for one tableware application, one plaster solution › wp-content › uploads › 2017 › 06 ›...

Industrial plasters,engineered to perform

For one Tableware application, one plaster solution

Arts & Decoration

Food/Feed, Environment & Agriculture

Gypsum & Plasterfor Construction

Materials

Metal Casting

Personal Care

Ceramics Saint-Gobain Formula is a world-leading supplier

of industrial plaster and gypsum products. Formerly the

industrial plaster division of BPB, Saint-Gobain Formula

is now part of Saint-Gobain Company, one of the top

100 industrial groups in the world.

Saint-Gobain Formula aims to be the world’s preferred choice

for industrial gypsum and plasters, with leading product

brands in all markets such as Ceramics, Gypsum & Plaster for

Construction Materials, Arts & Decoration, Metal Casting,

Personal Care, Agriculture, Food & Environment.

1 - TABLEWARE APPLICATION

Saint-Gobain and Formula in the world ......................................... p 2

The tableware process ........................................................................ p 4

Best practice .......................................................................................... p 5

Slip casting ............................................................................................. p 6

Jiggering ................................................................................................. p 8

Ram Press ............................................................................................ p 10

Case Mould ......................................................................................... p 12

Today, the Ceramic market with

its many applications represents one of our most important

strategic areas which is key to the continued success

of Saint-Gobain Formula. Saint-Gobain Formula largely

operates in markets located in Europe, Asia, Africa and the

Middle East.

In all ceramic applications (sanitaryware, tableware and

rooftiles), mould properties and performance are key to

achieving high quality finished items. Saint-Gobain Formula’s

ceramic plasters are highly valued for their technical proper-

ties, which include controlled porosity, mechanical strength

to ensure mould durability, dimensional accuracy and perfect

reproduction of fine detail, design flexibility and ease of use

compared to other techniques.

TABLEWARE APPLICATION - 2

For over 100 years, Saint-Gobain Formula, has specialized in the formulation of industrial plasters, working with customers by providing

a high level of customer service and assistance in over 90 countries as well as technical support.

Through product and supply chain innovation, Saint-Gobain Formula aims to build long term customer partnerships around the world by

operating in 8 countries. Saint-Gobain Formula was founded, bringing together the industrial plaster activity of 4 major international industrial

plaster specialists. (Germany, France, UK, Spain). Since that time, Saint-Gobain Formula has acquired companies and manufacturing sites

in Romania, Turkey, Egypt, and Thailand.


Saint-Gobain Formula offers a comprehensive range of tableware plaster formulations from its operations in Germany and Thailand for slip casting, jiggering, ram press processes and case moulds with dedicated products adapted to specific customer requirements.

CASTING

CLAY FABRICATION MOULD SHOP

1ST CALCINATION

2ND CALCINATION WHITE TABLEWARE QUALITY CONTROL

DECORATION PACKAGING

GLAZING

AdvAnTAGe oF uSinG plASTer:

& Ease of use: by simply adding water and mixing mechanically

& Quality of the reproduction: shape, dimensions and fine details

& Moulding behavior: sets quickly to the desired shape

& High level of homogeneity after it has set

& Easy reworking

The range of manufacturing techniques used to produce ceramic tableware is very wide.

Almost all make use of plaster:

l for designing and making the original model (modelling)

l for making the ‘tooling (block mould and case mould (case)

l to make the working moulds from the case mould (generally for slip casting, jiggering, or ram press processes)

Sou

rce

: Pill

ivu

yt

ChoiCE oF thE PlAstErSAinT-GobAin ForMulA, Best value for money for each manufacturing process.

ApplicationsSlip Casting Bone China Earthenware Stoneware

Jiggering ram press Case

Mouldproperties Porosity Hardness

porositycontrolled

Absorption Permeability Permeability

expansioncontrolled

- Easy demoultingEasy demoultingDimmenisionnalaccuracy

Dimmenisionnalaccuracy

particle sizedistribution

Reproduction of details




Key

para

met

ers

▼ ▼▼

Tableware Manufacturing process


CASTING

CLAY FABRICATION MOULD SHOP

1ST CALCINATION

2ND CALCINATION WHITE TABLEWARE QUALITY CONTROL

DECORATION PACKAGING

GLAZING

plaster to water ratio :

• Weigh each mix accurately

• Always add plaster to the water, NOT water to plaster

• Allow the plaster to soak at least one minute (to help

remove the air and allow each particle to be satura-

ted with water)

