Mineral fiber ceiling tiles, commonly known as mineral wool boards, are essential components in modern construction, offering superior fire resistance, sound absorption, and thermal insulation. For manufacturers producing up to 50,000 square meters daily, the production process is highly organized, efficient, and technologically advanced. Today, we take a closer look at how a high-capacity mineral wool board manufacturer produces these tiles from raw materials to finished products.
Step 1: Preparing the Raw Materials
The production begins with mineral wool, the core material for the boards. The mineral wool is carefully prepared and loaded onto conveyor belts to ensure a continuous flow. At this stage, additional auxiliary ingredients are incorporated to enhance properties like density, surface smoothness, and durability.
Step 2: Mixing the Ingredients
The combined raw materials are then transferred into a mixing tank, where they are thoroughly blended to form a uniform slurry. This step is crucial as it ensures that the final boards have consistent structural integrity and surface quality.
Step 3: Forming Wet Boards
Once the slurry is ready, it is fed onto a forming line, where it is shaped into wet boards. The forming line allows precise control over the thickness and dimensions, ensuring every board meets strict quality standards.
Step 4: Drying the Boards
The wet boards are then layered and fed into a high-temperature drying chamber, which can extend over 100 meters. The layering process is often likened to “steaming buns,” as each board is carefully stacked for even drying. Inside the drying chamber, the boards undergo a prolonged high-temperature treatment that solidifies their structure, resulting in dry, fully formed boards.
Step 5: Surface Treatment
After drying, the boards are flipped for surface processing, which significantly enhances their appearance and performance:
Applying Putty: The first step involves applying a layer of putty to smooth out any surface irregularities.
Secondary Drying: The boards are sent into a smaller drying chamber for secondary drying.
Spraying and Tertiary Drying: The boards are sprayed with a finishing coating and dried for a third time to ensure durability and adhesion.
Embossing: Using patterned rollers, different designs are pressed onto the surface to create decorative or functional textures.
Final Coating and Drying: A last round of spraying and drying completes the surface treatment, giving the boards a high-quality, finished appearance.
Step 6: Cutting and Customization
Once the surface treatment is complete, the boards are transferred to cutting machines, where they can be cut into any desired size or shape. This allows manufacturers to offer customized solutions to meet different project requirements.
Step 7: Packaging and Storage
The final step in the production process is automatic packaging, where boards are carefully stacked, wrapped, and prepared for storage or shipment. This automated packaging ensures efficiency and protects the boards during transit.
As a trusted integrated supplier of new building materials, Kente focuses on the production of mineral fiber ceiling tiles and ceiling grid systems, which are widely applied across residential buildings, commercial offices, industrial plants, and civil infrastructure projects. With a commitment to green and sustainable development, Kente continuously seeks smart manufacturing techniques and efficient energy utilization to minimize environmental impact.
Driven by the goal of promoting the advancement of the building materials industry, Kente places customer satisfaction at the center of its operations. Guided by the development philosophy of “Healthy Life, Smart Future,” the company provides innovative ceiling solutions to the global market. Kente strives to enhance living and working environments by delivering products that ensure safety, comfort, and superior quality, meeting the evolving needs of modern daily life and professional spaces.
The production of mineral fiber ceiling tiles is a complex, multi-step process that combines advanced machinery, precision engineering, and quality control at every stage. From raw mineral wool to finished, customizable ceiling boards, the workflow ensures that manufacturers can deliver high-quality products at scale. For companies producing up to 50,000 square meters per day, this streamlined process is essential to meet the growing demands of the construction and interior design markets.
By understanding this process, architects, contractors, and buyers can better appreciate the quality, durability, and versatility of mineral fiber ceiling tiles in modern construction projects.
