Apparently invisible. Chemistry in ceramics.

The growing use of large ceramic slabs, with increasingly larger formats and reduced thicknesses, has introduced new challenges in terms of processing, handling, installation and safety. In this context, back-meshing is a post-firing process in which a reinforcing mesh is bonded to the back of the slab, helping to retain fragments in the event of breakage while providing additional support during subsequent processing, handling and use. In this episode, we explore the back-meshing process, from mesh selection and the role of the two-component polyurethane adhesive system offered by Z&S Ceramco to different application technologies and the cross-linking stage. A journey through materials, chemistry and application technology to understand how mesh, adhesive and process need to work together to provide effective and reliable reinforcement.

Producing digital inks, glues and ink effects for ceramic decoration is a highly sophisticated process that relies on the careful integration of multiple formulation components. Achieving consistent performance, long-term stability and reliable production quality requires the use of a range of specialized additives, each playing a critical role in ensuring proper product functionality and processability. In this episode, we revisit the concept behind the DECOFLUX DP range: a modular additive platform developed to support ink manufacturers and ceramic companies that produce their own digital inks and glues in-house. From pigment grinding to final dilution, we explore how each element of the platform — from pre-optimized grinding media and universal dispersants to viscosity modifiers and stabilizing agents — has been designed to address the practical and evolving requirements of the formulation

Ceramic grit binders are often regarded as simple fixing agents, but their role within the production process is far more complex. In this episode, we explore how the management of rheology, particle suspension and application behavior directly influences the quality of the final result, and why the selection of a binder cannot be based solely on its adhesive strength. We trace the technological evolution of the GRANICER range, examining the characteristics and application logic behind its different product families. From solutions designed for dry applications to formulations developed for wet grit application, and up to the most recent systems engineered to provide greater flexibility, stability and integration with digital technologies, we analyse how each series was created to address specific production requirements.

This episode addresses the control of bacterial contamination in ceramic processes, a factor that is often invisible yet crucial for the stability of compounds and the quality of the final product. In a production context characterized by the unavoidable presence of organic substances, bacteria can rapidly proliferate, altering rheological properties and causing application defects. The episode analyzes the main intervention strategies, distinguishing between sanitizers, biocides, and preservatives, and presents the role of the PREVENTOL range in controlling contamination throughout the entire process.

Chemical product labelling plays a key role in ensuring safety and regulatory compliance across the entire industrial value chain. In this episode, we explore the European regulatory framework, focusing on how CLP, REACH and BPR interact, and how together they balance health protection, environmental safety and market access. We take a closer look at different product categories, highlighting their distinctions, areas of application and regulatory implications. We also examine the main technical communication tools — from labels and safety data sheets to the UFI — explaining their practical function and their importance in emergency response. A structured overview designed to help navigate obligations, responsibilities and best practices, turning regulatory requirements into a proactive tool for risk prevention and management.

This episode explores the technological development of temporary binders for the ceramic industry, starting from the TENACER range developed by Zschimmer & Schwarz. In today’s ceramic manufacturing environment—marked by large-format tiles, ultra-thin slabs, super white bodies with high glass content, and increasing variability in raw materials—maintaining the mechanical strength of the green body has become a key factor for ensuring both process stability and final product quality. The podcast introduces the main product lines within the TENACER range, outlining their different technological approaches and formulation strategies, while also highlighting the industrial considerations that guide their application in production environments. The episode also addresses several critical aspects of the ceramic process, including how additives interact with other production variables, the issue of black core formation, rheological behavior, and typical dosage ranges. Overall, it emphasizes that the effectiveness of binders is never determined by the additive alone, but rather by the careful balance between formulation choices and process conditions.

Zschimmer & Schwarz did not enter the water-based digital adhesives arena overnight; its position today is built on more than a decade of dedicated research, hands-on industrial testing, and continuous product refinement. In this podcast episode, we take a closer look at the AQUABOND range of water-based digital adhesives, exploring how the line has evolved, the technical principles behind it, and the development strategy that shaped it. Alongside essential background insights into the technological and market landscape, we provide a structured comparison of the different products within the range—highlighting their distinctions, intended functions, and performance profiles, and explaining how each formulation has been engineered for specific production environments. Water content, the presence or absence of fusible components, operating temperature, lubrication level, machine runnability, and other critical parameters become practical benchmarks to guide product selection—giving listeners a clear framework to assess and fully leverage the potential of the AQUABOND line in advanced industrial applications.

The pivotal role of rheological additives in ceramic processes: how deflocculants and binders shape the stability, viscosity, and workability of ceramic suspensions. The discussion explores particle interactions, colloidal stability, the electric double layer, and the main electrostatic and steric stabilization mechanisms. The goal is to highlight how the right use of additives can optimize production processes and enhance the quality of the final ceramic product.

This episode provides a quick overview of the “black core” effect—an internal discoloration in porcelain tiles, typically caused by incomplete oxidation of the ceramic body due to trapped organic residues. It highlights the production conditions that make the defect more likely to appear and then outlines practical corrective strategies to prevent it. All in just ten minutes.

