Quality Standards

The impact of ceramics on the textile production is usually underestimated.

During the yarn making and processing and later during the production of textile, each thread touches ceramics guides 40 times and more. Every encounter only lasts the friction of a second, but with an increasing demand for finer and thinner yarns, with increasing speeds and tensions, quality requirements on the ceramics are constantly rising.

For the untrained eye, it is often difficult to judge, which ceramic can be best meet the demands of the application. The wrong choice can devaluate or even damage the whole production output. The right choice adds an additional value to the finished product and is an investment that pays off.

This checklist provides the 10 most important factors that you should pay attention to, when purchasing ceramics:



1. Yarn Abrasion

Yarn Abrasion (Snow) is usually due to:


1.	low quality raw material - rough surface
2.	insufficient surface finishing
3.	sharp edges and small radius
4.	low density - sedimentation on porous ceramics
5.	polishing traces
6.	sub-optimal installation because of misfit

DOCERAM Standards:


1.	top surfaces through imported high quality raw materials with 90% of its grain size <1.6 µm
2.	surface roughness inspection
3.	various methods for applying the right finishing from standard to excellent
4.	in-house mould and die-making guarantees best shaping - strict quality checking
5.	no sedimentation through high density and unscathed surface - constant density inspection
6.	sophisticated polishing methods
7.	extensive size and surface checking according to DIN ISO



2. No Yarn Breakage

Yarn Splicing and Breakage is usually due to:


1.	pimples and holes on the ceramic surface
2.	hidden cracks with sharp edges
3.	grinding traces and cuts

DOCERAM Standards:


1.	high precision polished and heat treated one-cavity CNC-moulds and -dies provide perfect negative forms for top surfaces
2.	intelligent "soft-debinding" - no material "washout"
3.	careful handling and special satination treatment
4.	vacuum mixing - no inner air locks and material nodules - no inner tensions
5.	no cracks - 100% crack test - liquid penetration method
6.	careful surface inspection



3. No Heating

Modification of the yarn characteristics is usually due to:


1.	heating up of the ceramic thread guide

DOCERAM Standards:


1.	little heating through careful choice of the right material
2.	surface treatment



4. No Process Disturbance

Inhomogeneous Production Output is usually due to:


1.	inhomogeneous ceramics (shape, size, surface...)
2.	sub-optimal installation because of misfit

DOCERAM Standards:


1.	homogeneous parts through high precision moulding on CNC machines - special steels
2.	even characteristics from batch to batch through imported high quality raw materials and equipment
3.	strict process and end control - 15 employees engaged in quality control



5. No High Tension

High Tension in the production is usually due to:


1.	wrong shape
2.	sub-optimal installation because of misfit
3.	poor material
4.	insufficient surface treatment

DOCERAM Standards:


1.	best shape through intensive dialogue with machinery manufacturers and end users in Europe and Asia
2.	process-simultaneous control of dimensional accuracy and other faults
3.	imported high-quality raw materials
4.	various finishing procedures



6. No Installation Problems

Installation problems are usually due to:


1.	misfits
2.	breakage during installation

DOCERAM Standards:


1.	best fit through high precision products precisely to the drawing
2.	strict execution of DIN ISO 2768c
3.	detailed recordings for every batch as part of ISO quality system
4.	sampling ceramic core checking through demolition assures tension free products - density control



7. No High Costs

High Costs are usually due to:


1.	high buying price
2.	installation problems of the ceramics / reclamation
3.	low hardness - fast wear
4.	short lifetime

DOCERAM Standards:


1.	competitive pricing - blanket orders with special offers
2.	extensive final inspection of dimensional accuracy with callipers, gauges and good-bad tools developed by us
3.	little wear through high density with good hardness - constant hardness testing
4.	long lifetime under high speed and tension



8. No Optical Impairment

Optical Impairment is usually due to:


1.	material impurities
2.	different shades of colour
3.	different shapes
4.	dirty parts

DOCERAM Standards:


1.	chemically processed pure raw materials
2.	very clean production environment - 3 step mixing process in restricted clean area
3.	visual inspection does not allow colour variations
4.	ultrasonic cleaning



9. No Procurement Problems

Procurement Problems are usually due to:


1.	communication problems
2.	slow response
3.	insufficient understanding of the textile production procedure
4.	poor consultancy
5.	no prototype development
6.	no R & D
7.	no assembling
8.	unclear drawings or no drawings at all
9.	no stock
10.	small capacities
11.	long delivery times and delays
12.	unfavourable payment terms

DOCERAM Standards:


1.	Chinese, English, German spoken
2.	most modern communication equipment
3.	customers come first - fast response as prior target
4.	expert knowledge of textile process - intensive dialogue with machinery makers - experienced OEM supplier
5.	constant internal and external vocational training
6.	demand analysis and consultancy on material, machine-yarn-ceramic suitable design, ideal surface characteristics
7.	prototype development - various materials and shaping
8.	processes - in house tool making
9.	R & D department works on better qualities, special applications or customized problems
10.	complete assembling with metal, plastics, etc.
11.	professional CAD designing
12.	over 600 different products ready on stock
	production in 3 buildings on 5800 sqm - over 100 employees - extensive equipment
13.	immediate service from our sales offices in Guangdong, Fujian, Zejiang, Jiangsu and Shandong
14.	flexible payment terms depending on quantities, blanket orders, customer reliability etc.



10. No Shipping Problems

Shipping Problems are usually due to:


1.	poor packaging
2.	unclear labelling
3.	parts stuck in the Chinese customs
4.	delays with the forwarder or post service

DOCERAM Standards:


1.	special DOCERAM packaging for best protection
2.	clear labelling
3.	smooth shipping in China and overseas: China export license - no additional
4.	trading company required
5.	7 years export experience worldwide
6.	express service, usual air freight or sea freight depending on the customers requirements

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