Welcome to Futura Ceramics

Proven Performer




Manufacturing ceramic rollers that outperform the test of your expectations



Back to website

Company Profile

Futura Ceramics was founded in 2004 with the sole purpose of providing superior quality, consistency and timely supply of materials to the ceramic tile industry in India. Along with ceramic glaze frits & mixture products, the company has forayed in Ceramic rollers since 2009 with a highly specialized set-up of imported machinery, kiln furniture and skilled personnel. This expertise specially built using German technology for manufacturing price competitive ceramic rollers is pioneering in India. Within a short span of time, we have proved our mettle by establishing a strong reputation in the ceramic industry as a receiver of Capexil award for two years in a row and export award for 6 consecutive years for exporting ceramic frits and rollers. We have maintained a consistent quality supplier record in the export market and are recognized as the Indian pioneer in manufacturing and export of Ceramic Frit.

2

Product details

  • Futura Ceramic Rollers demonstrate proven performance for perfect processing of ceramic products across the conveyer belt as a result of superior quality, excellent thermal shock resistance and good B.D. Harnessing of the German technology used for making ceramic rollers protects the entire batch of ceramic products across the conveyer belt, thereby ensuring the desired output and securing investment.
  • Futura Ceramic Rollers are instrumental in manufacturing roller hearth kiln which is used for ceramic tile industries
  • Formulations based on Zirconia Toughened Mullite (ZTM) to make high density rollers. Use of ZTM rollers include the following benefits:
3

USP

Providing import substitute for ceramic rollers along with price competitiveness by harnessing high quality raw materials available in India

4

Quality Control

  • Highly qualified and skilled staff is in charge at each stage of manufacturing with rigorous quality controls
  • Introduction of highly efficient pulse firing techniques to improvise on quality
  • Frequently tested crystalline structure and Alumina content of the rollers
  • Quality raw materials like Calcined Alumina and plastic clays required for manufacturing locally are found in abundance
  • Perpetual improvisation on quality

Manufacturing Facilities

  • Three high temperature kilns for continuous production of rollers – THE LATEST BUILT WITH HIGHEST QUALITY STANDARDS AND PRECISION OF GERMAN TECHNOLOGY AND ENGINEERING DESIGN.
  • Capacity of up to 160,000 rollers per year considering OD 50 rollers being fired
  • State of the Art German Mixer machine for uniform mixing for higher OD rollers AND High Alumina content ball mills and pebbles for smaller OD rollers
  • Special roofing to avoid contamination during manufacturing process
5
6

Energy Efficiency

Our processes are designed with meticulousness and efficiency along with inspection of packaging of materials from one end to the other in a continuous cycle. Heat given off during the cooling cycle is monitored and reused to pre-heat the incoming material to be fired with monitored energy utilization system.



Environment Consciousness

  • Guided by the motto of reduce, reuse and recycle
  • Recycling water
  • Using natural gas- the cleanest fossil fuel


Specifications

Specifications are confirmed with the customer before confirming the final dimensions. According to the customer’s drawing, rollers will be cut, drilled and customized before dispatch. Installation of rollers for the entire kiln will be provided with technical support to train personnel for loading the rollers.

7

Roller properties and choice

Specifications of ZTM -09 rollers are

Al203 % 72 -74
SiO2 % 18 -20
ZrO2 % 4 – 6
Bulk Density (gms/cm3) 2.6 - 2.9
Apparent porosity % 16 – 18
Water Absorption % 6 – 8
Thermal Expansion (x 10 -7) 5.9 - 6.3
Thermal Shock Resistance Excellent
CMOR (MPa) 55 – 60
HMOR (MPa ) at 1350 0C 50 – 54
Maximum working Temperature
  1. 0C

Note: Chemical composition tested in a reputed lab with XRF method Physical parameters tested in our house lab only

A standard Roller diagram

8
9

Our Customer Details

Supplier for all ceramic tile manufacturers and S.S Patta manufacturer













FUTURA CERAMICS PVT LTD.
A/501, SAPATH IV,
OPP. KARNAVATI CLUB,
S.G.HIGHWAY,
AHMEDABAD - 380051 GUJARAT
INDIA.