This is part of the information extracted based on Sunlets technology's real sanitary ceramics factory construction case. Sunlets Technology provides unique sanitary ceramics production solutions for each sanitary-ware factory, and customizes high-pressure casting production lines according to customer needs, such as toilet high pressure casting machines, wash basin high pressure casting machines, smart toilet casting systems, suitable for ceramics sanitary ware production.
The following is a part of the whole plan. After sorting out, we will continue to update the content involved in the construction of relevant factories, hoping to help the bathroom enterprises planning to invest in the bathroom ceramic industry and plan to expand production capacity.
Based on the rich experience of serving world-renowned sanitary ware brands for more than 16 years, we provide high-quality pre-sale free consultation services, and you are welcome to contact us.
Annual Production of 1 million pcs Sanitary Ceramics Factory Building Plan
by Beijing Sunlets Technology Co., Ltd.
Chapter 1 General
1.1 Design Basis
According to the requirements of the customer, considering the compact construction, land saving, smooth process flow, manpower saving, reduction of ceramic defects rate, energy saving and consumption reduction, and cost reduction, combined with the current market trending demand and our Sunlets Technology Co., Ltd.’s successful cases for different sized ceramic production plants across the globe, hereby provide the following proposal.
1.2 Construction scale and product structure
1.2.1 Construction Scale
This plan is based on an annual output of medium and high-grade sanitary ceramics 1 million pcs.
1.2.2 Product Structure
Following product structure below:
serial number | product name | Annual output (K pcs/year) | The proportion(%) |
1 | One-piece toilet | 100 | 10% |
2 | Close-coupled toilet | 500 | 50% |
3 | Wash Basin | 300 | 30% |
4 | Pedestal | 100 | 10% |
Total | 1000 | 100% |
Annual output of 1 million pcs of tunnel kiln annual firing volume of various Sanitary ware Categories
serial number | product name | Annual output (K pcs) | Pass rate (average%) | Product unit weight (kg/piece) | kiln weight (t) |
1 | One-piece toilet | 100 | 80 | 35 | 4375 |
2 | Close-coupled toilet | 500 | 95 | 25 | 13158 |
3 | Wash Basin | 300 | 95 | ****** | ****** |
4 | Pedestal | 100 | 95 | ****** | ****** |
The output of one tunnel kiln | 1,000,000 | 18015 |
1.3 Construction Location: Customer Site
1.4 Construction Conditions
1.4.1 Factory site
This project requires a site of 90000㎡ . (According to 1.2 million pcs, 4000㎡ of land is required for production and construction)
1.4.2 Raw materials
Factory owner need to provide the local raw materials that can be used for the production of sanitary ceramics production, and the quality and reserves of raw materials in the origin.
1.4.3 Fuel
Natural gas and coal gas can be used in this project.
1.4.4 Water supply and drainage
The water supply project includes water supply and drainage in three aspects: ceramic production, employee living and fire protection. The production line of 1 million pcs uses about 40,000 tons of water per year, the water pressure is 20-25mmH g , the water hardness is less than 15 degrees, the PH is close to 7, and the water temperature is normal temperature; for the preparation of gypsum molds, water at about 10 ℃ is used; the equipment cooling water is recycled water.
Drainage: There are three types of drainage needs to be considered in a ceramic factory: production, living and rainwater. The production water is discharged after precipitation, and the waste water containing harmful components is discharged after treatment; the domestic sewage is treated by the sewage station in the plant area and then discharged into the urban sewage pipe network; the rainwater is collected into the urban rainwater pipe network through the plant area pipe network.
Teh factory needs a reliable clean water source for the ceramic manufacturing project.
1.4.5 Power supply
It is divided into production electricity and lighting electricity. A power distribution station is built within the factory, with high and low voltage power distribution devices and transformers. The low voltage centralized compensation is adopted in the substation, and the compensation power factor is above 0.9. The kiln requires two independent power supplies to ensure continuous operation of the kiln. An additional set of diesel generators is also required. Lighting electricity is supplied by an independent circuit. Lightning protection grounding is in accordance with local official standards.
Th factory needs a reliable electricity/power supply.
1.4.6 Earthquake and Meteorology
Teh factory needs to provide the geological conditions of the site and the meteorological conditions near the plant.
1.5 Main technical and economic indicators
Main technical and economic indicators of the sanitary ceramic production line with an annual output of 1 million pcs
serial number | project | unit | index | Remark |
1 | scale | |||
Medium and high-grade sanitary ceramics | pcs/year | 1,000,000 | ||
2 | Raw material consumption | *** | ||
Of which: slip production | tons/year | *** | ||
Glaze production | tons/year | *** | ||
Pigment and others | tons/year | *** | ||
3 | Auxiliary material consumption | |||
Of which: calcined gypsum | tons/year | *** | ||
4 | Fuel consumption (including heating) | |||
gas | Nm3 / day | *** | ||
5 | Water Consumption | tons/year | *** | |
6 | Equipment installed capacity | KW | *** | |
7 | Transformer capacity of the whole plant | KVA | *** | 2 units |
8 | CastingCasting dryer | Unit | *** | |
9 | Whole factory staff | people | ||
10 | Total investment | million | ||
Investment in production floor area | million | *** | Building for 1.2 million pcs | |
Equipment and mold investment | million | *** | ||
11 | Total production workshop floor area | m2 | ****** | |
12 | Total space | m2 | ****** | Including roads and green body storage areas |
13 | Sales revenue | USD/year | ****** | |
14 | profit | USD/year |
Note:
This is one part of the whole ceramic sanitary ware factory building plan, you can check for further information from