CERAMIC INDUSTRY IN BANGLADESH

Ceramic Industry is manufacture of useful and ornamental articles from clay by shaping and hardening it in high temperature. The industry is basically a development of indigenous pottery works. Broadly, ceramics denote the manufacture of any product made from a non-metallic mineral hardened at high temperatures. Industrial ceramics comprise all industrially used solid materials that are neither metallic nor organic. Major ceramic products include glass, earthenware, porcelain, and white-ware, porcelain enamels, brick tiles and terracotta, refractories, cement, lime and gypsum and certain abrasives. The art of pottery is perhaps as old as human civilization. Initially, it started with clay and then passed through stages of molding various media like wood, stone, shell and metal before reaching the age of ceramic and porcelain. Bengal passed through all these stages before reaching the ceramic age. Ceramic industry took a formal start in this country in 1958 with the establishment of Tajma Ceramic Industries Ltd. at Bogra. It is the oldest modern ceramic manufacturing plant in Bangladesh and is also the only ceramic factory located in North Bengal. Its production was very small and the quality of the product was not good. The Pakistan Ceramic Industries Ltd. was established in early 1960s and it went into production in 1966. It manufactured ceramic products for the domestic market. It was renamed as Peoples Ceramic Industries Ltd after the independence of Bangladesh. In 2001, Bangladesh had ten ceramic industry units. Five of them are fairly large and these are Monno Ceramic Industries, Shinepukur Ceramic Industries, Bengal Fine Ceramic Industries, Standard Ceramic Industries and Peoples Ceramic Industries. These companies produce high quality ceramic and porcelain wares. The annual production is about 15,000 tons of ceramic items. About 5,000 tons is exported to 45 countries. The remaining amount is consumed locally. Initially, all ceramic industries catered to the domestic market only. The Tajma Ceramic Industries has a showroom and an export department in Dhaka. It has been manufacturing porcelain tableware since 1958. Although it is the oldest producer of ceramics, the factory manufactures only about 12,000 pieces (4 tons) of assorted tableware per day, which is about half the capacity of other major ceramic tableware manufacturing plants. The company has been catering mainly to the domestic market. The Peoples Ceramic Industries, located in Tongi Industrial Area, about 20 km north of Dhaka, is one of the oldest and largest ceramic companies in Bangladesh. The factory went into production in 1966. The production capacity of the factory is about 28,000 pieces of assorted tableware per day. The company however, has had little success in the export markets. Recently, the company has developed a new brand 'Super China', which is drawing the attention of foreign buyers. Bengal Fine Ceramics Ltd. is the first industry in the country to make soft porcelain, which the company calls 'stoneware'. This is an off-white product manufactured by using local Mymensingh clay. The factory went into production in 1986. It produces about 24,000 pieces (6 tons) of stoneware per day. From the very beginning, the company concentrated its trading activities in the international market and has been quite successful in its endeavor. Recently, the company has established a sister concern, Standard Ceramic Industries Ltd., near gazipur, about 30 km north of Dhaka. The largest and most successful ceramic company in Bangladesh is the Monno Ceramic Industries Ltd, which started production in 1985 and manufactures very high quality porcelain tableware. This company has done well in the export market with its sales office in London and a permanent stall in the Frankfurt House-wares show. Shinepukur Ceramics Ltd was incorporated in 1997 with the aim of establishing a world class bone china and porcelain tableware industry. The company is located at Beximco Industrial Park, Gazipur. It started its porcelain and bone china units in April 1999 and November 1999 respectively. Since the beginning of its commercial operations in 1999, the company has distinguished itself as the fastest growing concern in the sector. It has captured about 60% of the domestic market share and is doing well in the global ceramic tableware markets. About 95% of raw materials for making quality and exportable ceramic products in Bangladesh are imported from abroad. The materials are imported mainly from Japan, Germany, New Zealand, South Korea and India. The prime raw materials of ceramic products are white clay and sand. The largest deposit of white clay in Bangladesh was first discovered in 1957 at Bijoypur of Mymensingh. The total reserve of white clay from this region is estimated to be 2.57 million tons. Clay was also found in Jaflong of Sylhet. But there is no clay or sand treatment plant at these places. To ensure proper quality and goodwill all ceramic tableware producing units use high quality raw materials. The machinery and equipment are also modern and conform to the latest technology and standard. Each of the units has its own in-house laboratory facility, quality control and testing mechanism. The products that are being marketed now are: dinner sets, tea sets, coffee sets, soup sets, fruit sets, plates, bowls, flower vases, mugs and various types of souvenir items. Most ceramic products are ovenproof, chill-proof and dishwasher-proof and free from any chemical hazards. At present, Bangladesh is exporting ceramic tableware to more than 45 countries, including the USA, Italy, Spain, France, New Zealand, the Netherlands, Australia and Sweden. [Zakir Hossain Bhuiyan]

