TL;DR
Tile dimension deviation is most often caused by mold wear. Measure the cavity dimensions during the next planned stop and replace or refurbish the mold when wear exceeds the tolerance.
What you might see
- tile length or width outside tolerance
- tile flatness deviation above the specification
- cavity fill weight inconsistent
- tile surface defects correlated to mold surface condition
Likely causes
Mold cavity wear from abrasive ceramic powder over the mold service life
Mold cavity warping from thermal or mechanical loading over time
Mold fill volume changing from cavity enlargement reducing tile density
Punch face wear creating uneven compaction across the tile area
Required tools
- Calibrated tile dimension gauges
- Inside precision gauge for cavity measurement
- Flatness gauge for punch inspection
- LOTO kit
Safety first
- Full lockout is required before entering the press or handling any mold components.
- Ceramic powder dust is a respiratory hazard. Use P100 respiratory protection when working near open mold cavities.
Procedure
- 1
Measure 10 consecutive tiles for length, width, and thickness. Calculate the mean and range for each dimension.[1]
- 2
If the mean dimension is outside the tolerance band, stop the press and lock out.[1]
- 3
Measure the mold cavity dimensions with a precision inside gauge. Compare to the new mold dimensions to quantify wear.
- 4
Measure the punch face for flatness. A worn punch creates uneven compaction.
- 5
If cavity wear exceeds the tolerance, schedule a mold change. Do not continue pressing outside dimension specification.
- 6
During mold change, clean the mold seat on the press platens and inspect the alignment pins.
- 7
After mold change, run a trial batch of 20 tiles and verify all dimensions are within tolerance before resuming full production.
Sources
Sacmi Sacmi PH / PCR Series Tile Press general technical documentation, Sacmi
Sacmi tile press mold inspection and replacement maintenance documentation (general)
More guides for Sacmi Sacmi PH / PCR Series
How to fix powder feed inconsistency on a Sacmi PH / PCR tile press
Tile weight variation from the press is almost always a powder feed carriage speed issue or a hopper level problem. Check the carriage stroke, fill shoe condition, and hopper level control before adjusting the fill weight.
How to diagnose hydraulic pressure loss on a Sacmi PH / PCR tile press
Low pressing force means the hydraulic pump is delivering below the rated pressure or the accumulator pre-charge is low. Check the pump output and accumulator before tracing individual cylinder seals.
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