Asian Ceramics - October 15 Edition

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October 2015

SEE US AT:

CERAMITEC 20-23 OCTOB ER MUNICH

INSIDE:

Brick industries of ASEAN Indonesia focus: p2 Province Profile: Jiangxi

PLUS NEWS, VIEWS, ANALYSIS AND MUCH MORE!

:

PEARL CASTING PLANT

MOULD DRYER

MULTI DECK WARE STORAGE SYSTEM

RAK CERAMICS

NEPTUNE’S INNOVATIVE DEVELOPMENT FOR SANITARY WARE INDUSTRIES

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WET SCRUBBER SYSTEM FOR INSPECTION / DRY FINISHING BOOTH

eptune has introduced a new concept in the area of inspection & dry finishing by developing multiple booths integrated with common wet scrubber unit”.

Conventionally these booths are connected with “bag filter unit / Exhaust Chimney” so that dust particles goes and gets settled in to it BUT over a period of time, bags of filter unit gets chocked and then real problems start as under,  Filtration efficiency of bag filter unit goes down and it starts creating back pressure.  This will ultimately results in poor suction of dust particles from booths and the whole area will become

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un-interruptedly with practically no maintenance and helps in improving sent to ware house recovery.

The dust particles collected in wet scrubber are also recovered fully, to be re-used in the body.

So, it offers great saving in body cost too,

REJECTED WARES / PITCHER / CULL CRUSHING & DRY GRINDING PLANT

eptune has developed Pitcher Crushing & Grinding System which provides total solution from sorting line Conventionally in

most of the companies, Pitcher (Fired Reject) is primarily broken manually which is very unsafe and

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dusty due to flying dust particles And then most dangerous situation will be sticking of these flying dust particles on glazed ware pieces  And ultimately, fired rejection percentage will be suddenly increase Hence after detailed study of this problem of industry, Neptune has introduced this new & innovative concept where the booths are connected with “wet scrubber” and here, all dust particles generates by the way of dry finishing process, goes to wet scrubber unit and gets settled by water jet spray effect and only clean air goes out from chimney duct.

This new system keeps the area clean



The primary breaking & crushing of there is all possibilities of man hazard, WHOLE PITCHER is done by specially Broken pieces are further crushed designed GC TOWER & ROTARY using jaw crusher and then it is either SHREDDER. This offers crushed output given for land fill requirement or it of < 6mm and this crushed output is is further ground to fine mesh SAFE sent to continuous ball mill to get fine around 100 or 240 # to be DISPOSAL powder of 100 # or 240 # final output, used in fresh body as 100% to be used in fresh body as per per company UTILIZATION IN BODY company requirement. requirement, Hence after Advantages detailed study of this problem of industry, 1.

No handling from sorting line.

Neptune has introduced this new & 2.

Zero disposal with 100% innovative concept where the WHOLE utilization PITCHER can be PUT to the system and 3.

Cost effective at the end, you get fine powder. It is 100% 4.

100% Human Safety safe operation. It is cost effective too,

MODULAR MULTI DECK AUTO STORAGE SYSTEM WITH MANIPULATOR

ow a day in sanitary ware industries have big Problem for ware storage (Mainly Green ware & Glazed ware) Neptune has introduced a new trend for the storage of Wares by developing a ‘Multi Deck Chain Bench with Loading & Un-loading Manipulator’.

If we are talking about existing problem for handling a Green pieces in sanitary ware industries as below.  Caster have only 1 day storage capacity at front of casting bench so caster has to move casting piece after one day than, Green ware had to store in transfer trolley which Trolley are stored in plant area so people has to use hidden capacity of plant  Required numbers of trolleys  Create congested environment inside the plant  Handling Rejection is higher due to

+ 91- 9687695944 PHONE : + 91- 2762 - 224551/224331

many times loading unloading in rack & trolley.  Caster efficiency will down Hence after detailed study of this

deck than chain will move by motorized and that piece will collect and transfer in 2nd deck with help of manipulator than in next cycle of casting, same manipulator will move 2nd deck’s ware in 3rd deck, 1st deck’s ware in 2nd deck so 1st deck is again ready for new casting pieces. So by way of this working method we can use in this chain bench in multi level 1.

