Producing tiles and ceramics is a complex and precise process made up of multiple stages, such as raw material preparation, firing, and final finishing. At any stage, defects may occur that can affect the final product’s quality. Being aware of these defects helps you make smarter purchasing decisions and ensures you get a high-quality product. This article explores the most common tile and ceramic defects that can occur during production.
Body (Biscuit) Defects
One of the most important stages in production is forming the tile’s body or “biscuit.” Any flaw here can lead to serious issues later.
- Cracks – These may appear during drying or firing. They can be surface-level or deep, usually caused by thermal stress or excessive moisture. While surface cracks may be hidden by glazing, deep cracks reduce the tile’s strength and durability.
- Warping or Bending – If the tile is not evenly heated or cooled during firing, it may warp. This is especially noticeable in larger tiles like porcelain or book-matched ceramics, making installation difficult. Large-format porcelain wall tiles must be completely warp-free.
- Size Variation (Caliber) – This happens when tiles are produced in slightly different sizes, leading to uneven grout lines. Precision manufacturing in modern production lines minimizes this problem.
- Air Bubbles and Voids – These occur when raw materials aren’t compacted enough or due to improper firing. They weaken the tile and increase water absorption.
- Stains and Contamination – Foreign particles, like iron or carbon, can enter raw materials during production and show up as unwanted stains after firing.
PMA | IMPERIO Solution
By using advanced production lines and strict quality control, we eliminate these defects at the manufacturing stage. Our durable, high-quality ceramics are the result of attention to detail. With PMA | IMPERIO products, you can be confident in both quality and durability.
Glaze and Surface Defects
After firing the body, glazing and surface finishing ensure both beauty and resistance.
- Pinhole – Tiny needle-like holes in the glaze, usually caused by gases escaping from the body during firing. They ruin the appearance and can trap dirt over time.
- Crazing – Fine, web-like cracks in the glaze, typically caused by mismatched thermal expansion rates between the glaze and body. These cracks may appear gradually, affecting both looks and durability.
- Blistering – Small bubbles on the glaze surface caused by trapped gas during firing.
- Color Variation – Slight or noticeable color changes can result from poor firing, glaze impurities, or incorrect kiln temperature control.
- Glaze Running – If glaze viscosity or firing temperature isn’t controlled, glaze may flow unevenly, creating drops and streaks.
- Crater – Small pits in the glaze caused by trapped air or foreign particles.
- Abrasion – Occurs in low-quality tiles with poor wear resistance, leading to quick scratching and dulling of the surface.
- Surface Unevenness (Waviness) – The glaze should be perfectly smooth. Uneven application or process issues can cause visible waves, especially noticeable under light reflection.
PMA | IMPERIO Solution
For our luxury interior design brand IMPERIO, glaze quality and surface finishing are a top priority. Using premium glazes and advanced firing technology, we ensure that IMPERIO tiles have flawless, beautiful surfaces. The variety of sizes and finishes allows you to create unique, high-end spaces.
Final Note
Knowing the potential defects in tiles and ceramics helps you make an informed purchase and ensures the product meets your quality expectations. High-quality, standard-compliant products not only look better and last longer but also reduce maintenance and repair costs in the long run. With PMA | IMPERIO products, you can enjoy unmatched quality and beauty.