Government College University, Faisalabad

(GCUF)
Department of Applied Chemistry
(ACH)

ASSIGHMENT
Course title: Glass, Ceramic and Cement Industry 4(3-1)
Course Code: ACH-663
Topic: Ceramic Industries in Pakistan
Submitted To:
Dr. Rafia Rehman
Lecturer
Department of Applied Chemistry
Submitted By:
Ayesha Mumtaz (9501)
Muhammad Bilal (9502)
Umar Sharif (9503)
Afia Altaf (9504)
Date of Submission:
November, 29 2019.
Ceramic Industries in Pakistan
Outlines:
 Introduction
 Historical background
 Industrial overview
 Conclusion
 References

Introduction:
The word “ceramic” is obtained from the Greek word “Keramos” which means burnt material.
The desires qualities are achieved through a high-temperature heat-treatment process called
firing. Ceramics can be defined as non-metallic, Inorganic solid used and processed at high
temperatures. They are one of the three most major types of engineering materials. The other
two are metals and plastics. Ceramics include such as daily materials like cement, glass, porcelain,
and bricks. The raw material used in manufacturing ceramic products are feldspar, silica, clay,
and talc.

General properties:

 Hard, strong and dense.

 High stability and melting point (due to presence of ionic bond)
 High temperature resistant, good electrical resistant and are resistant to chemical
attacks.
 High compressive and good tensile strength.
 some of these are insulators like other covalent material.
Classification:
There are three types of ceramics, which are as

 natural occurring
 produced from minerals through action of heat (cement, glasses, porcelain and
refractories)
 Abrasive material. (Heisenberg)
Historical background:
In early ages, ceramics were manufactured from clay, which was dried and fired to exhibit
permanent structure. But now a day, more superior techniques such as injection molding
sintering and hot pressing are used for desirable features.

Industrial overview:
Global Perspective of Ceramic Industry

World exports of ceramic products were the US $ 10.8 billion in the year 1999. Exports have
regularly decreased over the period 1995-99 at a yearly average rate of –6%. The USA was the
largest importer in 1999 with 19% of total global imports of Ceramics, while Germany was
second with an 11% share.

Ceramic Industry of Pakistan

Pakistan’s exports of ceramics have been insignificant. In 1999 exports of all ceramic goods were
$2.36 million. Pakistan’s imports of ceramic products in the year 1999 were the US $ 18.8 million.
41% of the total imports consisted of ceramic tiles. Mostly the ceramics industry provides to the
domestic demand of numerous ceramic products including sanitary ware, floor tiles, insulators
and refractories, etc. The growth in the ceramics sector is heavily dependent upon the growth of
the construction sector, which in Pakistan’s case has crossed through an erratic growth phase
during the last decade.
Ceramics can be divided into ceramic tiles, Tableware, Refractories, Sanitary ware, and Electric
Insulators. The production of insulators and tiles is concentrated in the organized sector, and are
fully documented. Though Sanitary ware, Tableware, and refractories are fundamentally in the
unorganized sector and thus the statistics provided are estimations.

Ceramic Tiles
The world export trend for ceramic tiles has declined by 0.8% over the period 1995-99. Though,
exports of ceramic tiles in 1999 had 52% of total exports of ceramics, which shows that ceramic
tiles have been the most significant of ceramic commodities in the world market.
The major exporters of tiles include Italy, which had a share of 43.3% in 1999 and Spain, which
had a share of approximately 29.2%. Others included Turkey, with 3.50% and Germany with
3.16%. Notably, Mexico’s exports have increased by 82% over the period 1995-99. The main
importers of ceramic tiles include the USA with 22% of the total imports in 1999 and Germany,
which had a 13% share. France had a share of 11% in 1999.
Pakistan’s imports of ceramic tiles have risen at a yearly average rate of 82.4% over the period
1995-1999. A major trading ally of Pakistan in ceramic tiles includes Spain, which accounted for
69% of total imports in 1999. Others include Dubai with a 10% share and Italy with an 8% share.