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problem of industry, Neptune has introduced this new & innovative concept where we are providing Multi storage deck at front of Casting Bench which caster will de-mould the green ware in 1st

WEB : www.neptune-india.com

5.

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E mail :

Advantages of the system Saving caster time for loading & unloading Saving caster physical effort Easy operation Saving of plant space which are hidden capacity of plant Less Quantity required of Transfer trolley Less handling loss Particular product can use as per market prospect

hardik.thaker@neptune-india.com ceramics@neptune-india.com

New: Gamma XD Series Re-defining the standard of image quality Banding-free printing thanks to new Adaptive Dot Placement Technology • Unreached level of image details, sharpness and color strength • Easy and fast print head replacement • Tile thickness scanner to avoid line stops •

Ceramics Printing Durst. The industrial inkjet specialist www.durst-online.com Italy · Austria · Germany · Great Britain · Spain · France · Sweden · USA · Mexico · Brazil · Singapore · India

News

Contents: October 2015

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Asian Ceramics Ed itorial & Distribution Schedule Asian C✷ ON-PAGE: full and halfAdisplawealth of exciting opportunities… y advertising era ✷ DIGITm AL: ic full and half displa rtising…and more Ethedultim ✷ DUMMY COVEs ! itoate,yriadve high al impa ✷ BELLY & ctDcreat ✷ ON-P ive… take ownership A-WRAwPS:eaRS:high is AGE: fu le, hard-hitting mess lthprofi ibeyan ll and ha agetr ✷ DIGI conv uticeon Sof the issue of ex lf display TAL: fu c it ll an No in ✷ DUM adve vem chedule g d ber ha rti op 201 lf sin5 MY COVE display p g or tu adverti ✷ BELL RS: the n itie16AC sing… ultim Y-WRA s…5 ●●●●●●●●

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Asian ittfuture for ea demand cycles saniw ■ Province profil take are? e: Shanding message ownersh ■ Gujarat p2: sanita ■ Heav convey ryware - growth or BONUS DISTR IBUTI ong ip of■ th y clay in consolidation? ance Bangl ON: e issadesh ■ Fuel ue : a new tile centre evolutio Maghreb SPECIAL FOCUS: AFRIC Bricks Expo Ahmedabad ■ SPECIAL FOCU ■ Capa n in As AN OPPORTUNI S: Freigh

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As the industry convenes in Munich for the December/January AC16-5 2016 AC16-6 triennial Ceramitec exhibition, thoughts Decemb er/Janu ary 201 are already turning to 2016 and the 6 AC16-6 AC16-1 AC16-7 exciting opportunities that await the AC16-1 industry. With ASEAN growth likely to be AC16-7 AC16-2 AC16-8 cemented by the new trading agreement, AC16-2 AC16-8 the re-emergence of Iran, the continued AC16-3 AC16-9 A growth in India and an upturn forecast C16-3 AC16-9 for Russia and the Middle East, it’s AC16-10 AC16-4 A C16-4 going to be quite some 12 months!

AC16-1 0 Make sure you keep up to date with Ma xim ise you r exp osu re, max imis e you r bud get…

M a x im is everything that happens, by ensuring e yo u r ex po su re, m a x im is e yo u r b u d g et n er ! your subscription to Asian Ceramics … is up to date. Also, check out our provisional Editorial and Distribution Schedule for the next 14 months on p.34 of this issue. ●●●

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BONUS profile: Shando ture for Asian saniwar ng d freigh Share SPECIA DISTRI BUTI■ e?s for t: cost saving ON L FOCU Asia : Brick ■ Irania n porce s Expo S: AFRIC lain spreads region Ah ●●●●●●●●

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t options for difficu lt markets Iran; ISH, China

■ China : the mi ■ Kiln furnitu d-year review re dema ■ Iran in ■ Gujar nd cycle focus: the heavy clay at influe■nce s Banglad p2: sanitaryw ■ Cost contro l in Asian tiles are - gr esh: a ne ■ SPEC w ■ Middl th eow East

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al ■ AN TileOP trade: daba options PORTwinne rsme and d losers UNITIES ■ Heavy clay indus SUPPLE tries MENT ■ Shar tile cent sanita IAL FOCU or cons rywar ed BONUS DISTRIBUTI olidae: evolution or revolution?

