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Here at PrimaPorcelain, we're pretty confident that by now you would all have a fairly strong understanding about porcelain and how we believe it is a superior flooring option to its natural stone counterparts. But do you know how porcelain paving is made to make it a better choice? If not, we are here to tell you! 

How is Porcelain Paving Made

 

The Manufacturing Process

Porcelain is manufactured using a mixture of sands, clays and other important minerals such as feldspar, which are then baked in a high-temperature kiln. Before the unbaked mixture is sent to the kiln, there is a lot of preparation that is required, followed by a fair bit of post-firing work to ensure the product that is sent out to trade is of a high enough quality and standard. Below we will look at each of these important stages to how porcelain paving is made.

The ingredients 

To create the base mixture for porcelain, four ingredients (plus water) are commonly used. These are:

  • Feldspar - A granitic mineral from a variety of sources 
  • High-quality fine clays sourced from Italy, Germany and Turkey 
  • Kaolin - Also known as China Clay in Britain and Ireland, sourced from Ukraine 
  • Quartzitic sand - A very pure and fine sand sourced from Germany 

Preparation 

Very specific quantities of these materials are mixed together with clean, cold water into a slurry, which is then processed in a ball mill to decrease the materials into very fine particles. These particles are so fine the finished product seems like a slippery mud with no discernible grittiness. If you were to rub it between your fingers, it would feel like a fine lubricant, leaving a soft streak across your skin. 

Drying

In this muddy form, the mixture of materials is very easy to move around, however, the majority of the water content has to be removed before the mixture can be taken any further. This is performed via a screen drier which utilises hot air and gentle rotation to decrease the moisture levels to approximately 6%. The water that is recovered can then be re-used to create a new initial mixture to keep wastage levels to an absolute minimum. 

Storing the Mix 

Once the water is removed from the mixture of materials, the dry-ish powder is then kept in a silo until it is required. Different mixes are kept in different silos, with up to 80 silos being held in certain manufacturing plants. Each of these silos holds a slightly different mix, with more or less clay, or a higher proportion of kaolin, for example. 

Blending

The next step of the process sees the mixture stored in silos being blended within specialised 'blending towers'. Each tower takes precise quantities of particular mixes from a variety of silos and creates a blend specific to the product that is being manufactured. For example, darker-coloured porcelain might contain more content from silo 19 and less from silo 26, while lighter-colour porcelain might use more from silo 11 and less from silo 7. The secret to producing high-quality porcelain lies in blending the perfect quantities of various mixes to produce the ideal 'biscuit' ready to be baked.  

Pressing 

The blended powder coming from the towers is then pressed into moulds. Some of these moulds will be smooth with zero surface relief, others will have specific textures or profiled surfaces. Some will be produced in a square-shape, others rectangle. Some will be small, some will be large. The blended powder is subjected to huge amounts of pressure, compacting it into the specific mould, so much so that it turns into a fairly hard material, similar to a biscuit before it is fired in the kiln.

Drying

After pressing, the moisture content of the 'biscuit' is reduced even further from the previous 6% to just 1-1.5% by passing it through another drier, again recovering the water to re-use. The material which emerges from this process is very noticeably harder, tougher, crisper and requires a tough more effort to snap into two pieces.

Finishing Touches 

After the material is dried, it is then coloured or printed on and placed in the kiln to be fired. Here this material is carried into the fierce heat of the kiln for around 100 meters, with temperatures reaching as high as 1,200 degrees celsius before going through an equally finely-controlled cooling stage. This cooling stage is just as important as the heating in producing a quality porcelain paver. Once this is over, the tile is then sized to the correct measurements and given additional treatments such as sealants, wax or protective coating before being checked over once more and packed up to be delivered to trade. 

This completes the process of how porcelain paving is made. A very delicate process which requires particular attention and detail at each stage. The finished product is a flooring material that offers extremely low-maintenance properties, high resistance to all fading, scratches and stains and overall premium-quality finishes. A material that is long-lasting and gorgeous to look at! You can browse our full collection of porcelain products by clicking below. Order your FREE sample to get a close-up look and see the quality for yourself. 

Browse Porcelain Paving >

 

For more information on our range of porcelain products, be sure to get in touch with a member of the PrimaPorcelain team today!

From living rooms to sunrooms, corridors and bathrooms, black and white porcelain tiles are a design feature that's been seen in homes for decades. This comes as no surprise, however, as black and white tiles are extremely versatile, offering interior and exterior living spaces tastes of both luxury and minimalism. Which is why PrimaPorcelain is offering this comprehensive guide on how to use black and white porcelain tiles for your home or property so that you can bring a stylish monochrome palette with absolute confidence. 

