PREAMBLE TO THE DESCRIPTION:
[0001| The following specification particularly describes the invention and the
manner in which it is performed:
DESCRIPTION OF THE INVENTION
Technical Field of the Invention
|0002|The present invention relates to an energy efficient method for
manufacturing of'tiles. More particularly, the present invention relates'to method
of manufacturing of tiles with reduced energy consumption.
Background of the Invention
|0003| Quality wall files are generally made by firing limes. In the lirsl
firing, the pressed tile is fired to make the biscuit. The biscuit is then glazed,
decorated etc. and fired in the kiln (called Glosl firing) to generate the finished
product — Glazed Wall Tiles.
I0004| Wall tiles are produced by say I% of the producers by the single firing
process called Monoporosaor by the more popular Dual firing process The single
firing process generated wall tiles do not give the high quality obtained by the
double fired process/dual firing process. So, most producers of wall tiles adopt the
dual firing process.
IOOOSI Further, in the conventional dual firing process, the green tiles are dried
and then fired at around I [20°C to l|45°C to make biscuit. This biscuit is then glazed (decorated, etc.) and then fired in the kiln again at about l070°C 10 l |00°C
(glost firing) to obtain the finished product.
Object of the invention
|0006| The principal objective of ‘The invention is to a, provide method of
manufacturing of tiles with reduced energy consumption.
10007] Another objective of the invention is to provide method of manufacturing
of tiles in which energy consumption drops of about 13% when compared to the
existing conventional methods.
I0008| Another objective of the invention is to provide method of manufacturing
of tiles to lower C02 emissions which will lead to lowering the greenhouse gases
generated.
|0009l Another objective of the invention is to provide a method'which
reduces company’s carbon foot print substantially.
[0010] These and other objectives and characteristics of the present invention will
become apparent from the further disclosure to be made in the detailed description
given below.
Summary of the invention
|0011| This summary is provided to introduce a selection of concepts in a
simplified form that are further described below in the Detailed Description. This
summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the
scope of the claimed subject matter.
|0012| The invention provides method of manufacturing of tiles with reduced
energy consumption. Example embodiments, the method includes firing a dry tile
in the first kiln a1 a temperature of 950° C. The method further includes firing the
glazed tile at a temperature of lHOOC in the second kiln. The method further
includes obtaining the final product/ decorated tile.
[0013] In some example embodiments, the first kiln comprises a first plurality of
burners. In some example embodiments, a number of the first plurality ot‘burners
is 72.
[0014] In some example embodiments, the second kiln ([03) comprises a second
plurality of burners. In some example embodiments, a number of The second
plurality of burners is 96‘
Brief Description of Drawings
|0015| The foregoing and other features of embodiments will become more
apparent from the following detailed description of embodiments when read in
conjunction with the accompanying drawings. In the drawings, like reference
numerals refer to like elements.
[0016] In the following description, for the purposes of explanation, numerous
specific details are sex Fonh in order to provide a thorough understanding ol' the
embodiments of the invention It is apparent, however, 10 one skilled in the art that the embodiments of the invention may be practiced without these specific
details or with an equivalent arrangement. In other instances, well—known
structures and devices are shown' in block diagram form in order to avoid
unnecessarily obscuring the embodiments oflhe invention.
|0017| FIG. 1 illustrates an apparatus manufacturing of tiles, according to one
embodiment of the invention.
[0018} FIG Illustrates a method of manufacturing of tiles with reduced energy
consumption, according to one embodiment of the invention‘
Detailed Description of the Invention
|0019| Reference will now be made in detail to the description of the present
subject matter, one or more examples of which are shown in figures. Each
example is provided to explain the subject matter and not a limilaxion. Various
changes and modifications obvious to one skilled in the art to which the invention
pertains are deemed to be within the spirit, scope and contemplation of the
invention.
|0020| The word “exemplary” is used herein to mean “serving as an example,
instance, or illustration.” Any aspect described herein as “exemplary” is not
necessarily to be construed as preferred or advantageous over other aspects.
l002|| FIG. 1 illustrates an apparatus for manufacturing of tiles, according to one
embodiment of the inventions the apparatus comprises a first Kiln (101) and a
second Kiln (103).The kiln is a thermally insulated chamber, a type of oven, that produces temperatures sufficient to complete some process, such as hardening,
drying, or chemical changes. Kilns have been used for millennia to turn objects
made from clay into pottery, tiles and bricks.
|0022| In some example-embodiments, _Ihe dried tiles are fired ax temperature of
950°C in the first kiln (IOI) and then fired at around lll0°C in lhe 2nd kiln For
glost firing. By this process about 13%energy is saved.
|0023| By firing the dried tiles in [he first Kiln (IOI) and the second Kiln (l03),
the quality wall tiles are produced. In the first firing, the pressed tile is fired to
make the biscuit. The biscuit is then glazed, decorated etc. and fired in the second
kiln ([03) (called Glosl firing) to generate the finished product/Glazed Wall Tiles
[0024] Conventionally, the biscuit firing mmperature is around [135°C based on
Loss of Ignition ofthe raw materials used For Khe body composition. The biscuit
so made is then glazed and fired at about l070°C Io IOSOOC to obtain the final
finished product.
|0025| Whereas, in the present invention the~biscui1 is fired at lower temperature
950°C in the first Kiln (IOI). This is achieved by selective body raw materials
usage. However,
(by firing the tiles at 950°C, the strength of body is less than
when biscuit .is fired at ll35°C. This aspect is addressed in the 2"d firing/ 2"" Kiln
(post glazing) by firing at l|l0°C in the second kiln (I03).

