琉璃瓦投资可行性分析及琉璃瓦简介
Feasibility Analysis of Investment in Glazed Tile and Introduction of Glazed Tile
琉璃一词产生于古印度语，随着佛教文化而东传，其原来的代表色实际上指蓝色。中国古代宝石中有一种琉璃属于七宝之一。现在除蓝色外，琉璃也包括红、白、黑、黄、绿、绀蓝等色。施以各种颜色釉并在较高温度下烧成的上釉瓦因此被称为琉璃瓦。The word “colored glaze” comes from ancient Indic language. It spreads eastward with the spread of Buddhist culture, and the original representative color indicates blue actually. A kind of colored glaze belongs to one of seven ancient precious stones in China. The glaze may be in red, white, black, yellow, green or bronze blue except for blue. The tile made from the firing of glaze with different colors under higher temperature is called glazed tile.
流光溢彩的琉璃瓦是中国传统的建筑物件，通常施以金黄、翠绿、碧蓝等彩色铅釉，因材料坚固、色彩鲜艳、釉色光润，一直是建筑陶瓷材料中流芳百世的骄子。 我国早在南北朝时期就在建筑上使用琉璃瓦件作为装饰物，到元代时皇宫建筑大规模使用琉璃瓦，明代十三陵与九龙壁都是琉璃瓦建筑史上的杰作。The colored glazed tile is a traditional building element in China, and it is often in golden, green or blue color. It is the most popular ceramic materials due to its solid materials, bright color and smooth glaze. In China, the glazed tile was used as the decoration for buildings as early as in Southern and Northern Dynasties, and it was widely used for imperial buildings in Yuan Dynasty. The Imperial Mausoleums of the Ming Dynasty and Nine-Dragon Screen are the masterpieces of glazed tile in architectural history.
琉璃瓦经过历代发展，已形成品种丰富、型制讲究、装配性强的系列产品，常用的普通瓦件有：筒瓦、板瓦、句头瓦、滴水瓦、罗锅瓦、折腰瓦、走兽、挑角、正吻、合角吻、垂兽、钱兽、宝顶等等。从传统琉璃瓦演变发展而来的西式琉璃瓦最先在日本和西班牙、意大利等欧洲一些国家得到应用，它将筒瓦、板瓦型制合二为一，结构合理，挂装简便，有效覆盖面积大，屋顶承重小。釉色丰富达百种以上，同时，它没有铅釉瓦釉面反铅影响装饰效果的现象。因此，西式琉璃瓦在现代建筑上越来越得到广泛应用。 After several years of development, the glazed tile has become a product with rich variety, stressed molding & making and strong decoration effect. The common tiles include semi-cylindrical tile, flat tile, eave tile, drip tile, arch tile, tile with animal sculptures, jet-angle tile, roofing tiles and etc. The western glazed tile evolved from traditional glazed tile was first applied in Japan, Spain, Italy and other European countries. It has the advantages of reasonable structure, simple mounting, large effective coverage area and small bearing on roof by combining semi-cylindrical tile with flat tile. The glaze has more than one hundred of colors. Meanwhile, the phenomenon that the lead on the surface of lead glaze affects the decoration effect will not occur. Therefore, the western glazed tile is widely used in modern architecture.
二 琉璃瓦的生产方法Ⅱ Production Method of Glazed Tile
琉璃瓦的生产工艺并不复杂，生产线设备可选用全自动生产线设备生产，也可选用部分机械设备和手工相结合的方式生产，全自动生产线设备自动化程序高，所需人工较少。采用部分机械设备和手工相结合的生产方式 The production process of glazed tile is not so complicated. The full automatic production line, or the combination of mechanical equipment and manual work can be used for the production. With higher automation, the full automatic production line requires few workers. The combination of mechanical equipment and manual work is applied.
（一）原料及制备(ⅰ)Raw materials and preparation
1 选坯料Blank selection
琉璃瓦可选用大青、二青、缸土、碱土、紫砂，木节等软硬质原料及废匣钵粉、瓷粉等原料。另外，也可用部分采用煤矸石、煤研灰等矿物废渣、工业副产品来降低生产成本，也获得满意效果。 用两种紫砂原料，将其置换白坯料中的青土成分而配成。 The hard & soft materials, such as blue clay, stoneware clay, alkali soil, purple clay and knot, saggar powder, porcelain powder and etc. are used to make glazed tile. In addition, the coal gangue, coal ash or other residues and industrial by-products may be used to reduce the costs, and a satisfactory effect will be achieved. Two kinds of purple clay are used, and they are made by replacing the black soil in white blank.
