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Vaal Sanitaryware is South Africa’s leading manufacturer and supplier of fireclay and vitreous china sanitaryware products to a broad spectrum of local end user markets and selected export markets. A business unit of the Group Five construction and materials manufacturing company, it has been producing ceramic sanitaryware in Meyerton since 1946. South Africa has two major sanitaryware producers (Vaal Sanitaryware & Betta Sanitaryware) which supply 80% of the local market. Its vast range of quality toilets, basins, bidets, sinks, urinals and hospitalware are well known throughout the country for the "Vaal" brand visible on all of its products.
The first stage of the manufacturing process involves a modeller making a plaster model of the finished size product according to a working drawing design. After modelling the article, a block mould is created from which a 'mother mould' or case mould is manufactured. This case mould is often made from epoxy resins. After producing many moulds from the resin 'mother mould', the working moulds are thoroughly dried before being taken into manufacturing area. The major raw materials used at Vaal Sanitaryware are ball clays, kaolin, feldspar and silica in various proportions. Casting then begins by pouring a liquid mixture of the raw materials used in the recipe, into the moulds. Glaze is then applied to the dried ware by the spraying method. The glaze itself consists of: zircon, feldspar, quartz, calcite, kaolin and zinc oxide. The final stage requires firing in a gas fired tunnel kiln at high temperatures to create the finished ceramic product.
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carbon, graphite products
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