Manufacturing

Raw Materials

Rocell Bathware is manufactured using the world’s finest raw material to produce premium quality vitreous china and fine fire clay bodies and glazes. With a well-established scientific process control system to verify incoming raw material properties and comprehensive Quality Management System, Rocell focuses on maintaining consistency of mineralogical and chemical composition of its raw material for a premium quality output.

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Product Design and Modelling

With its in-house research and design development centre, Rocell has the capability to produce exclusive, challenging and competitive designs. Development of prototypes, epoxy resin case moulds with synthetic rubber lining to case moulds takes place with script supervision and precision.

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Milling and Blunging

With minimal sound pollution, rubber line ball mills are used to mill hard raw materials’s such as Feldspar and Silica Sand. Ball Mill Slurry is then mixed with Ball Clay and Kaolin at the Blungers. These Blungers possess scientifically designed propellers to obtain effective and efficient blunging performance. Blunger slip properties are well controlled using well established process control systems.

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Slip Transferring and Storage

Blunge controlled slip is transferred through vibrating sieves to the storing arcs. In order to maintain homogenous condition of the slip, continuous agitation takes place at controlled RPM; and to de-aerate trapped bubbles in the slip, it is aged over 72 hours.

Casting – Vitreous China and fine fire clay

Rocell possesses a variety of casting methodologies to form their green pieces. Manual casting benches, battery casting machines, beam casting machines are semi-automated; while high pressure casting is robotized putting Rocell in a position to undertake casting of any complicated design successfully.

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Drying & Green-ware Inspection

Highly illuminated inspection booths with water curtains are used to ensure green pieces are meticulously inspected and screened in order to eliminate blemishes. All cast green pieces are then sent through a chamber of dryers which have the facility to control its internal humidity and temperature simultaneously, reducing moisture in these pieces to the standard level.

Glazing

Rocell possesses Manual, Robotized glazing and Trap Glazing facilities. All complexed designs are glazed using the robotic glazing machine. All water closets undergo trap glazing to uniformly glaze the trap area, ensuring better hygiene. Rocell’s well established process control system ensures unmatched surface quality of the glazed pieces after firing.

Firing

Fully automated, eco-friendly shuttle kilns help convert glazed green pieces, converting them into fully vitrified and sintered Rocell masterpieces.

Sorting & Final Inspection

With the utilization of Rocell’s fully automated testing facility, fired pieces undergo morphological and functional testing before reaching the customer. All the morphological inspections are carried out at the fully automated, inhouse testing facility in respect to the guidelines provided in the Eurpoean Standard – BS3402:1969 and the Australian Standard – AS1976:1994.

Quality Assurance

Flush Efficiency Test

In accordance with EN 997 standards, water closets are tested randomly for flushing efficiency. These tests include successful waste disposal, rinse volume after discharge (refilling of fresh water into the bowl after waste disposal) and determining the efficiency of washing the entire bowl surface area with fresh water.

Leak/Vacuum Seal Test

This test checks for leaks in the internal drainage system of the WC, preventing gas leaks and bad odours. Vacuum tests are carried out for all our water closets to prevent internal leakages. The water closet bowl and trap way are sealed and a vacuum is applied at a consistent -6 bar pressure and kept for 60 seconds to check for leakages in the bowl.

Load Bearing Strength Test

Load bearing tests are carried out on randomly selected pieces from each batch. A constant weight of 150kg is applied on washbasins and 400kg on water closets, applied consistently for 60 minutes to ensure that the strength of the product is in line with international standards.

Crazing Sensitivity Test

Hairline cracks, dents and breakages are detected using sophisticated test apparatus such as Autoclave for determination of crazing resistance and Dilatometer, to determine the co-efficiency of the expansion of sanitaryware body and the glaze.

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Our Certifications

At Rocell Bathware, each product undergoes the strictest guidelines and standardisation procedures, without compromise. This process is acknowledged and endorsed by a series of certifications including ISO 9001:2008 Quality Management System certification by SGS and ISO 14001 : 2004 for Environmental Standards for its continuous Green Initiative.

The brand stringently maintains the highest level of quality and design novelty, conforming to British Standard Specification BS EN 3402:1969. Whist carrying the CE certification for European Union consumer safety, health and environmental benchmarks, all flushing systems carry the water mark certification for water consumption and flush efficiencies.