■ Asianre S: Freigh SE E US ON: Yearplanner; Indian ■ Irania freight: co n?focus t optioTableware: a changtio st savin ATics e in n porce SPECI : Ce Ceram AL FOCU raf 2016 ns ■ gs SPECI S: ■ Tile air Asia: fo lai for As the brick industry foreca r dif , Iran; ISH AL FOCU S:fic tablew trade: wi n spreads ult maare st ation techniques , Ch regiona ia SEE US nners rkedecor ■ Heav ina AT: ts Ceram l ●●●

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ic Industry Club of ASEAN, Thailand ■ Iran in focu s: the he ■ Cost co av cla y optio ■ Midd ntrol in Asian ■y ASEA N tilensmanufacturing le tiles th ian Ceram ■ePakist brick an: ■ Asian East sanitar trend antry s indus indus ■ Fuel choice: powe ywar ics 2016 in turmo Tablewa il? ring the factories of e: evolu forectry ■ ASEAN in focus: ■ t ■ China tomorrow theasleade tiodema tile ■ Prov n or re rs' debate SPECIAL FOCU re: a chan nd ge in fo ■ SPECIAL FOCU inc voanaly lutionsis S: SE E US ■Asian cus g blocs: S: Asian porcelain ■ Turke e Profile: Gu AT: Ceramtableware de tradin tiles winne?rs and losers angdon y: a table SEE US AT: Ambiente, ■ SPECIco raFOCU ■ Pakis ic Indus tion te Germany; Unicera, S:ch Asian tan: an ware hotsp g try AL makers Turkey; niquetile ot Cevisama, Spain bAT: ■ ASEA industry SEE Clu s of US ASEAie, Cersa N in fo Italy in turm N, Th cu ailand ■ SPEC ■ ASEA IAL FOCU s: the leaders' oil?

N tile ma debate S: ■ Fuel SE E US choice: nufacturing AT: Am Asian po■rcelai po trends ■ China Provin biente, n tile ce sProfile: Fujian tile demawering th■e Rajast han: a rival for Gujar Cevisam Germ fa ■ anLanka ■ Sri As cto at? y; nd ian rie : Unicea new day dawns ■ Chinese ssanita analysis trading a, Spain of tomo rywar , Turkey; ■ Cost savingra blo ■ rroe wmarkets and makers strate gies for heavy clay SPECIAL FOCU cs: winn■ Korea: settin erSouth g a future stage s and los ■ Bangladesh: S: SE E US Egypt land of opportunity ian er ■ Prov tile s markets AT: Cersa Asian tile■ma ? inc ke SEE US AT: Official rs ie, ■ SPECI ■ Sri La e Profile: Fu Italy AL FOCUS: Raising Magazine: Indian Ceram jian nka: a ne investment funds ics; Tile & ■ Cost SEE US AT: Tecnargilla, Sanitaryware China w day saving dawns Italy str ■ Bang ■ Rajas ladesh: ategies for he th avy land ■ Chine an: a rival fo SE E US r Gujar se sanit AT: Offi of opportunit clay at ■ Sout ar ? yw cial Mag ■ Provin y? ce Profile: Qingh are ma ■ The Casting Couch azine Ind ai & Tibet■ Eg h Korea: se rkets an : Asia decides Sanitar design dm ian yware ■ :Kiln makers rywar tech: conflicts of intere yptian tile matting a futu■reVietna Ceram Ch■ina e markets and make ■ SP st?EC ics; Tile stage sanita rkets Gujarat p1: ■ Tile rs chang decoration: choosing ing & tiles, changing IAL FOCUS: the right option ■ Building blocks Raisi ■ Brick US AT: ■ Prov : heavy clay marke SE Etimes Tecnargil ng investmenopportunities in North Africa ince Pr ts in ASEA ■ SPECIAL FOCU N ofile: Qi ■ t SPECI la, ■ Kiln fuFOCU S: Tile inspection and AL nds S: Printing techn Italy design ng certification ology US tech: co hai & TibSEE ■ Gujar AT: SEE Keram US AT: The Big 5, Dubai ika, Indonesia; Mosb nflicts of et at p1: ch uild, Russia; ■ Build ■ an int Th 27th ging tile erest?