2、注浆坯料的制备 Preparation of casting blank
将原料按配方准确称量入球磨细碎，过60目筛陈腐备用。主要用来制作琉璃瓦的小、中型异型件。 The raw materials are crushed in ball mill after they are weighed according to the formula, and then screened with 20-mesh sieve for aging and standby. The materials are mainly used to make small and medium irregular glazed tile.
3、挤制和塑压成型坯料的制备 Preparation of blank molded by extrusion and plastic compression
将原料经粉碎后分类存放，不能混入杂质，坯料制备按照配方准确称量后，平铺于洁净地面，一种原料铺一层，然后加入一定量的水分，人工将其混匀。将混合坯料入搅泥机，搅练2—3次，陈腐两天后供成型使用。 The raw materials are categorized for storage after they are crushed. No impurity should be mixed. The blanks are laid on clean floor after they are weighed correctly according to the formula. A kind of material is laid in one layer, and then manually mixed with water. The mixed blanks are put into the pug mixer and mixed for 2-3 times. They can be used for molding after aging for 2 days.
（二）琉璃瓦的成型(ⅱ)Molding of glazed tile
琉璃瓦的成型方法，一般采用挤制成型、手工印坯、注浆成型等方法。西式瓦采用塑压成型。 In general, the extrusion, manual impressing or casting is used to mold glazed tile. Plastic compression is used to mold western tile.
1。挤型成型： 琉璃瓦的普通瓦件筒瓦、板瓦采用挤制成型，挤坯机是在搅泥机的出泥口加装一个与坯体尺寸相同的机头，待坯挤出后，用钢丝切成瓦坯，放支架上晾干、修坯、干燥后烧成。Molding by extrusion: the extrusion is used to mold common glazed tiles, such as semi-cylindrical tile and flat tile. A blank extruder will be made if a head with the same size as that of blank is added at the outlet of pug mixer. The blank shall be cut into tile blank with steel wire after it is extruded, and be fired after it is cooled on bracket, fettled and dried.
2。手工成型和注浆成型Molding by manual impressing and casting
琉璃瓦中的勾头，滴水瓦件以及走兽、钉帽、花窗和正吻、垂兽等构件采用手工成型或注浆成型。手工成型是将坯泥拍打成泥饼，在石膏模内压印出有花纹的坯体，稍干后起坯贴接，将工作面修整打光。 The manual stamping or casting is used to mold eave tile, drip tile, tile with animals, nail head and glassless window. The manual molding is to beat the throw clay into clay cake, to impress blank with pattern in the plaster mold, to raise the blank after it is dried and to polish the working face.
（三）琉璃釉料制备及施釉(ⅲ)Preparation of Glaze Materials and Glazing
1、传统琉璃瓦用釉Glaze for traditional glazed tile
传统琉璃瓦用生铅釉以铅丹作助熔剂，主要着色剂是铁、铜、锰、钴等金属氧化物，属于pbo－SiO2二元系统，约在850℃—1000℃温度中烧成。生铅釉随色剂含量多少，直接影响釉色深浅变化，可获得层次丰富的色彩。 The raw lead glaze is used to make traditional glazed tile, with red lead as the flux. The iron, copper, manganese, cobalt and other metal oxides are used as the colorant. It is of pbo－SiO2 system, and fired under 850℃—1000℃. The color of raw lead glaze will be dark or light with the changes in the content of colorant.
2、西式琉璃瓦用釉Glaze for western glazed tile
西式琉璃瓦用釉为熔块釉，熔块釉有较大的烧成温度范围和色釉选择余地。配制熔块要选用的化工原料（硼砂、碱面、铅丹等）应为工业纯，着色剂的纯度要高。熔块的好坏直接影响到釉面质量，应重视烧制的各个环节，提高熔块的质量，好的熔块应是透明的玻璃质。 The fritted glaze, with larger range of firing temperature and more choices of color glaze, is used to make western glazed tile. The chemical materials (such as borax, alkali, red lead and etc.) should be technical pure if applied to the preparation of frit, and the purity of colorant should be higher. As the quality of frit will directly affect that of glaze surface, each link of firing should be paid attention to and the quality of frit should be improved. A good frit should be transparent glassiness.
a）釉料的制备Preparation of glaze materials
将铅丹或熔块与生料严格按配方称量好，入球磨机研磨，料、球、水为1：1．7：0．8，要求细度：生铅釉0．04－0．06％，熔块釉0．05－0．12％（万孔筛余）。为保证釉有良好的流动性及防止沉淀，可加入电解质甲基纤维素。 The red lead or frit and raw materials are crushed in the ball mill after they are correctly weighed according to the formula. The proportion of material, ball and water is 1：1．7：0．8. The required fineness is 0．04－0．06％ for raw lead glaze and 0．05－0．12％(sieve residue) for fritted glaze. To guarantee good fluidity of glaze and to prevent sedimentation, the electrolytic methylcellulose shall be added.
b）施釉Glazing
琉璃瓦、西式瓦一般采用浇釉法或浸釉法。浇釉时要迅速，一次浇满瓦面可保证釉面平整光滑均匀。釉的比重控制在1．5－1．7之间。应注意施釉后要及时刮净底部。 For the glazed tile and western tile, the method of glazing by pouring or dipping is often used. The glaze should be poured quickly, and the fully poured tile will guarantee the level, smooth and even glaze surface. The proportion of glaze should be controlled between 1.5 and 1.7. It should be noted that the bottom should be cleaned immediately after glazing.
