International News

SOUTH AFRICA President opens Corobrik's Kwastina Factory

President Cyril Ramaphosa

delivered the keynote address at the official opening of Corobrik’s Kwastina brick manufacturing factory in Driefontein, Gauteng. The stateof-the-art factory forms part of an R800 million investment, which goes hand in hand with a further R200million earmarked to expand Corobrik’s concrete operations in KwaZulu-Natal. Corobrik is one of several local businesses that have responded to President Ramaphosa’s call on South African and international enterprises to invest in this economy. Kwastina produces clay face bricks, with its concrete operation targeting the plaster brick and block market. The President highlighted that the fact that the company is a local one that supports government efforts to empower and support local enterprises. “Corobrik has made a significant contribution to our efforts to extract greater value from our natural resources, by making its bricks from raw materials extracted from South African soil. This is an important part of government’s efforts to support localisation, supplier and enterprise development, as well as empowerment. “As we proceed with the implementation of our infrastructure plan, the demand for building materials will grow substantially. It is our intention that as much of these materials as is possible should be sourced locally,” President Ramaphosa said. The hi-tech facility is fully automated, from mixing the raw materials to the end product. Capable of producing 100 million bricks a year, the new factory will easily be able to meet larger-volume orders. In a first for the South African market, Kwastina will be flexible enough to produce small quantities of bespoke products for the architectural market. Kwastina is not only one of the largest brick manufacturing plants in sub-Saharan Africa, but also one of the most modern and energy-efficient in the world. After a comprehensive analysis of Corobrik’s existing manufacturing process, the Greenfield project resulted in a new shaping plant, a new fully automatic wet side, a setting plant for direct setting, two tunnel dryers and two tunnel kilns, and a new unloading and packaging plant for dispatch packs without pallets. “What makes this factory so exciting is that it allows us to compete anywhere in Southern Africa, landing product in regions traditionally not in Driefontein’s market as the new factory is more costeffective,” said Corobrik CEO Nick Booth. “It is going to give us an advantage in the market, not just in terms of technology, but also in quality and consistency, which are critical for specifications involving tight tolerances.”

INDIA Vijay Aggarwal appointed new chair at ICCTAS

Vijay Aggarwal, managing

director of Prism Johnson, has been appointed as the new chairperson at the Indian Council of Ceramic Tiles (ICCTAS). Aggarwal received his B Tech in electrical engineering from IIT Delhi and his PGDM from IIM, Ahmedabad, where he was awarded the Gold Medal for being the top ranker and the KV Srinivas Gold Medal for being the top allrounder. He began his career with SBI Capital Markets Limited and has several years of experience in the manufacturing sector. He has served as managing director of the Prism Johnson Board since March 2010 after previously serving as a director. He was formerly the managing director and CEO of the erstwhile H&R Johnson (India) Limited before it was merged with the company in 1998. Besides serving on the stakeholder relationship committee, he is also the chairman of the risk management committee, corporate social responsibility committee, and securities allotment and transfer committee. In a statement, H&R Johnson (India) - Prism Johnson Limited stated: “We wish that under the new able leadership of Vijay Aggarwal, the tile and sanitaryware Industry is further strengthened, becomes more customer focused, and achieves new heights in International business.”

OMAN Al Anwar receives new grinding plant from LB

At Al Anwar, the new LB

dry grinding and microgranulation line has been fully assembled and is ready for commissioning in the next few weeks. According to LB, the client required a new factory that would be capable of producing over 22,000 square meters of double-fired tiles in large sizes. LB's performance on the existing line has led Al Anwar to reaffirm their confidence in LB. Al Anwar, established in 1998, is the first and largest manufacturer of ceramic tiles in the Sultanate of Oman, and the first manufacturer of dry ground tiles in the Gulf region.

SOUTH AFRICA Christopher du Trevou appointed new ClayBrick Association president

The Clay Brick Association

of SA (CBASA) promotes sustainable, contemporary brick architecture and building design across the built environment: commercial, residential and landscape, underpinned by ongoing research, monitoring and stakeholder engagement. The CBA’s goal is to ensure that local property owners achieve long life, good value and sustained performance from brick walling and paving. As for most industries, the past number of years have presented significant challenges, despite which much progress was made under outgoing president, Hendrick van Dyk. "After the two-year pandemic, many businesses faced unprecedented challenges, followed by the looting and floods in KwaZule-Natal, but – as a country – we rose to the occasion and we’re coming back stronger,” said du Trevou in his recent inaugural speech. “As an industry, we need to commit to creating good and fair jobs, expanding our facilities and playing a key role in building infrastructure like schools, low-cost housing and clinics. It’s our responsibility to build cities and towns where families can be safe and warm, and to provide South Africans with the most sustainable option in clay bricks.” Essential resources include property-owner guides and technical manuals for builders, bringing together the makers and users of clay bricks with knowledge, choices and solutions. The CBA provides strategic direction for members through its investment in research and educational initiatives in energy-efficiency, reduced emissions, green building and sustainable construction.