[0026] Conventionally, the number oH‘uel burners used in the biscuit firing kiln is
96 when firing at ll35°C. Whereas, the present invention. when firing at 950°C
the number of burners in operation are 72 (Le‘, 23% less burners are used).
|0027| Similarly in the glosl firing kiln, conventionally, the number ol‘burners in
operation for lO70°C are 96. hm the present invention firing in the second kiln
(l03) for firing at H IOOC, the number of burners in operation are 2115096 with a
different firing profile‘
[0028] Therefore, the net fuel savings per day is ISOOScm/day. However,
conventionally, the energy consumption was l3500 scm/day.
[0029] With gas consumption reduced by lSOOscm/day the fuel savings is
1800/13500 x 100 = 13.3% of the fuel consumed in the conventional process is
saved by this invention.
|0030| FIG Illustrates a method of manufacturing of tiles with reduced energy
consumption, according to one embodiment of the invention. In some example
embodiments, the method includes at step 20], the dry tile is fired in first kiln
(101) at a temperature of9500C.
[0031] In some example embodiments, the method further includes all step 203,
the glazed tile which is output after glazing the tile obtained from the first kiln
(IOI) is fired at a temperature of I l |0°C in the second kiln (I02).
|0032| In some example embodiments, the method further includes at mp 203,
the final product] decorated tile is obtained.

|0033| RESULTS AND ADVANTAGES:
|0034| Lower energy consumption in many ceramic wall tile companies currently
producing tiles by (he longestablished double firing route if converted to the
above invented route can save the natural gas resources.
|0035| Lower C02 emissions which will lead to lowering the greenhouse gases
generated.
|0036| The many features and advantages of the invention are apparent l‘rom the
detailed specification, and thus, h is intended by the appended claims to cover all
such features and advantages of the invention, which fall withinlhe true spirit,
and scope of the invention. Further, since numerous modifications and variations
will readily occur to those skilled in the art, it is not desired to limit the invention
to the exact construction and operation illustrated and described, and accordingly,
all suitable modifications and equivalents may be resorted to, falling within 1|;e
scope of the invention.

CLAIMS:
I/We claim,
I. A method for manufacturing of tiles with reduced energy consumption.
comprising:
firing (20])adry tile, in a first kiln (l0I), at a temperature of 9500 C lo
obtain a biscuit tile;
firing (203), in the second kiln ([02), the biscuit tile which is output from
the first kiln (IOI) at a temperature of | I 10°C;to obtain the glazed tile (205),
in this second firing for the final product;
2. The method (200) as claimed in claim I, wherein the first kiln (IOI) comprises
a first plurality of burners
3. The method (200) as claimed in claim 2, wherein a number of the first plurality
of burners is 72.
4. The method (200) as claimed in claim I. wherein the second kiln (l03)
comprises a second plurality of burners.

5. The method (200) as claimed in claim 4, wherein a number of the second plurality of‘burners is 96.