How to make the same color and shade in Porcelain Tile : Color Matching
Every day in an average glazed porcelain production line at our factory in Morbi, India, we produce 15000 sq mtr of tile. In those 15000 we give customisation options to our clients in India and in the international market. One of the best reasons to purchase the porcelain tile from india is the endless choice of the collection we offer in multiple formats and surfaces with close to minimum moq (around 500 sq mtr).
If you consider that 500 sq mtr MOQ (Minimum Order Quantity) and 15000 sq mtr daily production capacity then we have to produce 30 different designs per day. However, that is not true, but still everyday we have to produce 10 to 15 products with different designs on each of our porcelain tile production lines in india.
In order to maintain the consistency in the surface and the design - color, we maintain the master tile of every design. This master tile is finalised when the production of any particular design is taken for the first time at the factory.
We have an entire section filled with the master tile dating back to the early 2006 for some of the initial designs which we launched when we started with the porcelain tile production.
Before taking the production of any designs, we first take a few samples to match the tile with the master tile. Sometimes the samples are matched within initial samples but sometimes it may even take 40 to 50 samples to match the colors with the master tile. Factors such as change in the kiln temperature, glaze-frit combination, body of the tile, seasonal effect, kiln age and all minor changes place a minor or major role on the production of a tile.
The key factors to consider during the matching of the porcelain tile :
Same color tone of the production sample with the master tile
Same value of whiteness in the white marble designs. Also some of the base colors such as pure white or black designs need to be matched with the same level of the whiteness or blackness. This can be measured with the L-A-B parameters of the tile. The more the L-value of a tile, the more white it is.
Same color tone across multiple formats
Same surface of the production sample with the master tile (Glossiness Value & the surface texture)
It seems easier to follow the above steps but the production team, design team and the QC team need to work together to maintain the color matching of every production every day.
Eagle eyes, problem solving and a dedication to maintain the quality standard are all required to maintain the color matching of the porcelain tile and we follow this routine every day at our porcelain tile factory in India.
Hope this article gave you an introduction inside the color matching process of the porcelain tile from india.