Ceramic Whitewares Training Modules

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Ceramic Whitewares Training Modules

Transcript Of Ceramic Whitewares Training Modules

CERAMIC WHITEWARES TRAINING MODULES
Our flexible industry-based whitewares training courses have been designed for tableware, tile and sanitaryware manufacturers, as well as retailers and suppliers.
The interactive modules are suitable for delegates with no prior or a basic knowledge of ceramics and highly beneficial to the more experienced; they provide participants with both the theoretical and practical aspects of whitewares manufacturing processes.
During the modules, participants are also given the opportunity to discuss any challenges or issues that they may currently be facing.

MODULE L1

UNDERSTANDING CERAMICS
1 Day Course
In order to understand ceramic products you need a knowledge of what they are made from and how they are made.
This module explains:
- What is a ceramic - The unique features of ceramics - Materials involved in ceramics - Ceramic manufacturing processes - Ceramic product types
The practical session will include:
- A hands-on activity around the basic forming processes - Identifying different product types - A factory/Lucideon tour led by the module tutors

At the end of the module, you will be able to:
- Understand how the materials and processes combine to give ceramics their unique characteristics
- Understand the unique characteristics and applications for each type of ceramic product - Identify various types of ceramic materials, processes and products - Demonstrate a knowledge of the most suitable ceramic product for a specific application

MODULE L2

MATERIALS SELECTION
1 Day Course
The raw materials selected for a body formulation should ensure that the end product has the desired appearance and required performance properties.
This module describes:
- The properties and characteristics of the raw materials from which tableware is manufactured
- Extraction and refining processes - Proportions used in the body recipes of the different tableware types - The effect of raw materials on unfired and fired properties
The practical session will include:
- Examining different raw materials in unrefined and refined states - Preparing plastic bodies from different proportions of raw materials - Demonstrating the effect of materials on unfired and fired properties (e.g.
contraction, colour, etc.) using prepared samples of different body formulations

At the end of the module, you will be able to understand:
- Different raw materials and their properties - What is achieved by processing raw materials - How raw materials influence the properties of pottery bodies

MODULE L3

CASTING SLIP SCHOOL
2 Day Course
Day 1: Slip Control
With the use of simple viscometers and slip density measurement, control of casting slip and glaze slip properties is achieved.
The module will explain how to:
- Measure and adjust a slip to a required density - Set up and operate the Torsion and Brookfield Viscometers - Use viscometers to monitor flocculant and deflocculant additions - Adjust a casting slip to the required fluid properties
The practical sessions will allow each participant to carry out the above activities.

At the end of the module, you will be able to:
- Measure and adjust slip density - Set up and take fluidity/viscosity and thixotropy measurements using the Torsion and
Brookfield Viscometers - Construct a deflocculant demand curve - Correct the fluid properties of a slip

Day 2: Casting
Slip casting is the process for producing large complex shaped items and handles.
This module explains:
- The casting mechanism - How deflocculants affect the casting process - Optimising body formulations for casting - Functions and uses of plaster moulds in the casting process - Casting faults and how to correct them
The practical session will include:
- Casting items from a slip at different levels of deflocculation, to various thicknesses
At the end of the module, you will be able to understand:
- The basis of the casting mechanism - How deflocculant additions alter casting properties - The function, pros and cons of using plaster moulds - The causes of the common plaster faults and how to eliminate them

MODULE L4

DRYING
1 Day Course
Careful control of clay bodies during the drying process is essential for preventing items cracking when releasing moulds and removing moisture.
This module describes:
- The drying mechanism - Determining the safe rate of drying - The principles of humidity drying - Different types of dryers - Operating an industrial dryer (case study) - Best practice guidance for the drying of tableware items - Tips for maintenance and energy savings - The principles of drying plaster moulds
The practical session will include:
- Measuring temperature and humidity - Determining the drying rate of a clay body in different conditions of
temperature, humidity and air flow

At the end of the module, you will be able to understand:
- The principles of the drying process - How to control the drying process - Drying of ceramic tableware items best practice - Drying plaster moulds best practice - Maintenance and energy saving best practice