INDIA India ceramic tile exports to reach INR180B in 2022

Indian ceramic tile exports are expected to touch a historic high of INR 180 billion (around $2.25 billion) in the ongoing financial year April 2022- March 2023 despite a number of headwinds. High raw material costs, increased freight rates, and shortage of containers have resulted in a fall in demand for tiles products in the recent past mainly for export oriented Morbi players. However, the scenario has changed in Q2FY23 with a significant fall in ocean freight rate, huge antidumping duty on Turkey by major European countries and significant rise in electricity and gas prices in Europe. These have trigged a healthy demand revival for Indian tiles in the European territory aided by competitive price advantage.

International News

Ferrari Stampi USA expands in Clarksville

United States

Ferrari Stampi USA announced that it will invest $1.4 million in expanding its manufacturing operations at the company’s US headquarters in Clarksville, on Dunbar Cave Road.

This project will result in 30 new jobs in Montgomery County.

The company’s expansion is a direct result of its decision to purchase Poligraph USA, which will support additional production lines at its US headquarters and help grow its overall customer base, according to a state news release.

Luca Silvestrini, president, Ferrari Stampi USA, said: “The American dream is centred around the idea that if you work hard, you can ‘make it’ in the US but hard work alone isn’t always enough as sometimes you just need the help of others.

“In our case, the state of Tennessee, especially Montgomery County, has been unbelievably supportive and hospitable in making this wonderful state our second home.”

“I thank Ferrari Stampi for its commitment to job creation in Montgomery County. I’m confident our state’s strong business climate and skilled workforce will support this company’s expansion and success in the years to come,” said Tennessee Governor Bill Lee.

“Tennessee’s central location and exceptional business climate offer international companies like Ferrari Stampi easy access to their markets around the globe. We are proud to be the home of Ferrari Stampi’s US headquarters and appreciate this company’s continued confidence in Clarksville and Montgomery County,” said Tennessee Department of Economic & Community Development Commissioner Stuart McWhorter.

A total of nearly 3,000 jobs have been committed and $1.3 billion in capital investments have been made since 2018, thanks to TNECD's support for 15 economic development projects in Montgomery County.

Senator Bill Powers said: “I’m pleased to help announce that Ferrari Stampi is expanding at its US headquarters in Clarksville with the creation of 30 new jobs. The company’s decision to expand in Clarksville is a testament to our friendly business climate, low taxes and great workforce. We wish Ferrari Stampi continued success moving forward.”

Ferrari Stampi USA was founded in 2014 by Italian company Ferrari Stampi to manufacture ceramic tile moulds and dies. With the addition of 30 new jobs, Ferrari Stampi will double its US headcount at their US headquarters in Clarksville.

PT PCI,d PT SMC launch new brand Infiniti Granite Tile

Indonesia

PT Platinum Ceramics Industry (PT PCI) has been present in the ceramics industry for five decades. With the aim of establishing a closer relationship with loyal customers and bringing the newest products to the market, PT PCI and its sister company, PT Surya Multi Cemerlang (PT SMC) conducted Product Launching and Customer Gathering events in four major Indonesian cities.

After introducing Lamina Granite Titanium a few years ago, PT PCI and PT SMC have now launched a new line called Infiniti Granite Tile.

According to the company's press release, this product is positioned as a product that is timeless and transcendent. It stated: "The dignified product can last for decades, offering granite products with a minimum load weight of 350kg / cm2 and infiltration of water less than 0.5%. Products made with Italian technology are recognised as products with the best durability in their class. For this reason, products that can be applied to both floors and walls are the most suitable products to be applied to all types of buildings that can last up to the next generation "Not only that, the latest motifs from the Lamina Granite Platinum & Ceramic Ceramics, were also introduced on this occasion. Titanium Lamina Granite is a pioneer of big slab granite products in Indonesia that is specifically designed to answer the challenges of a design that is of the size of relief and can be a substitute for perfect natural stone. Lamina Granite Titanium has the best specifications in its class, with sizes up to 1.2x2.4m and 8mm thickness & infiltration of water below 0.5%. Excellent products from PT. This SMC is a solution for the needs of architects who want to bring spacious and elegant nuances in the room.

All Platinum Ceramics product variants, Infiniti Granite Tile & Titanium Lamina Granite are available on the market.

Florim's new photovoltaic system is now operational

Italy

Florim’s new photovoltaic system is now operational on the roof of Plant 2 in Mordano (BO). This photosensitive surface area of 22,000 m2 with a nominal power of 4.5 MWp will help avoid the emission into the atmosphere of 1,400 tons of CO2 annually.

