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Manufacturing Facilities |
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| Baroda Plant |
It is located at VILLAGE DORA, TALUKA AMOD, DISTRICT- BHARUCH, GUJARAT. The place is around 60 km away from Vadodara.
This plant is the REGISTERED OFFICE of Bell Ceramics Limited. |
| The commercial production of floor tiles started in the year 1988. |
| From 26th March 1998, Monoprossa Fired Wall Tile production got started. |
| In year 2005, Double Fired Wall Tile production was initialized with introduction of 254 mm x 330 mm designs along with Edge-cut (397 mm x 397 mm) Floor Tiles. |
| The present capacity of plant is around 17,000 sqm per day. |
| The Technology used in this plant is Wet Process. |
| It is located at VILLAGE DORA, TALUKA AMOD, DISTRICT- BHARUCH, GUJARAT. The place is around 60 km away from Vadodara. |
| This plant is the REGISTERED OFFICE of Bell Ceramics Limited. |
| The commercial production of floor tiles started in the year 1988. |
| From 26th March 1998, Monoprossa Fired Wall Tile production got started. |
| In year 2005, Double Fired Wall Tile production was initialized with introduction of 254 mm x 330 mm designs along with Edge-cut (397 mm x 397 mm) Floor Tiles. |
| The present capacity of plant is around 17,000 sqm per day. |
| The Technology used in this plant is Wet Process. |
| Dora plant is has got State–of-the-art laboratory which is equipped with modern equipments as per the required testing procedures as per EN/IS Standards. |
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| Following are the equipments |
| Speedy Pot Mills (4 nos) » MMS, Italy make . for preparing the glazes in the laboratory for R&D and testing of incoming raw materials. High Alumina Porcelain jars (from Ceramic Instruments., Italy) are used for grinding purpose. |
| Jar Mill (2 Nos) » MMS, Italy make . for preparing the body in the laboratory scale for new development. High Alumina Jars (from Ceramic Instruments., Italy) are used for grinding purpose. |
| Electronic Balance (2 Nos) » High precision electronic balances are used to maintain higher degree of accuracy. |
| Dryer » MMS make, Italy for drying of purpose. |
| Laboratory Press » Ceramic Instruments, Italy make to press 8”x 6” tile for Body trials in laboratory scale. |
| MOR Machine » Ceramic Instruments,Italy, to test the MOR (Modulus of Rupture) of the tiles. |
| Abrasion Testing Machine » Ceramic Instruments, Italy, to test the surface abrasion of the tiles as per (PEI method) |
| Autoclave » Erection & Instruments, Ahmedabad ., to test the tiles for Crazing resistance. Tiles will be subjected to saturated steam pressure of 7.5 kgs/cm2 for 2 cycles. |
| Optical Microscope » To see the defects which are microscopic and for testing any impurities. |
| Digital Vernier Calipers » Mitutoyo make, Japan , to check the sizes in millimeters with an accuracy of 0.01 mm. |
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| Current Product Sizes |
| Wall Tiles: 200 x 300 mm, 254 x 330 mm |
| Floor Tiles: 300 x 300 mm, 400 x 400 mm, 397 x 397 mm (Edge-cut) |
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| Facilities |
| Roller Hearth Klin, well-proven for single firing, fast firing. |
| Screen Printing, screen preparation, design & development department and dark room. |
| A Large spray Drier and Slip house department. |
| A fully equipped R&D Division which continuously develops new designs, textures, colours and sizes of Wall Tiles keeping with the market trends. |
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| Raw Materials |
| Primary raw materials required for manufacture of Floor tiles are various types of clays, quartz, Calcite/Woolastonoite, Frits and Glazes. |
| Most of the raw materials are easily available in Gujarat and in the neighbouring state of Rajasthan. |
| Bell uses natural gas as fuel right from the inception stages .The fuel is sourced from GAIL. |
| Frits and Glazes are imported from abroad to give the world class quality and exotic look to the tiles. |
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| Manufacturing Process-Wall Tiles (Dora Plant) |
| Manufacture of Double Fast Fired Wall Tiles is a highly technology production process, with better quality & appearance. |
| Various raw materials are weighed individually and ground in a Ball Mill with water. The resulting Slurry consists of around 60% solids and 40% water. |
| The Slurry is then Spray Dried at High pressure to obtain a powder with around 5.5 % moisture content. |
| Such powders are stored in Stainless steel Silos. |
| Then the powder is pressed in high pressure hydraulic presses (Press no. 1 & 2) into the shape of a tile. |
| The tiles are then passed through a Horizontal Drier and subsequently through a Kiln where the Tiles are fired at high temperature. |
| There is a 75 meter long glaze line where glaze application is being done. |
| The tiles are printed in screen printing machines which work at very high speeds. |
| The glazed tiles are then passed through the second kiln where the temperature is even higher than the first kiln (around 1110 degree C temp). |
| This results in wall tiles with attractive appearance. |
| The tiles are graded for size, shade and then packed in automatic selection lines. |
| The Tile boxes are palletized and shifted to the warehouse with fork lift and are ready to be dispatched by trucks to adorn the walls of the buyer. |
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| Manufacturing Process-Floor Tiles (Dora Plant) |
| The Floor Tile manufacturing process is almost the same as that of the Wall Tile. |
| The only difference is that floor is fired only once. After taking the tile of press (Press no 3, 4 & 5), it is directly sent through the glaze line and screen-printing. |
| The Tiles are then loaded to cars. |
| The cars are taken to the entrance of the kiln. |
| After passing through the Kiln, sorting is done. |
| If the 400 x 400 mm tiles are to be made ‘edge-cut’, they are taken to a separate for edge cutting before being paced in the boxes. |
| The boxes are sent to the warehouse for storage/dispatch. |
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