Gypsum Products PCL. Saint Gobain GmbH Gypsum Metropolitan Tower 539/2 Kutzhütte Sri Ayutthaya Road, Ratchathewi 37445 Walkenried Bangkok 10400, Thailand Germany +66 2 640 8600 +49 (0)55 25 20 30