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CERAMIC TILE INDUSTRY STATISTICS: 1. 2. 3. 4. 5. 6. 7. World production: 6900 Million sq.mt. India's Share: 340 Million sq.mt.. World ranking (in production): 5 Per capita consumption: 0.30 sq.mt. Global Industry Growth Rate: 6% Growth Rate (India Domestic Market): 15% Organized industry turnover (India): Rs 3000 crores Glazed Wall Tile share: 40% Glazed Floor Tile share: 46% Unglazed Vitrified Tile share: 8% Glazed Porcelain Tile Share: 6% Unorganized Industry Turnover Rs 3500 crores Glazed Wall Tile share: 57% Glazed Floor Tile share: 35% Unglazed Vitrified Tile share: 6% Glazed Porcelain Tile Share: 2% Investments in last 5 years: Rs 2000 crores Organized sector: Share of Production: 56% No. of units: 16 Revenue (excise duty): Rs 300 crores Unorganized sector: Share of Production: 44% No. of units: 200 (approx..) (70% based in Gujarat region) Revenue (excise duty): Rs 350 crores per annum or less Job Potential: 50,000 direct 500,000 indirect

8. 9.

10.

11.

(Source: CWR, Countries listed according to output in 2009) Note: In 2009 the 10 major exporting countries represented 82% of the total exports and 16.7% of total world consumption.

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(Source : CWR, Countries listed according to output in 2009) Note: In 2009 the 10 major manufacturing countries covered 80.2% of world production.

(Source: CWR, Countries listed according to output in 2009) Note: In 2009 the 10 major consuming countries covered 67% of world consumption.

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Technology RAK Ceramics (Bangladesh) Limited has been manufacturing and supplying a wide range of tiles and sanitary wares in the ceramic sector of Bangladesh since 2000. Excellent designs and pattern can be created using specially selected wall and floor tiles, borders, corners. Many of RAK Ceramics' models come in modular designs, making it easier for the customer. The unique ambience patterns created using ceramic tiles and also Gres porcellanato tiles appeals most discerning customers. The company has two product lines, which are Tiles and Sanitary Ware. The company recently set up large scale Effluent Treatment Plant (ETP) to reduce environmental hazard, which started operation end of March, 2009.

Tiles In Gres Procellanato (porcelain / fully vitrified tiles), the company produces hundreds of glazed and unglazed porcelain, covering finishes such as polished, unpolished, rustic, Slate etc. In Bangladesh with three fold expansion Drive Company has reach capacity to produce over 8 million square meters of tiles per annum & has over 1000 different tiles models recipe. The salient features of the plants are:

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Gang of modern technological machineries: versatile 5 press, long range 5 kilns & multipurpose 12 ball mills. Latest equipment & technological application: Some unique patterns and finishes: are acquired through new technologies such as Roto Printing, Double charge, Granitech etc. Some unique antique style finishes and many specialized finishes in tiles have been possible due to such advanced Gres Procellanto technology. Modern European machinery: Computer controlled guided vehicles transferred semi finished goods from station to station, robots picked and placed semi finished tiles in many production steps as well as in sorting and packing the finished tiles, skilled technicians in sophisticated control rooms monitored raw materials in blending mills, wet and dry grinding vessels, presses, kilns, drying and cooling cycles, and many other operations. High Quality inputs: Imported raw materials like soda feldspar, potash feldspar, clays from India, Indonesia, Malaysia, Thailand. Fritz & glazes from Spain & other European countries. Ceramist R& D activity: Active team of ceramist to challenge customer demand & device cost effective input recipe solutions.