Tableware
Tableware, which comprises kitchenware, had undergone a partial decrease of 0.58% in world
exports over the period 1995-1999. This is the second main section in ceramic products and had
a share of 20% of the total exports of ceramic products in 1999.
Major exporters of tableware include China, which had a share of approximately 35% in 1999 and
Germany, which had a share of 16%. Important to note here is that in line with the global trend
of decreasing exports, all the major players in the tableware market have had a drop in export
shares except China which had undergone an annual average increase of 11%.
World imports of tableware have decreased by 12% over the period 1995-99. The average rate
of decrease is 3.23% per year. Countries tend to produce ceramic products for their domestic
consumption, which is why imports and exports show a declining trend. Major importing
countries include the USA with 19%, Germany with 9% and Italy with 8%.
In 1999 Pakistan had a share of 0.02% of total world exports of tableware. The value of exports
was $0.44 million.
Sanitary Ware
This class is the only one that showed some signs of growth. World exports of sanitary ware have
increased by 7.4% over the years 1995-99. The average growth rate is 2% per year.
Major exporters of sanitary ware involve Germany, which had a share of 13% in 1999 with exports
of $117 million. Spain and France had a share of 9% with exports of $87 million. Total imports of
sanitary ware in 1999 were $911 million. Major importers of sanitary ware included Germany
with 17% and the USA with 11% of total imports. Other key players in the import market include
Spain, France, and Canada.
Pakistan’s exports of sanitary ware topped at $205,000 in 1998-99 and improved by 48.5% over
the period 1995-2000. Pakistan exports to Saudi Arabia, Dubai and Oman i.e. Middle Eastern
countries. Pakistan received contracts for exports of sanitary ware to Iraq as well as some African
countries through International donor agencies, which is why exports have recorded an upward
trend.
Pakistan’s imports of sanitary ware have increased by 21% over the period 1995-2000. Pakistan
imports from Spain, the United Kingdom, and Thailand.

Refractories
Total world exports of refractories have decreased by 26% over the period 1995-99 i.e. from US$
2,252 million to US$ 1,672 million. Major exporters of refractories are Germany with a share of
26% and France with a share of 12% in 1999. All the major player's exports have decreased over
this period, except China which had shown a remarkable increase of 100%.

The main importers of refractories in the world were the USA with 17% of total imports of
refractories and Canada with 7% of total imports. Important to note here is that Germany’s
imports have decreased by 41% over the period 1995-99.

Pakistan’s exports of refractories were $0.04 million in 1999, which were 0.0023% of total exports
of refractories. Pakistan’s imports in 1999 of refractories were $4.06 million, which were 22% of
total imports of Pakistan of ceramics.

Electric Insulators
This is the most modest category in ceramic products by the rate of exports. Total world exports
of electric insulators have decreased by 21% over the period 1995-99 and had a value of $411
million. The main exporters of electric insulators are Japan, which had a share of 36% of total
exports in 1999 and the USA, which had a share of 14%. Germany’s exports have decreased by
43% during this period. Total world imports if insulators in 1999 were $404 million. The chief
importers of electric insulators are the USA with 16% of the total import share. Imports in Mexico
have risen by roughly 200% during this period.
Total exports of electric insulators in 1999 were $ 411 million, out of which Pakistan had a share
of $1.68 million which was 0.41% of total global exports. The global trend indicated that 72% of
the total exports of ceramic products were concentrated in tiles and tableware. Pakistan’s
exports, on the other hand, revealed that 70% of total ceramic products were concentrated in
electric insulators.(Muhammad 2016)
Domestic Industry – Overview

 Ceramic Tiles Industry developed in Pakistan in 1978.

 The first Tiles Manufacturing unit was installed in Karachi by Shabbir Tiles & Ceramics
Limited.
 The industry is a sub-sector of the “Non-metallic Mineral Products” Sector comprised of
Large-Scale Manufacturing.
 Extensive potential for growth available to the Industry, which is very reliant on the
increase of the construction sector of the Country. The real potential of the domestic
industry stands at ~400 million square feet of tiles per annum.
 The Market for Ceramic tiles has a positive outlook & is likely to develop in the future.
 Yearly Demand for tiles in Pakistan stood at 73million square meters in FY17.
 At present, annual demand for the industry stands over ~100million square meters of
tiles.
 Import gap filler of ~52% of the total demand due to underutilized domestic industry.
 Major Raw Materials used in the production of tiles are clay, natural minerals such as
feldspar and quartz, that are used to decrease the firing temperature, natural gas and
chemical additives that are required for the shaping process.

Production Process – Outline:

The Raw Materials are pulverized and crushed according to particle size before mixing and
grinding. For several ceramic products, including tiles, the body composition (including color,
Types of Tiles Produced in Pakistan of the tile) is decided by the quantity and nature of raw
materials. Hence, raw materials are batched according to their weights and composition before
being mixed to get the wanted tile product. Once the components are weighed, they are added
together into a mixer. Sometimes, it is essential to add water to improve the mixing of a
multiple-ingredient batch as well as to obtain fine grinding. The excess water is normally
removed via spray drying. Later, the tiles are created using multiple techniques depending on
the output such as dry pressing, ram pressing or pressure glazing. The tiles are then dehydrated
again, glazed and finally heated intensely to empower them and give them the wanted
porosity.

