Product Knowledge and Quality complaints in Tiles

Company Profile

Established in 1953, NITCO Group has a history of over 60

meritorious years in the Indian Ceramic industry.

The Company is one of the largest manufacturer and

exporter of Flooring Tiles in India, with Production

capacity of approx. 40000 sq. meters per day

NITCO Group spans the entire length and breadth of the

country with 3 factories and offices in major metropolitan

cities of India

NITCO Group is a winner of best Export Award for 12 years

and also the Udyog Ratna Award

NITCO Group is a Rs.800 crore Company, with multi-

product and multi-divisional activities.

Why Nitco??QUALITY CONTROL SETUP

(Reliability of the products)

1. Individual Body/Glaze/Packing Material Tested as Per Quality Plan.

2. Stage-wise Control on all process parameters

3. Automatic Quality Segregation & Packaging system.

4. Audit by QC Team before Dispatch.

5. Handling of Customer Complaints if any.

•We invest heavily on Technology & Quality Process Up-gradation.

• Only company in India have Continuous Ball Mill that produce homogeneous body material. (No

Batch-wise production)

•High capacity Press PH-6590 to make more Compact and Dense Tiles.

•High Definition Digital Printing with 6 Color Prism Printing Technology.

•Automatic Laser Guided Vehicle for movement of materials (No Manual handling of tiles).

Modulus of Rupture(MOR )- allowable bending strength of a tiles

Breaking Strength - strength of a tile to withstand without rupture

Crazing Resistance : rupture of glaze in the form of hair line crack due to difference in Dilatometer fit between body & Glaze surface

Abrasive resistance : the ability of a tile to resist surface wear caused by flat rubbing contact with another material ( abrasive particle).

frost resistance : the ability of ceramic tile to withstand freeze conditions with minimal effect. It is dependent on the tile's porosity and water absorption levels.

Technical Parameters

TILE

S

• Trulife Floor Tiles

• Trulife Wall Tiles

• Naturoc

• Ceramic

• Vitrified

• Duracottura

• Manufactured at Alibaug & Gujrat

MO

SAIC

O

• Mosaico

• Inlay

• Crafted at Kanjurmarg-Mumbai

MA

RB

LE • Natural Marble

• EngineeredMarble

• Processed at Silvassa

NITCOKey Business Areas

Tile (टाइल)

Ceramic Floor Tiles (WA 3-6 %)

Vitrified Tiles (WA ≤ 0.5%)

Ceramic Wall Tiles (WA 15-20% )

Red body White/Off Wht body

Polished vitrified tilesUnpolished Vitrified

tiles/Naturoc

Full Body or Color body

Glaze Vitrified body

Matt Finish Gloss finish

Double Charge or Ultra charge

SST

Full LapatoSemi LapatoNon Lapato

• Laparto – Antiskid, Scratch Resistant

• Rustic - Antiskid, Scratch Resistant

• Satin Matt – Smooth Antiskid, Scratch Resistant

• Matt - Antiskid, Scratch Resistant

• Gloss – Stain Resistant

• Wood- Antiskid, Scratch Resistant

• Matt – Heavy duty digital Pavers

• Vitrified (Soluble salt/ Double Change) - Gloss

Different types of Finishes

• The GVT means Glazed vitrified tiles. This type of

tiles are also made from the blend of different clays and

minerals like feldspar and quartz. This may be called in

another name like Gres Porcelain tile The word "grès"

means that the body of the tile is fired at 1200 degrees,

that makes it compact hard, and vitrified.

•Nitco ‘s brand name for GVT is NATUROC,

TRULIFE & MAGNIFIED.

•The top Surface will be decorated with the Imported

glaze and different types of printing like flat , roto or

digital depending on the nature of the product.

•The surface of the tile may be varying from the Stone

crest to Satin finish.

•The tiles may have the variation in shade to enhance the

natural look of the natural stone.

•This makes It highly resistant to moisture, staining and

wear.

GVT /

Naturoc /

Magnified

Gr-BIa as

per ISO

13006:201

2

WA :<0.5

%

10

Vitrified Tiles : Sub Segments

A normal polished vitrifiedtile.

The term SST stands forSoluble Salt stands for thewhich penetrates in to bodyto some extent during firingprocess and will retain thedesign after polishing process.

All SST tiles are made withsame technology

Two layered tiles

The bottom layer is madewith neutral body and top layeris decorated using differentcolored body powders fordesign

These 2 layers arecompacted together under highpressure

This compactness makes ithomogenous which makes itlong lasting

Soluble Salt Double Charged Double Charged Tiles

Batch Consideration

• BATCH CODE— SCYYMMBC• SC-- Supplier/Vendor Code• YY–- Manufacturing Year

• MM—Manufacturing Month

• BC– Production Lot/Batch**In this System all eight digit Must be same**

11

Colour No.---------Manufacturing Date (Year Month Date:-xxxx xx xx )

Manufacturing Plant

Note:-- Colour no & Plant must be same while manufacturing date

may be within 5-7 days span.

