Overhead Crane Solutions for Ceramic & Sanitary Ware Manufacturing
Sanitary ware ceramic manufacturing (high-pressure casting machines 5–15 t/unit, toilet molding lines with dies 2–6 t/set, tunnel kilns/roller kilns, glazing robots 50–200 kg) is a high-temperature, high-humidity, die-intensive industry. Recommended configuration: LD Type single-girder crane 3–5 t + MH gantry crane 5–10 t + electric flat car + KBK auxiliary hoists for glazing lines. Kelude Heavy Industry's sanitary ware solution focuses on rapid die changeover and kiln car logistics.
Sanitary ware ceramic manufacturing centers on high-pressure casting to produce toilets, washbasins, bathtubs, urinals, and similar fixtures. Unlike wall and floor tile ceramics, sanitary ware consists of three-dimensional molded products — dies are complex (2–6 t per set), wet green ware has low strength (prone to cracking), and finished pieces carry high value (50–5,000 CNY per unit). This article provides crane configurations tailored to the specific characteristics of sanitary ware production.
Raw Material Slurry Area — Ball Mills, Slurry Tanks & Spray Drying Towers
Sanitary ware raw materials consist of ceramic slurry (kaolin + feldspar + quartz). Ball mills (10–30 t per unit) grind the materials into fine slurry (fineness: ≤1% residue on a 250-mesh screen). Slurry tanks (20–100 m³ capacity) require crane assistance for maintenance of agitator motors and gearboxes. Spray drying towers (10–30 t per unit) convert slurry into dry powder for pressing. The raw material workshop has high humidity (slurry moisture vapor), so motors must be moisture-proof.
Recommended model: LD Type electric single-girder bridge crane, 3–5 t / span 10–15 m, with moisture-proof motor (IP55 + sealing cover + drain hole). A jib crane (1 t) handles ball mill liner replacement. A hoist at the tower top supports spray tower maintenance.
Price reference: LD single-girder 3 t: approx. 30,000–60,000 CNY per unit (moisture-proof version +10%). Kelude Heavy Industry's raw material solution for sanitary ware includes moisture-proof motors and a ball mill liner replacement lifting spreader.
High-Pressure Casting — Die Storage, Casting Machines & Finishing Lines
High-pressure slip casting is a critical step in sanitary ware production: the mold (resin, 2–6 t per set, including the die rack and resin lining) is closed on the casting machine, slip is injected at 1.5–2.0 MPa, and after the holding period the part is demolded, trimmed, and dried. Mold inventory is substantial—a single toilet model may require 20–30 mold sets in rotation—and molds are changed 3–8 times per day.
Recommended model: LD Type single-girder electric crane, 3–5 t with a 12–18 m span, covering the casting area and mold storage. A hydraulic mold cart (3 t load capacity, traveling on floor rails) transfers molds between casting machines. The mold storage area is equipped with multi-level die racks (3 t per level), serviced by the crane.
Price reference: LD Type single-girder crane, 3 t: approx. $4,500–$8,900 per unit. Hydraulic mold cart: approx. $4,500–$7,400 per unit. Kelude's sanitary ware molding package includes the hydraulic mold cart, die racks, and mold corner guards.
Drying & Glazing — Ware Cart Transfer and Glazing Line
Green ware (moisture content 16–20%) has very low strength (bending strength ≤ 1 MPa)—any impact during handling causes cracking and scrapping. Pieces are placed on ware carts (3–8 toilets or 10–20 washbasins per cart) and moved through the drying chamber (60–80°C) and glazing line for trimming. Glazing robots (50–200 kg) apply the glaze spray.
Recommended model: An electric flat car (1–2 t load capacity, running on rails that connect the drying chamber and glazing line) transports the ware carts. The car deck is covered with a 10 mm rubber pad for vibration damping. A KBK 250 kg workstation provides coverage for glazing robot maintenance.
Price reference: Electric flat car, 2 t: approx. $3,000–$5,900 per unit. Kelude's drying and glazing package includes the rubber-padded flat car and a KBK maintenance lifting point for robots.
Firing & Packing — Kiln Car Handling and Final Quality Control
After firing in a tunnel kiln (1200–1250°C, kiln cars carrying 3–8 t of finished ware), products exit the kiln and go through inspection, packing, and warehousing. Fired ware has a vitrified glaze surface (Mohs hardness ≥ 7)—strong but brittle, and it shatters on impact. Individual pieces are valued at $7–$740, and the finished-product breakage rate must be kept at or below 1%.
Recommended model: MH Type single-girder gantry crane, 3–5 t with an 8–12 m span, covering the kiln discharge end. It is fitted with a flexible lifting sling and a vacuum lifter (200 kg suction force, dual-circuit protection to prevent load drop in the event of vacuum failure).