Types of Tiles Produced in Pakistan

Ceramic tiles

 Unglazed Ceramic Tiles Glazed Ceramics

• Single glaze
• Double glaze
Easier to install and maintain Variety of types each with a different quality Easy to clean and have
a plain surface Best for home use in kitchens and washrooms Also used for high traffic areas
Available in Variety of Sizes
Wall Tiles Sizes:
22x66cm, 33x66cm, 27x77cm, 30x45cm, 20x50cm, 20x60cm.
Floor Tiles Sizes:
15x90cm, 60x60cm, 40x40cm, 30x30cm, 100x100cm.
Clay tiles or Terracotta tiles
• Clay Roof tiles
• Clay floor tiles
• Clay brick wall tiles
Stone or Marble tiles
• Floor tiles
• Wall tiles
Concrete tiles
• Circle paving tile
 • Concrete face wall tiles
• Concrete roof tiles
• Precast pavers
• Stone effect tiles
Mosaic tiles
• Marble mosaic
• Green Onyx
• Split stone veneer
• Brick mosaic

Rubber Floor tiles

Commonly used as a protection for easily breakable floor. Great uses in commercial and
residential settings.

Plastic Floor tiles

Suitable for heavy traffic areas and wet floors subject to movement, dampness and have usage
of oil. Used in factory floors, garages, gyms, sport complexes, schools.
Ceiling tiles
Light weight, used within buildings, provide thermal insulation, Improve the acoustics of a room

Sector Performance
Performance of Top Players of the Industry
Rs in million – FY17
Company Master Tiles Shabbir Tiles Karam Emco Frontier
& Ceramics & Ceramics Ceramics Ceramics Ceramics
Industries
Revenue 5127 5020 861 1007 427
Net profit 516 (151) (75) 29 8
 Turnover 26% 8.85% 28.01% 4.89% 4.52%
Growth
Current Ratio 0.92 0.81 1.13 0.99 0.77

Industry Developments
Pakistan Tiles a new entrant in the Industry in April-18 through installation of a used plant from
China and OEM from Italy.
Master Tiles Installed Capacity being increased from 11mln square meters to 19mln square
meters in FY18. Further increase in pipeline.
EMCO industries ceramic tiles segment was closed in FY17. Entire focus shifted to transmission
poles.
Frontier Ceramics – Floor tiles eradicated from the market in FY17
New Entrant Hashoo Group expected to enter the market in FY19.(2018)

Alternative raw material for ceramic manufacturing (Post-treated

incinerator bottom ash)
Introduction

The world production of building and tiles ceramics requires massive amount of natural raw
materials, which until now is based mainly on the traditional system clay-silica-feldspar.
Nevertheless, several studies made in the last decades are related to the substitution of
conventional raw materials by other natural resources as zeolites, volcanic rocks, and nepheline
syenite. Another widely studied possibility is the application of different industrial residues or
wastes as alternative raw materials. Many of these works are focused on characterization and
utilization of different alternative fluxing agents; this is a consequence of the high cost of
feldspars and the limited number of appropriate deposits. Promising results were obtained
using soda–lime glass cullet, cathode ray tube of TV or PC monitors (CRT glass) and granite
cutting sludge.
Since the new fluxes have different chemical compositions, some of the new ceramic batches
show significant variations in the forming and firing behavior. In general, the alternative fluxes
form melts with lower viscosity than the corresponding feldspar melts, which decreases the
sintering temperature and/or leads to formation of high percentage of glassy phase.
For this reason, in order to obtain sintering behavior and mechanical characteristics similar to
the industrial compositions, the feldspars are partially substituted. In general, the addition of
higher amount of fluxes leads to an increase of amorphous phase in the final product.