Black Porcelain Tile White Porcelain Tile

Classic Styling 

When it comes to black and white porcelain tiled floor, you won't find a more classic design than the tried and tested checkered-look. A timeless design that is sure to leave any and all guests wowed as they first set their eyes on it. If you're looking to make a real grand impression, your home's entrance corridor is the perfect place to lay your black and white porcelain tiles, giving your guests an immediate stunning impression of your property. You can complement your floor with luxurious furniture for an interior design that screams lavishness. 

If your home is lucky enough to boast a big bathroom, then large black and white porcelain checkered tiles are an excellent choice to make a bold statement. Couple your checkered floor with classic bathroom fittings to create a traditional look that's sure to never go out of fashion. If, on the other hand, your bathroom is a little on the smaller side, a mini-checkered style floor will give the illusion of a larger space. Pair your floor design with plants and accessories to complete this gorgeous monochrome look!

 

Switch It Up 

For those of you who are feeling a tad more adventurous, a recent trend that has been sweeping homes up and down the country has seen white porcelain tiles paired with darker-styled wood tiles. This high contrast look offers all the same benefits of the classic checkered look but with added texture, perfect for those looking to push the boundaries. This style is particularly effective in a living room or in front of a traditional fireplace, bringing a new dimension to your living space in the most beautiful way possible. 

Another option that you could try is is to combine black and white tile to define sections within an open plan place. Black wooden flooring, for example, can be used in areas of your home that are in desperate need of a little more warmth such as dining and living areas. Couple this with some beautiful white porcelain tiles to clearly indicate where your kitchen space begins for a modern design that doesn't compromise on functionality.

 

Pleasure with Patterns 

If you're looking to add an element of fun with your black and white floor, why not add some eye-catching patterns that mimic an original feature of an older property? Geometric tiles are an artistic way that you can add detail and intricacy to your home while paying homage to a classic aesthetic. If you're looking to create a more contemporary interior design, however, an escher-esque box tile flooring design will add a look that will be impossible to ignore. Couple this with white gloss furnishings and monochrome accessories for a dramatic look that stands together and makes an instant impact. 

 

And there you have it! Our guide to white and black porcelain tile for your home. We hope that you will now be well-equipped with the inspiration needed to add a monochrome vibrancy to any room in your property. Be sure to browse our extensive collection of black and white porcelain below to find the flooring product that suits you. 

Black Porcelain Tiles >                   White Porcelain Tiles >

 

For more information on our collection of black and white porcelain tiles, please do not hesitate to contact a member of the PrimaPorcelain team today by calling 02920 803 756 or emailing info@primaporcelain.co.uk

 

Despite the recent difficulties faced over the past few months, the team here at PrimaPorcelain are extremely excited and proud to share the latest updates regarding our project with former English Premier League Champions, Leicester City Football Club! The Foxes have been hard at work over the last year building their state-of-the-art, £100m training complex which is set to be completed for the start of the next Premier League campaign and progress over the last few months has really started to pick up. 

PrimaPorcelain has helped in the creation of the new Seagrave training ground by supplying over 600 square metres of our gorgeous Concrete Silver porcelain paving which is being installed within the players' hydrotherapy garden and courtyard terraces located in the main building. The porcelain tiles are being installed on top of our adjustable, self-levelling support pedestals, which have contributed to the quick turnaround and progress on-site. 

Take a look at some of the fantastic images coming out from the training ground below:

  

 

 Concrete Silver Paving >

 

As well as high-quality porcelain paving and tiles, our sister company TimberTechUK have also supplied Leicester City with more than 500 square metres of their EasyClean Terrain+ Silver Maple composite decking, which is being installed on balconies of the main, centrepiece building. 

Silver Maple Composite Decking >

 

The whole team here at PrimaPorcelain are incredibly proud of the progress made so far on the installation of our porcelain tiles and very much look forward to seeing the finished results. Be sure to keep an eye out on further updates from us, where we will be showing off the final look! 

If you would like to enquire about our Concrete Silver porcelain tiles or any other products in our range, then please do not hesitate to get in touch with a member of the PrimaPorcelain team today, we are more than happy to help with anything you may have. 

Travertine Grey paving on patio

This beautiful patio area was created using our 20mm Travertine Grey porcelain paving! We love how our stylish grey pavers look alongside those curved white garden walls. Very modern!

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Textured non-slip porcelain paver

It rains a lot in this country. If you live in the UK and you have a garden, that garden of yours is frequently going to get wet.

This is nothing new, but it is something to bear in mind when you're shopping for outdoor tiles. Your patio will need to be capable of withstanding Britain's infamously wet weather, but perhaps even more importantly, you need to know that your paving won't get too slippery after a shower.

After all, you don't want to slip and hurt yourself when you're trying to relax and enjoy your garden!

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