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Sanitary Ware In sanitary ware, various models of wash basin (mounted as well as pedestal), water closets (WC) and water tank (WT) accessories and marble shade sets are produced. State of the art plants produces over 900,000 pieces per annum & over 30 different models of sanitary ware. The salient features of the plants are: Latest Italian Technology: For production including computerized kilns. Medium Pressure Casting Plants: For production of wash basin, pedestals, cisterns, lids and accessories. Battery Casting Moulds: To produce water closets. Highest Quality Raw Materials: Ball clay and kaolin from U.K., glazes from Spain and stains from Germany. In House Quality Control and Testing: A laboratory of the highest standard. ** Recently we introduced Robotic Sprayer for glazing on the surface of sanitary wares. Moreover, Double Flushing, Soft Closing Hinges, Spreader of urinal bowl are the exclusive accessories. We are also producing all type of seat & cover ourselves in our factory.

http://www.ceramicindustry.com/Articles/Feature_Article/BNP_GUID_9-5-2006_A_10000000000001098326 Manipulating the properties of powdered materials can help make ceramic processing easier and faster while supporting improvements in product quality. One of the variables often controlled is particle size. However, this may be complicated by the tendency of powders to agglomerate and cake, which can increase particle size away from the design intent and ultimately compromise production. Powder rheometry can be used to determine the conditions that will help prevent powder caking. Particle Size and Powder Flow Enlarge this picture

Figure 1. Measuring BFE with a powder rheometer. Modern ceramic powders undergo careful processing to ensure that factors such as purity and particle size do not adversely affect production. Powders often require mixing with water or additives to make them suitable for different forming methods such as extrusion, slip casting, or injection molding.

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When forming a green body from the resulting ceramic mixture, the sizes of any pores within it relate directly to the size of the ceramic particles present. Larger particles pack inefficiently and can result in pores that weaken the finished product, while powders with smaller particles (or a mix of particle sizes where the fine particles fill the voids between larger particles) can be used to control pore formation. Compared with smaller particles that provide a high surface area, the presence of larger particles can also increase the time and temperature required for the product to achieve full density during firing or sintering. Manipulating particle size (and, potentially, particle size distribution) in ceramic manufacturing processes is therefore important for achieving greater process control. Once the appropriate particle size specification is identified, the focus shifts to achieving and maintaining the most advantageous powder properties during manufacturing. Here, caking and agglomeration can be a complicating factor, since these processes increase particle size, thereby reducing the beneficial impact of early processing steps or of a carefully selected feed material. Characterizing Powders A widespread problem in many areas of powder processing, agglomeration occurs through mechanical or chemical interactions between particles during storage. Many of the raw materials used in the ceramic industry exist in powdered forms, with caking compromising both process and end use performance. The particles that make up a ceramic powder can range from the nanometer to the micrometer scale, so an initial granulation step is often required to make them uniform in size. This step presents an opportunity to improve powder flow and reduce caking through the careful blending of powders and any added constituents. However, making the most of this opportunity in order to develop strategies that reduce the risk of caking over the longer term requires the means to characterize the powders involved and to understand their behavior under specific conditions. Caking is primarily an issue related to powder storage. Humidity, temperature and consolidation are all factors that may promote caking, which can occur through a number of different mechanisms. Temperature changes that lead to condensation in a keg, container or tanker, for example, can result in particles dissolving, enabling the formation of agglomerate bridges through chemical bonding. Alternatively, particles forced together by consolidation may eventually simply mechanically aggregate. Whatever the mechanism, the end result is the same: changes in the way the powders flow, which leads to problems with storage, supply and potentially compromised product quality. Powder Rheometers Enlarge this picture

Figure 2. Investigating the impact of consolidation on caking by tracking changes in BFE as a function of time. The reliable analysis of powders and their behavior has logistical and economical benefits in many instances, for both processing and product quality. However, powder behavior is complex. Many physical, environmental and chemical factors affect powders, making it difficult to reproducibly measure properties and predict behavior. With a number of traditional tests, accuracy, reproducibility and/or process relevance are not always guaranteed.