However, if the alternative flux is characterized by a high crystallization trend, the crystallinity
of final ceramics might be increased. This effect can be obtained using glass–ceramic frits or
waste residues with high crystallization tendency (as slag and fly ashes). In this case, due to re-
crystallization processes during the sintering and cooling steps, the amount of residual
amorphous phase decreases, leading to an improvement of the mechanical properties. Among
these residues, the pre-treated bottom ash from municipal solid waste incineration (MSWI) can
be selected for testing the feasibility as component into ceramics body.
In 2008 about 32.5 million tons of municipal solid wastes (MSW) have been produced in Italy.
Great amounts (44.9%) have been landfilled without pre-treatment, while only 10.9% of the
MSW have been incinerated. From the incineration of municipal waste, bottom ash with
volume ranged between 10% and 12% of the starting waste volume and weight between 20%
and 35% of the starting waste weight, is obtained. According to these data, in Italy, the annual
production of MSWI bottom ash could be estimated in about 797 thousand tons, a significant
amount of which is landfilled (about 49.2%). Although bottom ash is classified as non-hazardous
waste according to the European Waste Catalog (190101), its disposal requires high costs.
Therefore, the development of reusing incineration bottom ash as ceramic material has to be
strongly promoted. This idea has a double environmental benefit: avoidance of MSWI ashes
disposal and reduction of ceramic raw materials use. In the last years in Italy some companies
became active and specialized in post-treatment technologies of bottom ashes. The objective is
minimizing waste production by transforming it in a reusable material. The treatment starts
from a complex process of selection and physical/mechanical treatment (aging, sieving and
washing) of incineration bottom ashes. After the process, an inert material with silica-based
matrix, rich in iron, calcium and aluminum oxides is obtained. This material can be successfully
applied mainly in cement as substitute of extracted raw materials or in the ceramic sector.
Ceramic bodies, such as tiles, are heterogeneous materials, consisting mainly of natural raw
materials with wide range of composition. For this reason, such bodies could tolerate different
types of alternative raw materials, even in high percentages. This is achieved by the reduction
in the use of raw materials, transport, energy consumption, waste processing and by recycling
of high-quality secondary raw materials.
Porcelain stoneware tile, characterized by very low water absorption (<0.5) and high values of
density and mechanical properties (bending strength >35 MPa), represents the best product, in
terms of technical performances, developed in the field of ceramic tiles belonging to BIa group.
This product is the result of an industrial processing of a mix of raw materials, rich in fluxing
agents that, fired at temperature around 1200 °C, develops a large amount of glassy phase (60–
70%) able to obtain a strongly densified material. A typical composition contains 25–50% of
kaolinites and ball clays, 50–60% of feldspar sand and 5–10% of quartz sand.

Results and discussion

As observed in the inert PTBA contains iron, calcium, aluminum and silicon oxides (in different
amount depending on particle size and with major concentration of the heavy metals into the
fine fraction) while kaolin clay contains silicon and aluminum oxides. Crystalline phases of the
PTBA and kaolin identified by XRD are reported in. As observed in the kaolin are present
kaolinite (Al2 (Si2O5) (OH)4), quartz (SiO2) and illite ((K, H3O) Al2Si3AlO10 (OH)2). Regarding the
bottom ash, the L fraction presented as crystalline phases calcite (CaCO3), akermanite-gehlenite
(Ca2(Mg0.5Al0.5) (Si1.5Al0.5O7)), quartz (SiO2), albite calcian ordered (Na, Ca) Al(Si,Al)3O8) and
covellite (CuS) traces; while for the F fraction only calcite, akermanite ((Ca1.53Na0.51)
(Mg0.39Al0.41Fe0.16)Si2O7), quartz and albite calcian ordered were identified.(Schabbach,
Andreola et al. 2012).
List of Ceramic Industries in Pakistan:
1. Perfect Associates (5th floor, M.A. Jinnah Road, Sindh, Karachi, Sindh)
2. Artisans Galleria (G-3 Mall Jubilee Town, Lahore, Punjab)
3. Future Designz (Lahore, Punjab)
4. The city Tiles (Karachi, Sindh)
5. Balochistan Glass Ltd. (Karachi, Sindh)
6. Crystal World Glass Furniture (Lahore, Punjab)
7. Crystal world glass furniture (Islamabad, Punjab)
8. FACO INDUSTRIES (Karachi)
9. MUNAF SIDDIK ASSOCIATES (Karachi, Sindh)
10. Pakistan Safety Glass Work(Pvt) Ltd (Karachi, Sindh)
11. AL NOOR REFRACTORIES(Rawalpindi)
 References:

(2018). "Ceramic tiles Industries in Pakistan."

Heisenberg, W. "ceremics, cement, Refactories and glass ": 653-654.

Muhammad, A. ( 2016). "Ceramic Industires in Pakistan.".

Schabbach, M., et al. (2012). "POSt-treated incinerator bottom ash as alternative raw material for ceramic
manufacturing." europian ceramic society 32(11): 2843-2852.