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1. Production Line Overview
The toilet production line is an intelligent manufacturing system for ceramic sanitary ware, following six core steps: blank forming, glazing & firing, functional component assembly, full-performance testing, finished product packaging, and storage. Using precision molds, high-temperature firing, and water-saving processes, it transforms ceramic raw materials into finished toilets. Compatible with siphon, direct-flush, and smart models, it supports flexible production for diverse specifications, including flushing and heating functions.
2. Blank Forming Line
As the foundation of toilet structure, this line prioritizes “compactness + forming accuracy” to avoid defects. Raw materials (kaolin, porcelain stone) are crushed into micron-level powder via ball mills. After pressure filtration, dehydration, and vacuum refining (removing bubbles/impurities, mud moisture 22%–25%), ordinary toilets use automated high-pressure grouting molds (accuracy ±0.2mm, 15–20MPa hydraulic pressure). Smart toilets rely on CNC engraving for shaping. Formed blanks are polished to remove flash burrs, then sent to drying kilns (60–80℃, 8–12 hours, moisture ≤3% to prevent cracking). Conveyor belts transport blanks, with codes scanned to record model information.
3. Glazing and Firing Line
This line determines toilet surface texture and durability, focusing on “smooth glaze + high-temperature curing” for bathroom environments. After dust removal, ceramic glaze is spray-applied via robotic systems (glaze thickness 0.8–1.2mm). Inner walls use high-pressure pouring to avoid pinholes/hangs; high-end products add microcrystalline self-cleaning glaze for stain resistance. Glazed bodies enter tunnel kilns, undergoing preheating, high-temperature sintering (1280–1320℃), and cooling (18–24 hours) to form dense, acid/alkali-resistant, anti-leakage ceramic structures. Post-firing, visual inspections check for glaze flaws (scratches, color differences); unqualified bodies are diverted, while qualified ones proceed.
4. Functional Component Assembly Line
Adopting a “partitioned station + standardized installation” model, this line ensures reliability of flushing, sealing, and smart functions. Conveyors move ceramic bodies to workstations equipped with flushing systems (siphon/direct-flush), water-saving tanks, and flush valves (≤6L per flush). Smart toilets add heating modules, spray guns, sensors (IPX4 waterproof), and electronic controls. Key steps include installing anti-leakage flanges, testing tank tightness (30-minute pressure, no leaks), and verifying smart features (33–38℃ flush temperature, 5–10cm sensing range). Component specifications (flush valves, control panels) are recorded at each station to prevent errors.
5. Full-Performance Testing Line
Multi-station tests ensure toilet safety, water-saving, and durability for sanitary standards. First, appearance and size checks identify glaze scratches/cracks; laser rangefinders verify pit distances (300mm/400mm, deviation ≤5mm). Anti-leakage tests inject water into tanks, maintaining pressure for 1 hour (no seepage). Core performance tests include flushing efficiency (single flush rate >95%, sewage discharge >85%) and water-saving compliance (national first-level standards). Smart toilets undergo electrical safety tests (insulation ≥500MΩ, leakage response ≤0.1s). Test data is uploaded in real time; unqualified toilets are repaired, while qualified ones are cleaned.
6. Finished Product Packaging and Storage Line
Focused on anti-collision protection and warehousing for fragile ceramic toilets, qualified units are wrapped in pearl cotton (protecting glaze/edges), placed in dustproof bags, and packed into customized thickened cartons (secured with foam molds). Labels mark type, pit spacing, batch, and “handle with care” warnings. AGVs transport boxes to smart storage areas, sorted by “type + pit spacing.” The system updates inventory in real time and controls storage humidity (<60%) to prevent glaze damage from moisture.
7. Core Advantages of the Production Line
- Durability & Water-Saving: Core processes (forming, firing, testing) have >70% automation. High-temperature firing ensures ceramic density, and water-saving features cover the entire line (meeting environmental requirements).
- Flexible Production: Supports mixed-line production of ordinary/smart toilets and varied pit distances. Product changes take ≤2 hours (via mold replacement and parameter adjustment), adapting to diverse market orders.
- Intelligent Management: The MES system collects real-time data (blank pass rates, glaze defect rates), improving equipment failure warning response by 20%. Unique traceability codes track raw materials, firing batches, and test data for quality control and after-sales service.
- If you have any questions or needs about the automated assembly line, please contact us via email: [email protected]