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For One Tableware Application, One Plaster Solution

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For One Tableware Application, One Plaster Solution 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 slip 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 Earthenware Jiggering ram press Case Stoneware 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 + CLAY 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 FLUIDITY innovative technology 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%) TIME & Fluidity of MC plasters remains stable during pouring 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
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