China Procured Materials

A1-0131-11.16Alibuag

01161103-03.11.16Morbi plant

Quality Marking Process

On Every Boxes

A1

FIRST GRADEA2

A3

DLX/DXSECOND GRADE

C1 THIRD GRADE

12

Do’s And Don’t

Stacking of Box Specially for wall tile

Major Reasons for Complaints

17

Warpage

o Laying Problem.

o Batch Mixing.

o Manufacturing Defects.

Size Variation

o Quality Mixing.

o Laying Problem.

o Manufacturing Defects.

Rectification/Diagonal

o Poor Edge Finishing.

o Diagonal Variation..

o Laying Problem.

Size Variation

Major Reasons for Complaints

19

Shade Variation.

o Dispatch Error From Factory/Depo/Dealer Stock.

( Mix Lot)

o Quality Mixing.

o Vendor Mixing

o Wrong Stamping.

o Roto/Digital Printing.

o Manufacturing defects.

Others Prob.

o Pop-Up

o Crazing

o Stain/Dust Absorption & Others

Pop-UP/Buckling of Floor

Reason :-

Tiles may pop-up/Buckle either one of the following reason.Development of stress due to moisture expansion of tiles.Low Quality of adhesive/cement which cause of low bonding strength to tiles.Poor Workmanship of tiles laying.

Solution :-

Need to leave at least 1mm gap between tiles. Selection of right quality and right proportion of cement/adhesive.Allow the bed tiled floor for at least 3 days for complete setting of tiles. Avoid walking over the tiles during the period.

Stains

Reason :- Usage of Poor cleaning of tiles with Lizol / Klinol etc (Very mild germ cleaner chemicals)

Solution :- Suggest to clean the tiles with Tiles Cleaner viz. Bal Endura/Laticrete/Roff tiles Cleaner.

Crazing

Reason :- Difference in thermal expansion of body and glaze.

Solution :- Replacement of tile with fresh one if laid within 6 month of Nitco billing.

Loss of Gloss

Reason :- Had cleaned the tiles with strong chemicals result that the shining /polishing get off.

Suggestion :- Replacement of tile with fresh one. (Not from the NITCO as this not a manufacturing complaints. Its purely Application Problem).

Surface Defects during Installation of Tiles

Defects After Installation of Tiles

Measuring

the Visual

defects

Warpage Shade variation

Size Variation

Warpage

Filler gauge used to measure warpage or unevenness between tiles

Depth gauge used to measure warpage or unevenness between tiles

Advantages of Using Spacers

• It will help the tile to get fix for long time and protect the tile from deboning & Pop-up• It increase the aesthetic look .•The Gaps should be filled with Epoxy Grout which is Having Several advantages A. Anti Bacterial

B. Anti Dust C. Anti Corrosive D. Leak Proof

Some Illustration are give in following slides

ROTO COLOR MACHINE

Digital printing machine

6 Color Bar Digital printing machine manufactured by

SACMI (Italy) and 1st time in India

ENTRY SIDE EXIT SIDE AFTER GETTING PRINTED

Shade Variation on Printing

Products Display-Studios

Nano Coating Machine and its Purpose• Nano liquid is a special type of liquid which due to its small

particle size enters in to the Micro pores of the tile surface and after that it expands and cover the hole. This process leads to increase the glossiness of the tile as well as it imparts the anti stain property in the tile. The Photo graph of the Nano Application machine is as follows.

Moving Roller for even distribution

Rotating assembly

The Pipe through which the nano liquid is coming and it falls on the Moving Roller which is touching the tile surface and nano liquid gets distributed evenly on the tile surface.

Centering of tiles & Use of ARROW MARK & SPACER

36

Advantage of our Vitrified Over Gujarat market

Having More strength than the local vitrified tiles our tile is having the strength( MOR) of > 40N / mm2.

Having high glossiness due to firing at the high temp of around 12200c and polishing with the 48 head polishing machine with imported Grit. Our Glossiness for the platinum product is more than 94.

We are using the Imported Nano liquid for final finish so more Durable.

Definition of printing is also more due to printing with Sharp imported squeeze Rubber.

Water absorption (<0.07 %) is also less than that of the Gujarat product due to maturing the tile in such a high temp of 12200 C

Body brightness is also more than that of the local vitrified tiles because of using the high grade raw material for production.

The Body impurities is also less than the local Vitrified tiles because of using the strong Magnet at the tile of Slip preparation.

Thank you for your kind Attention