• Respect mixing ratio mentioned in our Product

Datasheet:

– Plaster to water ratio too high: plaster becomes

too thick and is liable to lead to air bubble entrap-

ment

– Plaster to water ratio too low: Plaster particles may

sink before the plaster sets (giving an uneven qua-

lity and abnormal mould swelling, with the addi-

tional risk of hairline cracks). Tiny air bubbles may

be trapped under mould surface which will start to

appear as the mould starts to wear. A low plaster to

water ratio increases the mould’s absorption capa-

city to the detriment of its mechanical strength

Cleaning

• Gypsum is a very powerful setting accelerator. Clean

all the blending equipment after every mix is highly

recommended

blending

• Use only mechanical blending

•Type of blenders:

• Use automatic equipment to ensure perfectly repro-

ducible conditions everytime

Type of water:

• Low dissolved salt (< 400 ppm), to avoid risk of

efflorescence

•Temperature between 15°C and 20 °C

drying

• Good drying ensures good mechanical properties

and consistent mould life

• Drying should start 10-12 hours (minimum)

after mould making

• Temperature < 40°C in dry condition

Type of blender:

3 blade propeller

diameter of the blade :

¼ to 1/3 high of the

mixing bucket

Mixing speed:

200 rpm to 400 rpm

Mixing time:

2 to 5 minutes

Type of blender:

Defloculating Turbine

diameter of the blade :

Less than ¼ of the

mixing bucket

Mixing speed:

900 to 1500 rpm

Mixing time:

2 to 5 minutes

best practice++++


VSlip casting The casting technique, in which clay slip comprised of a specific formulation of ceramic minerals suspension in water, is poured into plaster moulds, is the basic technique used for the production of ceramic items.

Absorption

Highporosity

Clay into plaster mould

Remove Excess Slurry

Water absorprtion(from clay to plaster)

➔ Formation of the skin

Demouling

The porosity of the plaster mould absorbs the water in the slurry and thus causes a deposit of material to form on the inner wall of the mould, taking the shape of the mould. The thickness of this “skin” is proportional to the time for which it is allowed to form.


products

product Manufacturing site pWr initial setting time benefits

Molda TW 75 Thailand 1.33 6-18 min- High absorption capability- Available in long or short setting time- Can be also used to produced short series products in Jiggering

Supraduro MC 70 Thailand 1.43 15-20 min- Multicasting plaster- High absorption capability

Almod 60 Germany 1.45 10-15 min- Excellent for slip casting- Good balance between mechanical properties and absorption

capability

Molda Sn 75 C Thailand 1.50 10-15 min- Fine particle size- Good balance between absorption and mechanical behaviour- Stable workability

Molda Sn 75 e Thailand 1.50 12-15 min- Fine particle size- High absorption capability- Stable workability

Supraduro MC 65 Thailand 1.55 15-20 min- Multicasting plaster- High mechanical strength- High absorption capability

Multicasting Plaster

saint-Gobain Formula MC innovative technology, is the most adapted solution to optimize performance and effectiveness of your process.

Multicasting plasterSupraduro MC multicasting plaster range has been developed to improve absorption rate and mould life.our Multicasting products allow customers to improve productivity by increasing the number of casts in the same period of time.

Multicasting plaster characteristics include:porosity is not affected by a variation of pWr (+/– 20%) & Fluidity of MC plasters remains stable during pouring & plaster can be poured as soon as it has been blended

& Casting time is longer, even though the plaster starts to set earlier

Mechanical strength of the moulds is significantly impro-ved, thus enabling quicker release and improved mould behaviour.

MULTICASTING PRODUCTS(various P/W)

COMPETITOR PLASTER

Initial {

End ofcasting

Star

t of

cas

tin

g

Casting time of traditional plasterIST tract product

IST multicasting productCasting time of multicasting product

EST

TIME

FLUIDITYi n novative tech nology

KeY FiGureS

& up to 20 % increase in mould life

& up to 5 casts/day

& Stable mould making process


VJiggering

Harder plaster

Permeability

To improve productivity in ceramic piece manufacturing, the jigge-ring and jollying techniques were developed using malleable clay bodies, formed on plaster moulds, for all pieces that have an axis of revolution (circular profile: plates, cups, etc.).


