M.D.Prajapat Ceramics Believes in delivering quality and hence quality inputs are necessary for them. They purchase the best Quality Raw Materials for their production. Their main ingredients are Black and Red Clay.
The Cubes are then pressed into shape in machines. The machines are semi-automatic or manual. They have dies or the shaping.
The semi –automatic machine is quite fast and can give out production quickly as it has more dies and faster working cycle. However, the quality still remains good. The cast shape is then taken onto a wooden plate that is laid on the rack. Once the rack is full, it can be moved to another place to enable natural drying.
In the manual Machine, The clay is laid and the worker stamps it with the machine. He removes the piece and leaves in on rack.
The slurry remains there for some days depending on the weather. The main objective is to dry out the slurry and minimize the moisture content. It is a natural drying process and takes time. However, this natural drying leads to best quality of the clay, which enhances product quality and uniformity
The Dried out clay is then cut into small standard cubical pieces. It is not possible to handle the clay as a whole or in irregular shapes. The standard pieces make the movement of the cubes of clay easier and manageable. This clay is stored for use at a later stage.
The Kiln is then used for firing. It occupies a large area and has compartments with entrance on the outer periphery. The compartments are used intermittently to fire the shaped roof tiles.
An empty compartment is cleaned. The Shaped Roof tiles are placed into the compartment very carefully. The compartment is then packed on the outer side, to stop the hot air to blow out. The roof tiles get totally baked by moving hot air within the Kiln.
The roof tiles are removed intermittently from the compartments.
The Mixing of the Clay, other additives and water is done in pre-measured proportions. Blingers are used to mix them. Blingers are placed next to the clay Dumps to have faster Transportation for the clay.
The mixed material is then sieved to remove it from dirt and other unwanted particles. These particles tend to make the product weaker and hence are sieved out.
The slurry of the mix that has passed through the sieves is transferred to one of the many Drying Wells through a gutter system.
Vacuum Process is then carried out on the clay cubes. It cleans the cubes as well as reshapes them to pre-decided sizes. The moisture content is also controlled in this process as the next phase requires the moisture content to be well maintained for shaping.
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