Cerambath, China e Casting ing blo s, ch ck Co ■ Vietn ■ SPEC am sanit uch: Asia de IAL FOCU s: heavy clay anging times marke ■ Tile S: es SE E US decora aryware ma cid tile markets in south AT: KeramTile inspection ts in ASEAN tio rke■ Roof ■ Brick ern Asia and and cece ■ Provin ika opportu n: choosing th ■tsExpor Profile t patter rtific kers ns for Asian e right ma nit ■ SPEC ation: Xinjiang 27th Ce , Indonesia; ■ Iran M IA opnd: ■ Thaila osin rambath L FOCU ies in North Af tionthe Lampang tiles bufocus: ild, Rutablew are and sanita S: Print ric factor , Ch SE Erywar ssi ■ina J-V or OEM: e US option a; ■ South AT: The s? ing techno a ern India: a tile and decisions for tile make sanitaryware centre Big 5, Du rs logy INSID ■ Technical ceram ■ FREE ■ Prov ics demand in South E: YOUR 2017 YEAR bai ince Pr Asia PLANNER ■ SPECIAL FOCU of ■ Iran S: Chinese machinery in focu ile: Xinjiang SEE US AT: Official ■ Roof exports ■ J-V FR EE WI TH or OEM s: tableware an Magazine: Ceram tile ma : de rkeMiddl ■ Expo ics China TH IS IS SU d ■ Tech in soeut East Stone & Ceram rt patte ; ts nical ce cisions for tile sanitarywar E hern As ic,ail Dubai ■ Th rns for e optio ramics ■ SPEC ma ia ke an Asian tile demand ns?

Th e 20 17 Ye rs IAL FOCU d: the ■ Sout in So s S: arp lan SE E US hern Ind Lampang fa AT: Offi Chinese mach uth Asia ctor ■ FREE ia: a tile inery ex cial Mag IN an SID d sanit E: YOUR azine: Ce find ports East Sto arywar out 20 how ram 17 by e ne & Ce contacting: YEAR PL ce ics China ramic, Du ANNER ntre ; Middle Paul baRusse ll, Tel: i FR E E +44 (0) 208 638 0619 Valerie Adam W ITTel: Email: prussell@asi son, H +44 anceramics.com (0) 208 133 5273 find ou T H IS Email: vadamson@ t how IS S U E T he 2 0 asiancerami by cont Paul Ru www.asianceram 17 Y ea rp cs.com acting: ics.com sse Email: pr ll, Tel: +44 (0) la n 208 63 ussell@ 8 0619 asiance ramics.

Valerie com Adamso n, Tel: +4 Email: va 4 damson (0) 208 @asianc 133 5273 eramics. com

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nce BONUS y industries losers DI SPECIA STRIBUTION:■ Province Profile: Guangdong L FOCU arplan Turke y: a S: Asia: ■ Ye netablew r; Ind are hotspot

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10 Inside Asia

Emilceramica and Simpolo unveil their j-v.

14 Welcome

A new ceramic corridor?

16 Across The Continent

Openings, closures and industry moves from across Asia.

26 International News Our eye on the international arena.

30 Material Matters Raw materials news and views.

32 Comment & Analysis

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See us…where?!

Ceramitec Munich, Germany 20-23 October Hall: A2 Stand: 411

We look forward to seeing our readers and advertisers at the show!

Tableware in the UK fights back.

8

asian ceramics

october 2015

www.asianceramics.com

News

www.asianceramics.com Features 36 The brick industries of ASEAN

Yogender Malik looks at how the brick industries of South East Asia have adapted to modern manufacturing techniques and are gearing for the future.

42 Indonesia: tableware and sanitaryware focus

Jahir Ahmed concludes his analysis of Indonesia by focusing on how the country’s tableware and sanitaryware industries are being impacted by rising gas prices.

56 Province Profile: Jiangxi

In the next of our Province Profile, AC turns its attention to the developments taking place in Jiangxi.

36 “Locally made extruders are now common in most brick manufacturing facilities/ plants”, see p.36 “The government knows gas price increases will make Indonesian ceramic wares expensive both at home and on the world market”, see p.42 “The problem for the regional shows is that there is only a finite amount of money for companies to spend on marketing and advertising”, see p.82

56

Anaylsis 34 Looking forward The AC editorial and distribution schedule for 2016.