plASTer properTieS – ChoiCe oF The plASTer• Mould life is significantly extended compare to casting

process/moulds• Harder plaster and/or plaster offering a higher plaster

to water ratio is used• Mould porosity is no longer a critical quality; overriding

quality here is air permeability to enable effective use of the vacuum suction

products


Supraduro MC 70 Thailand 1.43 15-20 min- Multicasting plaster- High absorption capability

Supraduro MC 65 Thailand 1.55 15-20 min- Multicasting plaster- High mechanical strenght- High absorption capability

Molda TW 63 Thailand 1.63 7-11 min- Good balance between mechanical properties and permeability- Controlled in expansion

Keram pink Germany 1.64 10-15 min - High permeability

Keram blue Germany 1.75 10-15 min- Good balance between permeability and mechanical strength- Expansion controlled

Molda TW 56 Thailand 1.80 6-10 min- High mechanical properties- Very fine surface detail- Controlled expansion

Keram 52 Germany 1.92 9-14 min- Expansion controlled- Very high strength

Multicasting Plaster

saint-Gobain Formula can evaluate customer requirement and propose the best value for money according to the mould life requirement (depending of the production organization, process habits or tableware series size).


Vram press

thanks to our expertise around the world saint-Gobain Formula can provide technical support on mould making process.

Very Hard plaster

Permeability

Air network

Air is blown into this network during the setting process thereby ensuring that the mould is porous enough, to enable the clay piece to be demoulded after it is formed.

plASTer properTieS – ChoiCe oF The plASTer

• Mould life: more than 1000 pieces can be pressed depending on the raised surface pattern, the type of plaster and the manufactu-rer’s quality requirements

• Ram press moulds are formulated in order to insure best mecha-nical properties and to help the permeability required to evacuate water included in the clay

• Dimensional expansion of plaster mould is more important. Formula specifically controls expansion of every ram press product

Ceramic body with high plasticity is shaped by exerting pressure, using two halves of a mould made of very hard plaster, embedded with a porous network of porous non-metallic flexible tubes/air hose.


products


Keradur 4000p Germany 3.00 19-25 min- High strength- Controlled in expansion

duropress Germany 2.86 21-26 min- Good permeability- Controlled in expansion

Specificity of plaster mixing

• Controlled slip temperature

• Mechanical mixing: mixing time from

5 to 10 min

• Compressed air activation:

– Push the thermometer into the plaster

to a 2cm depth

– The compressed air circuit should be

connected (manometer set to 0) during

the minute following the end of setting

(measured with Duromoter Shore

A = 40), this correspond to a rise of 5°C

in temperature

plaster preparation specificities: installing porous air hose

Galvanised Gird To hold the air horse

Air hose diameter 5 to 6 mm

Air hose position distance from the shape

25 mm to 30 mm

Air hose position distance between 2 lines

25 mm

Air hose position distance from the edge

30 mm minimum

Air blowing inputfrom the centre to the edge

Time (min) pressure (bar) Step0 0 Plaster introduction to water

20 0 Initial setting time32.5 1.5 First water35 3 Mould removing45 5 All the water is exuded

020

Time after plaster pouring

Air

Pre

ssu

re (i

n b

ar)

25 30 35 40 45

1

2

3

4

5

6

best practice | ram press++++


VCase Mould

Saint-Gobain Formula pro-

poses extreme hardness and

flawless dimensional stabi-

lity plasters for case moulds.

Such moulds are used to pre-

pare working moulds for cas-

ting, jiggering and ram press

applications

products


exaduro Germany 3.00 10-15 min- High strength- Controlled in expansion

olafdur Germany 3.33 9-14 min- Very high strength- Very high dimensional accuracy (limited in expansion)


For one Tableware application, one plaster solution

Food/Feed, environment & Agriculture

Gypsum & plasterfor Construction Materials

personal CareArts & decoration

Metal Casting

Ceramics

www.saintgobainformula.com [email protected]+62-21 24520522

Saint-Gobain Formula serves all these markets

thailandThai Gypsum Products PCL. Gypsum Metropolitan Tower 539/2 Sri Ayutthaya Road, RatchathewiBangkok 10400, Thailand +66 2 640 8600

GermanySaint Gobain GmbHKutzhütte37445 WalkenriedGermany+49 (0)55 25 20 30

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for one tableware application, one plaster solution › wp-content › uploads › 2017 › 06 ›...

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