The investment is in addition to the many energy efficiency measures introduced over the years, consistent with a sustainability policy geared toward minimising the company’s impact on the environment and the local area.

When added to the two installations already existing in Fiorano Modenese, the new system brings the total installed capacity to 12.2 MWp, amounting to 64,000 m2 of panels. This is another important step in Florim’s drive to reduce CO2 emissions and is in keeping with the amendment to the company’s bylaws that spells out its commitment to climate neutrality.

CeramTec plans Marktredwitz site expansion

United States

The advanced ceramics manufacturer CeramTec is planning to expand its presence at the Marktredwitz site. The already existing manufacturing complex is to be expanded in the coming years to include, among other things, a further production hall.

Hadi Saleh, CEO, CeramTec said: "Our well-filled order books make it necessary for us to expand capacities. At the Marktredwitz site, we have already been able to count on an extremely reliable and sustainable network of employees and partners in the past. We are therefore pleased to be able to further expand our presence in Marktredwitz and thus also play an even more important role as an employer in the region in the future." CeramTec currently employs more than 800 people at their Marktredwitz site. Among other things, the new building is to be designed with a special focus on sustainability aspects. "In the CeramTec Group, we introduced measures for an even more conscious use of energy some time ago and have already implemented various projects and measures. The new building offers us excellent opportunities to produce even more energyefficiently and sustainably in the future and thus make an important contribution to the energy transition in Germany," said Saleh. Subject to official approval for the project, the start of construction with initial work is planned for 2023.

CeramTec is a global medtech platform focused on high-performance ceramics (HPC) solutions, which develops, manufactures, and markets ceramic parts, components, and products. The company has over a century's experience developing and producing advanced ceramic materials for a wide range of uses in the HPC industry. Its HPC products are used in a variety of applications, including medical applications such as hip replacements, orthopaedic implants, dental implants, and medical equipment, as well as industries such as mobility and electronics. Its manufacturing and distribution centres are located in Europe, North and South America, as well as Asia and its headquarters are located in Plochingen, Germany.

VitrA celebrates 30 Years in the UK

United Kingdom

International bathroom brand VitrA is celebrating 30 years of supplying bathrooms in the UK.

Due to what the company describes as its quality manufacturing, strength in domestic market leadership, and innovative production capabilities, VitrA was one of the first European manufacturers to be successful in the domestic market, which at the time was dominated by British names.

When VitrA entered the UK market in the early 1990s, the company already had 30 years’ experience in ceramic manufacturing and 10 years’ experience in brassware manufacturing, as well as an enviable portfolio of products. While VitrA brought new design styles into the UK, products were always produced according to UK plumbing systems. It also designed products suited specifically to the British market, such as the Chelsea and Chartwell ranges. The company was also one of the first non-British manufacturers to become a member of the Bathroom Manufacturers Association, reflecting its sense of duty to the UK industry.

Building on the success of the retail market, VitrA started to supply to the commercial market over 20 years ago. Within the first five years, the company won the contract for the new Heathrow T5 terminal and created the K basins specifically for this project. It has also nurtured relationships within the hospitality sector including IHG & Hilton, leveraging the company's global presence.

In the early 2000s, VitrA launched a collaboration with Welsh designer Ross Lovegrove. The range, called 'Istanbul', (freestanding basin pictured below) was and still is unlike anything else on the market. For the UK, this was the start of a long history of designer collaborations, culminating in the launch of Liquid with British designer Tom Dixon last year. (The Liquid collection below at VitrA London, the company’s new flagship showroom in London)

Today, VitrA operates over 2,000 sqm of warehouse space in Oxfordshire and a team of over 60 people. The company continues to grow from strength to strength, addressing the industry's new challenges and changes in buyer behaviour.

Last year VitrA opened a showroom in London for architects, designers, and specifiers, marking a new milestone in the company's journey. VitrA London is not only a space to showcase products, but also to engage with the community through events, workshops, and installations

Corrigendum to article featured in Asian Ceramics Issue AC22-5

Rapid post – pandemic recovery for kiln furniture:

Please note that IMERYS current open operation for its Ceramics Kiln Furniture activities are in Hungary and Spain

NCIA using data to manage energy crisis

Australia

The National Ceramic Industries Australia (NCIA) is reducing the costs associated with its energy costs with the help of OFS, a Melbourne-based manufacturer performance software company.

In addition to being the country's largest tile producer, NCIA is one of the largest users of natural gas at a single site.

As a result of the current energy crisis, the company contacted its data and technology partner OFS to find out if it could measure its energy usage in real time, joule by joule. As part of its performance management solution, OFS already provides its services to NCIA, which uses sensors to monitor the performance of its production in real time. The company installed new sensors to track energy consumption against production accurately.

