Step 1: Preparing divider moulds and colours
- Prepare divider molds.
(*) If customers want to have a new pattern that is not available in our existing range, we will be able to create new divider mold for new design. This will be done at an additional cost. Colors will be mixed according to our customers’ color choice. We have a standard range of 80 colors for our customers to choose from. Our customers only need to specify the codes of colors to be used for the chosen patterns. See our Color Chart.
(*) If customers want to have a new color that is not available in our existing range, we will be able to test new color. This will be done at an additional cost.
Step 2 : Placing divider mold into steel mold
Steel mold is prepared and divider mold which molds the tile design will be placed inside the steel mold.
Step 3 : Pouring colors into the mold as the first layer
A liquid mixture consisting of white cement, natural marble powder, color pigment, and additives (to be mixed to the right color) are poured by hand into the mold. Different liquid mixtures will be needed to create different colors in one tile.
Step 4 : Making next layers
Applying a mixture of sand and cement as the third layer (back layer) until the required thickness of tile is achieved.
Step 5 : Pressing by hydraulic pressing machine
All the materials will be pressed by hydraulic pressing machine. Moisture from the liquid colored layer will be absorbed through the dry back layers. Tiles will be pressed twice for good strength.
Step 6 : Forming tile and taking out tile from the mold
Tile has been formed and taken out of the mold. Now, we can see a beautiful tile with pattern and colors.
Step 7: Curing tile
After the forming stage comes the curing stage. Tiles will be cured under water and then placed on racks for curing at room temperature.
Step 8: Coating with sealer, checking quality and boxed
After tiles are dried completely, they will be treated with sealer to protect the surface of tiles and go through serious quality control by checking piece by piece to carefully select the good tiles before packaging.