72 Talking Shop

In an interview undertaken by El Periódico Mediterráneo, Luis Hernández Sanchis, chairman and managing director of Grespania, SA discusses developments at the company.

Your favourite magazine is now available at the App Store… download today to see your first sample issue!

Asian Ceramics: now for mobiles, ipads and androids

76 Insight

Analysis and insight into ceramic supply and demand in Brazil.

Asian Ceramics:

Asian Cera Asian Cer mics amics Edit orial & Dist A we Editorial & A wealth of h of ex Di exciting opporribution Schalt edu le citing oppstribution tunities… ortunitie Schedu Nove mber s… le 2015

✷ ON-P ✷ DIGI AGE: full and ✷ ON-PAGE half ✷ DUM TAL: full display : and ✷ DIGITAL: full and half display half ✷ BELL MY COV display advertisin ERS: full and half advertis Y-WR the ✷ DUMMY adve g display advertis ing APS: COVERS: rtisin high ultimate, ing…and the ultimate ✷ BELLY-W g…a profi high more! nd mor , high RAPS: high le, hard impa ■ Heav profile, hard-hit impact creative e!

-hitting ct crea … take y clay ■ Fuel ting messag owners messagetive… take in Mag hip e conveya of the ■ Capa evolution hreb own issue nce conv ■ Heavy ership eyan clay in Maghreb ■ Prov city build in Asian ■ Fuel evolution ce of the ers: the heav ince profi BON issue in Asian futur y clay ■ Capacity US heavy DIST le: Shandong e for Asian builders: SPEC ■ Province the future clay ■ China:IAL FOCURIBUTION saniw for Asian profile: the mid-year ■ Chin saniware BONUS DISTRIB Shandong : Brick are?

S: AFRIC ■ Kiln furniture review ?

■ Kiln a: the middemand AN OPPOs Expo Ahm SPECIAL FOCUS: UTION: Bricks ■ Gujarat cycles p2: Expo ■ Guja furniture year ■ RTUN edab sanitaryw Shar AFRICAN Ahmeda ●●

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William upgrades to an ipad, but still casts his unsympathetic eye over industry issues: this month he assesses why regional exhibitions are an essential part of the industry make-up.

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Inside Asia EMILCERAMICA AND SIMPOLO: A NEW JV IN INDIA

W

e want to keep the Emilceramica DNA even in India, that is, create sophisticated design, high quality products as we have always done in Italy as well as in Ukraine, home to our second production site. We identified Simpolo as the best Indian producer with whom to sign a strategic agreement in a country with a vocation for creating high quality products, says Luca Majocchi, CEO of Emilceramica, explaining the foundation of Simpolo Emilceramica Pvt. Ltd. in India, highlighting the fact that the two parties are fully in sync regarding strategy, have the same market vision and the same notion of how to take advantage of present and future opportunities.

With a growing domestic market, India is the ideal platform on which to build a new establishment, which will be in Morbi, in a position and a structure that will allow the company to also supply

other markets in the Asian sub-continent. Despite originating in a country where cheap labour and inexpensive products are easily accessible, the two partners are «interested in design, quality and customer service», explains Luca Majocchi. The system we designed ensures us that the products meet the Made in Italy standards in terms of quality and efficiency», continues the CEO. Production will focus on large formats starting from 60 x 120cm and upwards and the modularity of the technology adopted in the system is the key with which the factory will be able to guarantee the entire range of formats.

To reach these goals, Emilceramica and Simpolo chose Italian technology. We selected the best technology for the most delicate, critical part of the production, that is, from the press to when the product comes out of the kiln, as a 'warranty' of the utmost quality

of the final product. The heart of the process is System's GEA 44,000 mould-free pressing system in the latest and most advanced version available to date - 2.0 - in order to obtain top quality and performance. Digital printing with cutting edge Creadigit machines will allows us to process decorations to the highest levels, a crucial factor for the product's success on the marketÂť, adds Emilceramica's CEO. Finally, System's technology will facilitate reaching another goal set by Emilceramica and Simpolo: respecting European parameters in terms of energy consumption. ÂŤWe will certainly benefit from GEA because of its very low consumption, not only for the energy costs but also in considering the system's overall sustainabilityÂť, concludes Majocchi.

