Professional Development – Crossville Plant Tour

Traveling is often associated with exploring vibrant cities, breathtaking landscapes, and rich cultural experiences, but sometimes, the most fascinating journeys are those that take us behind the scenes of everyday items we often overlook. An intriguing destination to explore is a tile manufacturing plant so if you're passionate about design, craftsmanship, or simply curious about the making of those beautiful tiles that adorn our floors and walls, a visit to a tile plant offers a unique and enriching experience worth trying.

One of our interior designers, Courtney Nelson, had the opportunity to tour the Crossville Manufacturing Plant in Crossville, Tennessee, where she gained valuable insights into the tile manufacturing process. During her tour, Courtney observed cutting-edge technology and design innovations, including the latest digital printing techniques, eco-friendly tile production methods, advanced kilns, robotics and automation used throughout the facility. This experience deepened her understanding of tile quality and durability, enhanced her ability to make more informed decisions on tile selections, and allowed her to foster a greater appreciation for the craftsmanship.

Photo: Interior Designers, Architects, Industry Reps, & Territory managers that attended the Crossville Plant Tour

Fun Facts Learned:

When Crossville first entered the tile industry, they offered only one tile size.
Tennessee hosts numerous tile manufacturing plants because of its proximity to the essential raw materials required (feldspar & clay) for tile production.
For back-of-house areas, choose true porcelain tiles over quarry tiles, as quarry tiles can absorb dirt and grease, whereas porcelain tiles do not.
All excess tiles from the manufacturing process are recycled by being re-crushed at 'Mount Crushmore.' (Photo: The raw material crushing process)
Crossville contributes a significant amount of tile to non-profit organizations like Habitat for Humanity.
The final color, texture, and design of the tile become evident only after curing.
All Tile shrinks during the curing process, making precise sizing during manufacturing crucial. This is why many tile edges are recertified - to ensure that all tiles in a batch are consistently sized. This process helps achieve uniform grout joints for installers. (Photo: Tile before and after being cured & machine used to recertify tile)
Crossville produces some of the hardest porcelain tiles in the industry.
In partnership with Toto, Crossville incorporates crushed porcelain toilets into some of their white tile products. (Photo: Toto toilets preparing to get crushed)
Tiles sold at big box stores are not always 100% porcelain.
'Mount Crushmore' (Raw material pile) is visible on Google Earth. (Photo: Mount Crushmore)
Quality control is typically managed by women, who are recognized for their meticulous attention to detail.
While Crossville has several plants in the area, Plant 4 is nearly fully automated, with minimal human contact with the tiles.

If you're undecided about visiting a tile manufacturing plant, remember that it's more than just a factory tour—it's an immersion into the world of design and craftsmanship. You'll develop a new appreciation for the beauty and complexity of tiles, as well as the skill involved in creating them. Whether you're a design enthusiast or simply curious about the manufacturing process, this behind-the-scenes experience will give you a deeper understanding of this often-overlooked aspect of interior design.