Price reference: MH Type gantry crane, 3 t: approx. $5,900–$11,900 per unit. Kelude's finished-goods package includes the vacuum lifter, anti-drop dual-circuit protection, and flexible lifting sling.
Sanitary Ware Crane Configuration Overview
| Process | recommended model | Tonnage | special requirements | reference price |
|---|---|---|---|---|
| Raw Material Pulping | LDMoisture-Proof+jib crane | 3~5t | IP55moisture-proof motor | 3~610,000 |
| Slip Casting | LD+Hydraulic Mold Change Cart+die rack | 3~5t | die2~6t/Quick Change≤20Minutes | 3~1110,000 |
| Drying and Glazing | Electric Flat Car+KBK | 1~2t | Rubber Pad Vibration Damping/Dry Blank Cracking Prevention | 2~610,000 |
| Firing and Packaging | MH+Vacuum Lifter | 3~5t | Dual-Circuit Anti-Fall Protection | 4~810,000 |
Kelude Service Advantages for Sanitary Ware Plants
Kelude Heavy Industry tailors sanitary ware solutions to each process stage — moisture-proof raw material handling, quick mold change for casting, crack-free green body transport, and vacuum lifter fall protection for finished goods.
Quick Mold Change System
A hydraulic mold transfer car (3t load capacity) moves dies between casting machines along floor rails, working with a multi-tier die rack. Mold change takes ≤20 minutes, and die inventory is reduced by 30%.
Finished Product Breakage Prevention
An MH gantry crane with a vacuum lifter (dual-circuit fall protection) and flexible lifting slings cuts finished product breakage during loading and unloading from 3% to below 0.5%.
FAQ
Q: Why are sanitary ware molds so heavy (2~6t per set)?
A: Sanitary ware molds (resin molds) consist of three parts: ① the mold frame — steel or aluminum, weighing 1~3t, ensuring a closing accuracy of ±0.1mm; ② the resin lining — polyurethane resin contoured to the product shape, weighing 0.5~2t; ③ the slip casting piping system — distributes slurry to all mold cavities, weighing 0.3~1t. The complex geometry of toilets requires multi-piece mold splitting, bringing the total weight to 2~6t. Mold service life is approximately 5,000~10,000 cycles. Kelude Heavy Industry's die storage solution includes a multi-tier die rack (3t load per tier) and polyurethane mold corner guards.
Q: How do you prevent cracking in green bodies (16~20% moisture) on kiln cars?
A: Green bodies have very low strength (flexural strength ≤1MPa). Crack prevention measures: ① kiln car travel speed ≤20m/min (reduces start-stop impact); ② a 10mm rubber pad with locating recesses on the car deck (green bodies sit in the recesses to prevent sliding); ③ electric flat car rail straightness ≤±3mm (prevents jolting); ④ 5mm thick EPE foam diaphragms between green bodies for cushioning. Kelude Heavy Industry's drying and glazing solution includes rubber-padded kiln cars, foam diaphragms, and a cushioned start control system.
Q: Why recommend a vacuum lifter over traditional lifting slings for kiln car loading and unloading?
A: Fired sanitary ware (vitrified glaze, Mohs hardness ≥7, smooth surface) poses problems with slings or wire ropes: ① slings slip on the smooth glaze — unsafe; ② sling contact leaves pressure marks — affecting appearance; ③ irregular shapes make sling centering difficult. Vacuum suction cups (80~120mm diameter each, 4~6 per lifting spreader) attach directly to the unglazed inner surface of the fixture (e.g., near the toilet outlet), providing 200kg of suction per cup. Dual-circuit protection ensures that even if one circuit fails, suction remains ≥100kg per cup. Kelude Heavy Industry's finished goods solution includes vacuum lifters with dual-circuit protection and fall arresters.
Q: How do lifting requirements differ between a sanitary ware plant and a wall/floor tile plant?
A: The main difference comes down to four factors: ① Dies — sanitary ware dies weigh 2–6 t/set (wall and floor tile dies are 200–500 kg/set), requiring a larger tonnage crane; ② Green body — sanitary ware bodies are three-dimensional wet castings prone to cracking (tile bodies are flat pressed), so handling must be gentler; ③ Glazing — sanitary ware uses robotic spray glazing (tiles use curtain glazing), and the glazing line maintenance is supported by a KBK crane; ④ Finished products — sanitary ware pieces are moved individually with a vacuum lifter (tiles are palletized and moved by electric flat car), so the requirements differ. Kelude offers two tailored solutions for sanitary ware and wall/floor tile production.
