Irregular distribution
Engobe applied non-uniformly, with excessive material build-up in some areas.
Analytical Case Study
Controlled application of refractory engobe on large formats.
How National Ceramics Uzbekistan solved the problem of applying engobe to the back of large formats and slabs, improving product quality and reducing kiln maintenance costs.
The challenge of applying engobe to large formats
National Ceramics Uzbekistan produces large-format ceramic tiles and slabs on high-capacity production lines.
Applying refractory engobe to the underside of the tiles is a fundamental stage of the process, as it directly affects final product quality, surface flatness, the cleanliness of the kiln rollers and the continuity of production.
The existing machine could not guarantee a uniform distribution of the product, generating increasingly significant quality and operational issues.
A non-uniform application that generates hidden costs
The engobe applied with the existing system showed an irregular distribution across the entire underside of the piece.
Positioned on the kiln-inlet roller table, the system has a direct impact on productivity: the difficulty of ensuring correct application could cause downtime, or push operators to favour production continuity at the expense of application quality, with long-term consequences.
Roller wear and cleaning
Frequent need to clean the ceramic kiln rollers and risk of premature replacement.
Flatness defects
Flatness issues and deformations visible in reflection, especially on glossy products.
Waste and line stops
Higher scrap and more stoppages, with a direct impact on overall line efficiency.
The diagnosis: the limit was the application system, not the engobe
The analysis carried out at the plant showed that the limit was not the engobe itself, but the way the product was laid down.
A solution was therefore needed that could control the distribution of the refractory engobe precisely and repeatably across the entire width of the piece.
| Parameter | Previous solution | New solution |
|---|---|---|
| Control of product quantity | Imprecise | Precise and repeatable |
| Uniformity across the width | Not guaranteed | Uniform across the full width |
| Adaptation to different runs | Difficult | Fast and flexible |
| Application consistency over time | Variable | Constant |
| Washing and adjustment | Slow | Fast |
Engobing machine with RollerPress: laser-engraved silicone roller
Inter Ser proposed installing a new engobing machine equipped with RollerPress, a laser-engraved silicone roller.
The technology transfers the engobe in a controlled, uniform way across the entire underside of the piece, with a stable application that is repeatable over time.
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High-precision laser engraving
Accurate control of the amount of product deposited and the ability to adapt the deposit to different production runs.
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Dedicated silicone roller
Uniform engobe distribution, with a stable application that is repeatable over time.
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Process control
Simple setting parameters the operator can maintain and check, reducing application variation.
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Fast washing and adjustment
Greater production reliability and lasting application consistency thanks to quick, simple adjustments.
Installation on the kiln-inlet roller table
The new engobing machine equipped with RollerPress was installed on the kiln-inlet roller table, the point where applying refractory engobe directly affects productivity and product quality.
The system’s ease of use lets the operator maintain and check the application parameters without calling on maintenance, ensuring production continuity and application consistency over time.
In the Field
Photo gallery of the project
Product quality and roller life: benefits measured on the line
Before
High downtime
Engobe application (traditional system)
After
+8% Productivity
Engobe application (RollerPress)
Precisely controlling the amount and uniformity of the engobe not only improves product quality, it generates measurable benefits across the entire efficiency of the kiln area.
| Metric | Result | Impact |
|---|---|---|
| Product quality | +2% | Fewer chips and better flatness |
| Kiln roller cleaning | +15% | About 2 extra weeks every 8 weeks of operation |
| Roller consumption | -22% | Lower spare-part and maintenance costs |
| Production stability | +8% | Greater operational continuity and fewer kiln gaps |
What this case demonstrates
A uniform application of refractory engobe on the underside of slabs and tiles is an essential requirement to preserve the condition of the kiln rollers and guarantee the best characteristics of the finished product.
01
Process control
The precision of engobe application is essential to guarantee quality and production stability.
02
Product quality
A uniform distribution improves flatness and appearance and significantly reduces scrap.
03
Operational efficiency
Keeping the kiln rollers clean means fewer maintenance interventions, fewer unplanned stops and lower operating costs.
Next step
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