If your ceramic tiles—especially mosaics—are warping, sagging, or collapsing during high-temperature firing, the problem might not be in your kiln settings. In fact, 9 out of 10 cases we’ve analyzed trace back to one silent culprit: incorrect tray material selection.
You’re likely using standard refractory bricks or low-grade alumina trays that can’t handle sustained thermal stress above 1200°C. These materials expand unevenly under heat, leading to deformation—and ultimately, product loss. But here’s the good news: there’s a smarter way forward.
Let’s talk numbers:
| Material Type | Avg. Thermal Expansion (ppm/°C) | 抗折强度 (MPa) | Recommended Use Case |
|---|---|---|---|
| Standard Fire Clay Tray | 5.2–6.0 | 15–25 | Low-temp applications only |
| Alumina Silicate Tray | 3.8–4.5 | 35–45 | General ceramics |
| Composite Alumina-Mullite Tray | 2.6–3.2 | 55–70 | High-temp mosaics, sanitaryware, roof tiles |
As you can see, composite alumina-mullite trays offer up to 40% lower thermal expansion and 2x higher mechanical strength than traditional options. That means less warping, fewer rejects, and longer tray life—even at 1350°C.
“After switching to composite trays, our tile warpage dropped from 12% to under 2%. We saved over $18K/month in waste.”
— Ahmed Hassan, Production Manager, Saudi Ceramic Co.
But it’s not just about material specs—it’s about matching the right tray to your process. For example:
And yes—you should monitor tray aging too. A simple rule: if your trays show visible cracks or increased weight loss after 6 months of use, they’re no longer reliable. Replace them before failure hits your yield.
Is your tray already showing signs of warping? Don’t wait until it ruins a batch. Start with a proper assessment—and get ahead of the curve.
