The production process of mosaic tiles, such as the Hexagon range, involves several steps:
- Material Preparation: The raw materials, including clay, feldspar, and silica, are mixed and ground to create a fine powder. Water is added to form a clay-like mixture.
- Shaping: The mixture is then shaped into small tiles by pressing. For mosaic tiles, the tiles are typically formed into small hexagonal shapes.
- Drying: The shaped tiles are dried in a controlled environment to remove excess moisture and harden the clay.
- Glazing: The tiles are coated with a layer of glaze, which can be matte or glossy, to give them their desired appearance and protect the surface.
- Firing: The glazed tiles are fired in a kiln at high temperatures, typically around 2000°F (1100°C), to fuse the glaze to the surface and harden the clay.
- Assembly: The tiles are then assembled onto a mesh or paper backing to create the mosaic sheet. The tiles are spaced evenly and adhered to the backing using a special adhesive.
- Packaging: The finished mosaic sheets are packaged and ready for shipping.