（四）琉璃瓦的烧成(ⅳ)Firing of glazed tile
西式琉璃瓦采用一次烧成。烧成后用窑炉为煤烧推板窑，投资较少，也可用隧道窑，氧化焰烧成。 The single firing is used for western glazed tile. The coal-firing pusher kiln can be used to fire the glazed tile for lower investment; or tunnel kiln may be used to fire the tile with oxidation flame.
西式瓦一次烧成是将成型好的坯体干燥施釉后直接入窑烧成，烧成温度为1150℃－1200℃。瓦件不是满施釉可以倚靠摞叠或采用特殊支架的办法烧成。 The single firing of western tile is to fire the molded blank in the kiln after it is dried and glazed. The firing temperature should be 1150℃－1200℃. The tile not glazed fully may be fired by stacking or using special bracket.
（五）琉璃瓦成品的检验(ⅴ)Inspection of finished glazed tile
琉璃瓦、西式瓦除应具备良好的内在物理性能（抗折抗压、吸水率、耐急冷急热性能和耐冻性能）外，主要检验项目为外观质量。 The glazed tile and western tile should have good physical performance internally (anti-fracture and compression resistance, water absorption, chilling & heating resistance and freezing tolerance). The appearance quality is the main item to be inspected.
产品外观要求光滑整洁，釉色鲜亮纯正。瓦件组装一起，釉色要基本一致。造型纹样规整清晰，产品允许尺寸公差±2mm，达到以上要求即为合格。如有图纸和实样，应严格按标准检验。琉璃瓦还有一些特殊检验方法：如板瓦，四块围拢应为圆筒，即呈360°。筒瓦两块拼合也应构成一圆筒。勾头、滴水马筒、板瓦粘接呈夹角应为135°±5°。 The product appearance should be smooth and clean, and the glaze color should be bright and pure. The glaze colors shall be the same after the tiles are assembled. The modeling and dermatoglyphic pattern should be regular and clear, and the allowable dimension tolerance is ±2mm. The product shall be qualified if it meets the requirements above. The inspection shall be carried out in strict accordance with drawing and sample if there are any. There are some special inspection methods for glazed tile. For example, the flat tile should be in cylindrical shape if four tiles are gathered, i.e., in 360°.The semi-cylindrical tile should be in cylindrical shape if two tiles are gathered. The angle for the bonding of eave tile, drip tile and flat tile should be 135°±5°.
(六)投资分析 (ⅵ)Investment analysis
1,设备投资(按日产1万片计算)120万 Equipment: 1,200,000 Yuan (by daily output of 10,000 glazed tiles)
2,厂房投资20万左右 Factory buildings: about 200,000 Yuan
3,原材料20-50元/吨,0.07元/片 Raw materials(20-50 Yuan/ton): 0.07 Yuan/tile.
4,电费0.1元/片Power charges: 0.1 Yuan/tile
5,煤耗0.4公斤*0.7元=0.28元/片Coal consumption: 0.4 kg * 0.7 Yuan = 0.28 Yuan/tile
6,工资0.2元/片 Wage: 0.2 Yuan/tile
7,釉料0.02-0.2元/片 Glaze materials: 0.02-0.2 Yuan/tile
8,原材料,工资,电费,煤耗合计0.67元/片 Total of raw materials, wage, power charges and coal consumption: 0.67 Yuan/tile
9,其它管理费用等0.2元/片Other administration expenses: 0.2 Yuan/tile
10,成本合计0.87元/片Total costs: 0.87 Yuan/tile
11,市场售价2元左右Selling price: about 2 Yuan/tile
12,1年以产销200万片计算,年利润226万元. The annual profit will be 2,260,000 Yuan if 2,000,000 tiles are made and sold per year.
天津市银丰机床成套设备有限公司
地址:天津市东丽区程林工业区
电话：022-24712998 24719372
传真：022-24718346
网址：www.yfjc.com
Email:yfjc98@126.com
Tianjin Yinfeng Machine Tool Whole Set Equipment Co., Ltd.
Address: Chenglin Industrial Area, Dongli District, Tianjin
Tel: 022-24712998 24719372
Fax: 022-24718346
Website: www.yfjc.com
Email:yfjc98@126.com |