Advertiser feature

SITI B&T Group change the rules of the game.

Beyond ceramic slabs SUPERA®, a new concept to produce big slabs XXL. A technology manufactured with the most advanced techniques in the sector, has an innovative design and is equipped with patented intelligent systems. It is flexible and versatile in terms of thicknesses, it totally eliminates waste and it solves the problems that typically arise in the production of ceramics slabs.

The innovative features of SUPERA® EXTREMELY HIGH FLEXIBILITY SUPERA® eliminates the need for moulds and foundations and does not require special transport. It is highly flexible and can produce panels up to 1200x3600 mm (25,000 t) in size and their submultiples in a wide range of thicknesses (from 5 to 25 mm). It will soon also be available in a 1600x4800 mm (33,000 t) version to produce the increasingly popular 80x80 cm size.

The specific configuration depends on the required size.

SUPERA® has an average production capacity of 9,500 sqm/ day, although this varies according to thickness. The possibility of cutting the panels into submultiples before or after firing ensures a high degree of flexibility in both production and storage.

GREATER PRODUCTION EFFICIENCY SITI has reproduced the typical advantages of traditional pressing on a discontinuous belt press. In particular, it is equipped with three hydraulic pistons designed to guarantee uniform shaping on the edges and splitting of the panels to minimise deformation during pressing. The innovative system of mobile powder containment plates patented by SITI solves the problem of side waste, one of the major challenges facing technicians working with large sizes given the non-negligible cost of waste and scrap. This system consists of a mobile wall shaping device powered hydraulically during the pressing stage. The press is also equipped with a breathable system that allows for effective venting through a semiporous membrane (perturbation in the powders is a significant factor that risks adversely affecting the end product). This leads to greater production efficiency.

12

asian ceramics

october 2015

LOWER CONSUMPTION Start & Stop, the new patented technology which is also available on EVO 3.0 series presses, improves performance and efficiency in terms of consumption as it enables the press to operate only when actually required. This results in up to 30% reduction in consumptions thanks to the use of a poweron-demand hydraulic generator equipped with inverter-controlled motors which eliminates consumption during the phases of the cycle in which hydraulic energy is not required. The group consists of a high flow asynchronous motor coupled directly to a fixed capacity hydraulic piston pump. Each hydraulic generator is capable of delivering a pressure higher than 420 bar. With START & STOP, the total required power can be split by using a number of hydraulic generators in parallel. This means that the individual group requiring maintenance can be isolated rather than having to take the press out of operation.

TOTAL QUALITY CONTROL One feature passed on from the EVO 3.0 press series is Genius Box®, the innovative electronic quality control system for outgoing panels. It is capable of providing intelligent feedback on the SUPERA® shaping parameters, automatically adjusting the parameters that control the shaping stages or modifying the type of deaeration. Equipped with sheet-of-light type sensors (linear camera + laser), Genius Box® inspects the surface and edges of the panel to map all its characteristics and defects. The constituent devices are able to monitor bulk density, non-optimal particle size distribution, individual variations in the forming force on different surfaces, non-optimal moisture content of the spray-dried product, and moisture content of tiles both on the line at the SUPERA® exit and off the line (by means of spot checks).

SUPERVISORS TECHNOLOGY AND REMOTE SUPPORT SERVICE SUPERA® is equipped with its own supervision system, which uses a 21” touchscreen monitor complete with a direct softwareoperator interface allowing for complete diagnostics of the state of the system. It provides historical data, analyses the overall performance of the system(s) (display and analysis of trends and

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Advertiser feature

alarm logs) and highlights any abnormalities to enable corrective action to be taken.

Moreover, the UNICO supervisor system is also able to centralize the performance analysis of all SITI plants for the production of large sizes in operation in the factory (from raw materials preparation through to product finishing), track production batches and produce statistics on productivity, yields and consumption.

On request it is also able to integrate with the remote support service to enable SITI technicians to carry out work remotely and reduce response times. This service can monitor multiple production sites from a single location so as to give ceramic manufacturers a constant supervision capability and provide a rapid response to all production requirements. This allows problems to be solved almost instantly, minimising plant stoppage risks, improving the quality of work and internal efficiency and optimising operating costs.