This provided NCIA with the data necessary to predict with pinpoint accuracy how much energy is required to produce each product. As a result of the insights gained, the company was able to negotiate the best possible deal with its gas suppliers because its production schedule could be matched with its energy requirements. This has resulted in an average monthly savings of $40,000 and a yearly saving of approximately half a million dollars.

NCIA factory manager Craig Oliver said: “Forecasting penalties and trying to manually count energy usage is incredibly expensive. OFS has automated that entire process and positioned us to mitigate the surges in energy prices and optimise how we buy our gas.”

OFS CEO James Magee said: “NCIA should serve as industry best practice to absolutely minimise the cost impact of energy on the sector – you can’t manage what you can’t measure.

“The energy trauma facing Australia’s manufacturing sector is immense, and it’s disheartening that it’s come at a time of such renewed confidence in, and hope for, the sector. But manufacturers are resilient, and I hope the current crisis will spur more to leverage digital transformation to optimise their operations.”

OFS is an Australian company that provides productivity and efficiency improvement software (OEE software) to global manufacturing industries. The company's customers include Kraft/Cadbury, Coca-Cola Amatil, Electrolux, AstraZeneca, Heinz, Orora, Dulux Group, Unilever, Food Plastics Co, PACT Group, Labelmakers, Visy Industries, Murray Goulburn, Tatura, Sanitarium, HB Fuller, Standard Can and NCI.

NCIA reduced wastage and increased production using OFS software

ACIMAC attends Ceramic Expo Bangladesh, Asean Ceramics Thailand

Italy/Bangladesh

ACIMAC, the Italian Ceramic Machinery Manufacturers' Association, participated in two important events in Asia, the first in Bangladesh and the second in Thailand.

From 24 to 26 November, the third edition of Ceramic Expo Bangladesh was held in Dhaka's International Convention City Bashundhara and Acimac sent a delegation that included ICF & Welko, Officine SMAC, Sacmi, System Ceramics, and Tecnoferrari. The exhibition was last held in 2019 and brought together more than 300 ceramic manufacturers and suppliers from over 20 countries around the world. The event was particularly significant since Bangladesh produced 100 million square metres of tiles last year but has the potential to produce more than 150 million. Further, the fact that the country is an emerging economy with a large ceramic industry, a skilled workforce, and adequate natural gas supplies makes it a strategic partner for Italian suppliers of ceramic machinery, ACIMAC said.

Next, the Italian delegation travelled to Asean Ceramics Thailand, an international exhibition held at the IMPACT Exhibition Centre from 30 November to 2 December at which ACIMAC organised a joint Italian participation in collaboration with the Italian Trade Agency. Five Italian companies were in the delegation namely, Essepienne, Expert Lab Service, Keran, Officine SMAC and Tecnocer Italia.

As per ACIMAC, Thailand is another rapidly growing market that produced 148 million square metres of tiles in 2021 but has the potential of producing more than 180 million square meters in the future. Thailand's construction sector has seen strong growth since the government introduced economic packages in 2020 with the goal of raising GDP and bolstering consumer and investor confidence.

Since both countries are part of Southeast Asia, Italy's second largest export market outside the EU, these two exhibitions are important events for ceramic machinery suppliers. It is estimated that the region imported €272 million worth of machinery from Italy in 2021, accounting for 17.6% of Italy's total ceramic machinery exports (a rise of 68.6% over the previous year).

Mohawk buys Elizabeth Revestimentos

United States

Mohawk Industries has entered into an agreement to purchase Brazilbased Elizabeth Revestimentos. When combined with Eliane, which became part of Mohawk in 2018, the company will be the largest producer of ceramic tiles by revenue in Brazil, which is the second largest ceramics market in the world.

Elizabeth produces porcelain and ceramic tiles and sells mainly to the retail, home centres and constructors channels. Founded in 1984, it has four manufacturing units strategically located to optimise distribution. Coupled with Eliane's manufacturing strengths, Elizabeth's advanced manufacturing assets will enhance the product offering, operational efficiencies and service capabilities of the combined business.

Mohawk Industries is a global flooring manufacturer that creates products to enhance residential and commercial spaces around the world. Its vertically integrated manufacturing and distribution processes provide competitive advantages in the production of carpets, rugs, ceramic tiles, laminate, wood, stone and vinyl flooring. Its brands include American Olean, Daltile, Durkan, Eliane, Feltex, Godfrey Hirst, IVC, Karastan, Marazzi, Mohawk, Mohawk Group, Pergo, QuickStep and Unilin. Over the past decade, Mohawk has transformed its business from an American carpet manufacturer into the largest flooring company in the world.