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Powder rheometers* offer multi-faceted powder characterization that delivers an array of powder properties designed to support process optimization studies. Such systems allow for repeatable and robust measurements that sensitively differentiate between physically and chemically similar samples. Dynamic powder measurement, one of the methodologies used by a powder rheometer, has been shown to be an especially reliable method of analyzing powders when investigating the impact of factors such as aeration, compaction and attrition. Dynamic measurement involves recording the axial and rotational forces acting on a helical blade as it traverses through a sample (see Figure 1). Basic flowability energy (BFE) is the key dynamic baseline measure of a powder and is defined as "the energy required to rotate a blade down through a sample at a controlled rotational and vertical velocity." Powder rheometers use well-defined and automated test methodologies that make BFE measurements highly reproducible for many different types of powders. Experimental Caking Data Experiments based on measuring changes in the BFE of a powder under different conditions provide information about the likely severity of caking in the variety of environmental conditions encountered during storage. The study described here, which examines the effect of consolidation on caking activity, illustrates how successful this experimental approach can be. Similar protocols can be used to study the impact of elements such as humidity or temperature, for example, or to inform decisions taken during the formulation stage or when setting granulation targets. In the experiment described, duplicate sets of a powder blend were stored for periods of up to 10 days. One sample set was stored without consolidation, while the other was subjected to compaction with a consolidating stress of 9 kPa. BFE was measured as a function of storage time for each set of samples (see Figure 2). For both the consolidated and the unconsolidated samples, BFE increased only marginally during the first four days of the experiment. However, after five-and-a-half days, the BFE of the consolidated samples showed that the powder was twice as resistant to flow as it was when first loaded into the storage vessel-a state that the unconsolidated samples did not reach until day eight. The BFE continued to rise for both sample sets with no sign of leveling off. The implication for this blend is that shorter storage times under low stress conditions are advantageous, and consequently should be the target within the process environment. Mass Flow vs. Funnel Flow Experimental data of this type can be used to inform storage design or selection. If the powder blend described previously is stored in a vessel that operates under mass flow conditions, for example, then reducing storage times and only partly filling the container will help alleviate problems associated with caking. With mass flow, material transitions uniformly through a container on a "first in, first out" basis, a condition achieved through the appropriate matching of the geometry of a storage vessel with the properties of a powder. On the other hand, if this powder is stored in a hopper that exhibits funnel flow, then the results of the experiment suggest that problems are likely. Funnel flow occurs when the hopper walls are too shallow and/or the outlet is too small compared to the optimum conditions for a powder. A "funnel" forms within the center of a surrounding "stagnant" region where powder is static. Material trapped in this stagnant region and toward the base of the container is subject to consolidating pressure, creating ideal caking conditions for susceptible powders. In this instance, steps would be needed to modify or change the hopper, preferably toward a mass flow regime. Caking Management Caking can quickly reduce the value of an expensive product, and it is important to develop strategies that reduce its occurrence. Understanding how powders behave in specific circumstances can play an essential role in process optimization.

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The advent of powder rheometers has delivered the means to sensitively differentiate between even very similar samples and to examine how various environmental factors affect the behavior of particular powders. The resulting information aids in the management of caking and in ameliorating the impact of factors such as humidity and consolidation, encouraging the development of storage conditions that fully meet the requirements of the powder. For more information, contact Freeman Technology Ltd. at Boulters Farm Centre, Castlemorton Common, Welland, Worcestershire, England WR13 6LE; call (44) 01684-310860; fax (44) 01684-310236; or visit www.freemantech.co.uk. *Including the FT4 from Freeman Technology.

Tim Freeman Tim Freeman is director of operations at Freeman Technology, Worcestershire, England.

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