In ceramic manufacturing, aqueous suspensions play a crucial role in shaping processes and determining the final quality of products. However, foam formation can disrupt production, leading to defects and lower efficiency. This episode dives into the world of foaming phenomena, exploring how they arise and how they affect the properties of suspensions. We discuss surfactants, which can encourage foam formation, and defoamers, which help keep it under control. What key insights are needed to effectively manage these challenges?

A closer look at one of the most common flaws that can affect both the performance and the appearance of ceramic glaze. In this episode, we break down the key causes, explain how they arise, and share practical ways to prevent them. For a deeper dive into the topic, check out episode #39.

What is rheology and what is it used for? This episode answers exactly these questions. Without delving into complex details, it presents a few key concepts to help navigate topics such as viscosity, material behavior, and process control. It’s a first step toward understanding the practical role of rheology in improving quality and production efficiency. In ten minutes.

Wettability is, in general terms, the property that describes a liquid's ability to adhere to a solid surface. It can also be understood as the process through which effective contact is established between a liquid and a solid. In some cases, solid surfaces exhibit low wettability—a characteristic that, while not inherently problematic, can lead to significant issues in the ceramic industry. When raw ceramic bodies or suspended particles display poor wettability, production inefficiencies may arise, ultimately affecting the quality of the final product. Wetting additives play a crucial role in creating the optimal conditions for achieving proper substrate wettability. But how do they work, and in which applications are they most commonly used?

The electrical conductivity of water is a key parameter in industrial production processes, as it reflects the amount of dissolved ions that can directly impact the stability and efficiency of operations. When conductivity levels go unchecked, they can compromise the quality of the final product, cause corrosion in equipment, or alter the reactivity of the materials used. In this episode, we explore why continuous monitoring is essential and what strategies companies adopt to keep conductivity within optimal limits. We discuss not only direct treatments like reverse osmosis and deionization, but also indirect approaches: the use of additives and rheological modifiers can help mitigate the negative effects of high conductivity, ensuring more stable processes and more reliable end products. Zs_lab, educational, Zschimmer&Schwarz, Tiles, Ceramco, Chemistry, Ceramics,

In this episode, we dive into the essential role of chemical additives used during the grinding phase of ceramic glazes—a crucial step that sets the stage for successful application on the glazing line. We focus on dispersants and binders, compounds that give the glaze the right balance of cohesion, stability, and flow. But there’s no one-size-fits-all solution here: the type of additive must be tailored to the specific application method, whether it's airless spraying, bell, or curtain coating. A technical yet accessible look at how chemistry drives performance—right from the start.

Digital printing has transformed the ceramic industry, opening the door to highly sophisticated, versatile, and customizable designs. At the core of this shift are ceramic digital printers—advanced machines that use inkjet technology to precisely apply both functional and decorative materials. While the focus is often on inks and printing performance, there’s another category of fluids working quietly behind the scenes: maintenance fluids. Though they don't directly impact the final aesthetic result, they play a vital role in keeping printers running smoothly and extending their lifespan. In this episode, we explore three key types of maintenance fluids: cleaners, stand-by fluids, and model fluids—each essential for ensuring reliable and consistent digital printing performance.

In the world of ceramics, temporary binders play a crucial role in improving the cohesion and workability of slips. These substances, often polymer-based, act on a chemical level by creating bonds between particles, increasing the mechanical strength of the mixture. In this episode, we explore what they are, how they work, and why they are essential in modern ceramic processes.

This episode takes inspiration from the thesis work of the Head of Research at Zschimmer & Schwarz Ceramco. The goal is not to focus on the specific topic explored in that study (in this case, the well-known issue of the "black core"), but rather to highlight the research methodology and the meticulous, in-depth work that takes place every day in the laboratories of chemical companies serving the ceramic manufacturing industry. Although it begins in an academic context, the process described closely mirrors the structured, methodical approach followed by laboratory professionals in real-world industrial settings.

In the ceramic field, a “top glaze” refers to the glaze applied as the final layer onto the unfired ceramic substrate. This glaze can serve multiple functions, but it primarily protects the underlying decoration and imparts specific technical and aesthetic properties to the surface. This episode focuses on this particular class of glazes, taking a closer look at the key functions and rheological characteristics (among others) that the suspension must exhibit, depending on the chosen application method and the type of ceramic product being manufactured.

After more than fifty episodes exploring topics of general interest—always through the lens of chemistry and ceramic production—we’ve decided to have some fun. We posed a few simple questions to artificial intelligence, asking it to write a short text about chemistry with complete freedom to choose the themes and highlights. The result? Amusing, sometimes absurd—mostly accurate, but not always. As we know, Large Language Models (the technology behind AI’s ability to understand and generate text) can produce content that sounds convincing and is often correct, yet it’s not immune to errors or even clichés. With so much information available online, inaccuracies are just a step away. That’s why it’s essential to keep in mind that this is, above all, an experiment—and, let’s not forget, just a bit of fun!