Composite Alumina-Mullite vs Traditional Refractory Brick: A Performance Comparison for Ceramic Tray Selection
30 08,2025
Product Comparison
Choosing the right ceramic tray material is critical to preventing defects like warping, sagging, or cracking during firing. This article compares composite alumina-mullite trays with traditional refractory bricks across key performance metrics—thermal stability, thermal shock resistance, wear resistance, and chemical inertness—tailored to applications such as mosaic tiles, sanitary ware, and roofing tiles. By analyzing temperature ranges from 1000°C to 1400°C, it outlines deformation risks, maintenance cycles, and practical strategies to extend tray life and improve firing yield. Real-world case studies and expert insights help you make data-driven decisions that boost kiln efficiency and product quality.
How to Choose the Right Ceramic Tray Material? A Practical Guide for Production Managers
As a technical lead or production supervisor in ceramic manufacturing, you’ve likely faced it: unexpected product warping, sagging, or even complete collapse during kiln firing—despite following standard procedures. The culprit? Often, it's not your process—it’s the tray material.
In this guide, we’ll break down two common options: traditional firebrick and advanced composite alumina-mullite trays. Based on real-world data from over 300 industrial kilns across Europe, Asia, and North America, here’s how each performs under different temperature ranges (1000°C–1400°C), and why choosing wisely can boost your yield by up to 18%.
Application-Specific Needs Matter Most
Not all ceramics are created equal—and neither are their trays:
- Wall & Floor Tiles (e.g., Mosaic): Requires high thermal shock resistance due to rapid heating cycles. Firebrick shows >25% higher deformation risk after 50 firings at 1200°C.
- Sanitary Ware: Needs chemical inertness—especially when glazes contain alkaline components. Composite alumina-mullite resists glaze contamination better than firebrick by 40% (based on ASTM C270 tests).
- Slate Roofing Tiles: Must maintain flatness over long burn times (>12 hrs). Traditional bricks show measurable warpage (>1.5 mm) after 30 cycles; composite trays stay within 0.3 mm tolerance.
| Property |
Traditional Firebrick |
Composite Alumina-Mullite |
| Thermal Expansion Coefficient (ppm/°C) |
4.2–5.0 |
2.8–3.3 |
| 抗折强度 (MPa @ 1200°C) |
25–30 |
45–55 |
| Wear Rate (g/cm² per cycle) |
0.08–0.12 |
0.02–0.04 |
“We switched to composite alumina-mullite trays in our sanitary ware line last year. Within six months, we reduced tray-related defects from 7% to under 2%. It wasn’t just about durability—it was about consistency.” — Engineer, Jiangsu Ceramics Co.
Temperature Zones = Risk Zones
For kilns operating between 1000°C and 1400°C, here’s what works best:
- Below 1200°C: Both materials perform adequately—but firebrick still has higher wear rates over time.
- 1200–1350°C: This is where composite trays shine. Their lower thermal expansion prevents micro-cracking and deformation.
- Above 1350°C: Only composite alumina-mullite maintains structural integrity beyond 100 cycles without significant degradation.
If you're currently using firebrick trays, consider tracking deformation every 10 firings. Many factories miss early signs of failure until they lose batches worth thousands of dollars.
Want more? Download our free “Ceramic Tray Selection White Paper”, which includes a full decision matrix based on your kiln profile, production volume, and product type. Or join our private technical group—where engineers share real-time insights from global kiln operators.
