The production of ceramic tiles in KAI Group passes through several stages:

 Charging of raw materials
A certain quantity of the stored raw materials is taken according to the type of tiles and the approved recipe. The raw materials are weighed by a conveyor scale and transported by a screw conveyor to the drum /ball mill/, where they are mixed and upon reaching the preset parameters the obtained mixture /shlicker/ is drained into a storage tank.

 Shlicker atomizing
From the storage tank the shlicker passes through a vibration sieve in order the particles to reach  the required dimensionsand enters into a tank from where via a pressure pump it is sent to the АТМ /atomizing dryer/. The obtained  powder passes through a vibration sieve and enters silos for maturing.

 Spray-dried powder pressing
After it has stayed in the silo the spray-dried powder is fed into a press where the tiles are formed /the base or so-called tile body”/. The pressed tiles are transferred to a dryer and then passedonto a glazing line for glazing and decoration.

 Glazing and decoration
All pressed tiles go through:
1. Irrigation – made to ensure a better contact between the “body” and the next layer called engobe
2. Engobing – a special material is used to smooth any rough areas on the surface of the “body”, that might appeat  during the pressing process or the transportation of the tile by the conveyor.
3. Glazing – the basis is painted in various colors depending on the model and color of the tile.
4. Decoration – done by means of rotocolor  heads with cylindrical form, that apply the colors and patterns, enabling the application of 4 to 5 colors depending on the model of the tile.
The tiles are then loaded onto railroad cars.

 Firing
The filled railroad cars are transported to the entrance of the kiln. Then they are unloaded and the tiles are fed into the kiln, while the temperature is being strictly controlled at each point of the process, depending on the type of the tile and the raw materials used.

 Sorting of the ready production
After exiting the kiln the tiles are again transported by a screw conveyor to the sorting facility:
1. They are sorted by the sorting workers according to the visible defects on their frontal surface.
2. They pass through a float meter that measures their straightness.
3. The dimensions of the tiles are checked by a laser calibrating machine – 5 calibers are usually sorted simultaneously.
In case of determined deviations in the straightness or caliber the tile is labeled as 3rd grade or as waste.

 Packaging
The production is packaged and placed on a pallet along with tiles of the same grade, caliber and pattern. Once the tiles are packed into a carton box a printer fills a special table with the following data: model name, barcode, grade, caliber, pattern, sorter’s number and manufacturing date. The information is necessary for providing better services to the clients.

 Storage
The graded production on the palettes is transported and stored in a warehouse from where it is later taken on its journey to the consumers.