MODULE L5

KILN FIRING
1 Day Course
All saleable items must pass successfully through the firing processes.
This module describes:
- The reactions which take place in a clay, quartz and feldspar body during the firing process
- Changes to bodies which occur during firing - The firing curve and the key control points - Use of pyrometers to measure heat work - Features of the different types of kiln - Kiln atmosphere - Kiln pressure - Use of thermocouples - Investigating firing problems - Maintenance and energy saving
The practical session will include:
- The use of a pyrometer (Bullers Rings) - Gradient firing trials - The use of thermocouples - A fault solving exercise

At the end of the module, you will be able to understand:
- The principles of the firing process - How to control the firing process - The firing of ceramic tableware items best practice - Maintenance and energy saving best practice

MODULE L6 PLASTER MOULDS
1 Day Course
It is impossible to produce saleable items from plaster moulds if the moulds are in any way faulty.
This module describes:
- How plaster is produced from gypsum rock - The storage and ageing of plaster - Measuring the properties of plaster - The plaster water blending process - The physical effects of early and late poured plaster - Vacuum blending - Mould drying - Measuring mould properties - Mould making best practice tips - The effect of mould properties on ware quality (case studies)
The practical session will include:
- Making specimen moulds at various pouring times and plaster to water ratios
- The use of the mould permeability apparatus - A demonstration of plaster tests - Mould faults (case studies)
At the end of the module, you will be able to understand:
- The basics of how gypsum is processed to make plaster - The ageing process - Best practice for making mould - Best practice for drying mould - Solving common mould faults - Solving common ware faults that arise from plaster mould issues

MODULE L7

FORMING PROCESSES
1 Day Course
The opportunities and constraints of forming processes: hand-throwing, jiggering, roller-head making, ram pressing, granulate pressing, slip casting and pressure casting.
This module explains:
- The basic principles of hand-throwing, jiggering, roller-head making, ram pressing, granulate pressing, slip casting and pressure casting
- The basic requirements to make each process work effectively - Which process to choose for a specific requirement
The practical session will include:
- Forming the same item by slip casting and plastic forming - Viewing examples of different forming processes - Producing the same item by two different manufacturing routes (group
discussion)

At the end of the module, you will be able to understand:
- The basis of each forming process - The requirements to make each process work successfully - The criteria on which the choice of forming processes are made

MODULE L8

GLAZE & GLAZE APPLICATION
1 Day Course
Basic types of: glazes, raw materials choices, compositions, preparation and firing applications.
This module explains:
- What is a glaze - Different types of glazes, component materials and compositions - Glaze preparation - Glaze control - Glaze application - Firing of glazes
The practical session will include:
- How to prepare a glaze - Setting a glaze to the required fluid properties - Glaze application - Firing

At the end of the module, you will be able to understand:
- The generic glaze types and how they are formulated - How to prepare a glaze batch - How to modify glaze slip properties - Glaze application, dipping and spraying - The firing process

MODULE L9

TESTING OF CERAMIC MATERIALS & PRODUCTS
1 Day Course
Includes the raw material semi-processed and finished product material tests which are carried to support manufacturing control at the factory; analytical tests which may be carried out to support quality control and fault solving; regulatory and service performance tests.
This module explains:
- Why testing is necessary - Selecting a representative sample - The tests which are used for factory quality control - The analytical tests which are required to support quality control and fault
analysis - The regulatory and service performance tests
The practical session will include:
- A tour of the Lucideon testing facilities to view the various tests which are carried out

At the end of the module, you will be able to understand the principles of:
- Why testing is required - Selecting a representative sample - Factory quality control testing - Analytical testing - Regulatory and performance testing

MODULE L10

INTRODUCTION TO CERAMIC TABLEWARE & GIFTWARE FOR THE RETAIL SECTOR

1 Day Course
An understanding of the basic principles of ceramic products, the characteristics of different types of products, common faults, regulatory and service performance testing requirements.
This module explains:
- The basic processes involved in a typical ceramics tableware factory - The different types of ceramic products (china, stoneware, earthenware,
etc.), how they are produced, their defining features and uses - The common manufacturing faults and how they may be eliminated - The regulatory and service performance requirements and test methods - The key points to observe when visiting a ceramics tableware factory
The practical session will include:
- A hands-on activity around the basic forming processes - Identifying the different product types - A factory/Lucideon tour led by the module tutors

At the end of the module, you will be able to:
- Understand how the materials and processes combine to give ceramics their unique characteristics
- Understand the unique characteristics and applications for each type of ceramic product - Identify the various types of ceramic materials, processes and products - Demonstrate a knowledge of the best ceramic product for a specific application
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