UNLIMITED FINISHING AND AESTHETIC POTENTIAL SUPERA® stands out for its exceptional aesthetic versatility. As it is not limited by the structure of a mould, it can produce up to 10 surface textures at the same time. A texture can be changed in under 15 minutes thanks to a punch/format quick-release system.

The system also offers outstanding aesthetic potential by exploiting digital decoration technology from Projecta Engineering and material finishing technologies from Ancora, both of which are SITI B&T Group member companies.

Rather than just a pressing technology for large-size tiles and panels, SUPERA® is the heart of a complete production line consisting of cutting-edge technological solutions.

SITI B&T Group is the only one equipment’s producer able to offer technological solutions for the entire production line of ceramic slabs, from the raw materials preparation plants to the decoration and finishing technologies.

The line also includes the Greenfire® XXL kiln with an entrance width of 3850 mm, which brings energy savings of 30% and improves productivity by more than 25%. Equipped with the innovative

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Titanium® heat recovery burner, it can fire tiles of various sizes up to 1600x3200 mm.

PROJECTA ENGINEERING & DIGITAL DESIGN SUPERA® stands out for its exceptional aesthetic versatility. As it is not limited by the structure of a mould, it can produce up to 10 surface textures at the same time. A texture can be changed in under 15 minutes thanks to a punch/format quickrelease system.

The system also offers outstanding aesthetic potential by exploiting digital decoration technology from Projecta Engineering and material finishing technologies from Ancora, both of which are SITI B&T Group member companies.

As regards digital decoration, the EVO 8 has the largest printing width of all printers currently on the market (1890 mm) and is able to decorate very large tiles and panels, up to 1600x3200 mm in size. By partnering with Digital Design, which develops high-quality graphic design projects, Projecta Engineering is able to deliver the most innovative technologies for creating varied, complex and original products based on a flexible combination of different processing techniques with perfect synchronization between digital graphic design, texture and dry or wet applications of materials. The EVO 8 can now be used in conjunction with the new digital decorating machine G5, the first fully modular and customizable system with a printing width ranging from 700 to 1400 mm.

ANCORA The latest news to discover is XXL Green Cut, the cutting machine for unfired large slabs up to 4000 x 1350 mm equipped with a transverse and longitudinal row of disc cutting units to cut the slabs in both directions and at positions that can be set via the touch-screen control unit.

GRIPSTRONG The plant layout is completed by the Gripstrong fired panel storage system and the Bigmover LGVs for handling large sizes.

october 2015

asian ceramics

13

Welcome

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ramics.com

October 2015

EDITORIAL

Business leaders in the UK have submitted a bid to create 9,000 jobs along part of a major trunk-road in the northcentral part of the country. They have drawn up plans to create a so-called Ceramic Valley of businesses between Cliffe Vale and Tunstall.

The new Enterprise Zone (EZ) will aim to become the country's centre of excellence for the development of 'advanced materials' by tapping into the city's ceramics skills and expertise.

Advanced materials looks at the development and production of ceramics outside the pottery industry. It comes as Penkhull-based Lucideon is working to create an applied materials research and innovation centre in the city.

SEE US AT:

CERAMITEC

20-23 OCTOBE R MU NICH

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Brick industries of ASE AN Indonesia focus: p2 Province Profile: Jiangxi

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Stoke-on-Trent and Staffordshire Local Enterprise Partnership (LEP) has submitted the Government bid alongside a second scheme to develop six employment sites across the county.

LEP chairman David Frost said: "The Enterprise Zones will have a major positive impact for our area, not only in financial benefits to businesses and the LEP, but also in raising the profile of Stoke-on-Trent and Staffordshire.

"An Enterprise Zone is a very strong marketing tool in attracting inward investment and strengthening our reputation nationally and internationally as a great location with a positive approach to innovation and growth."

It is hoped the Ceramic Valley will allow the UK to compete with growing technical ceramics sectors in the USA, Germany and Italy. It is part of moves to diversify the industry from traditional pottery to technical ceramics.

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City council deputy leader Abi Brown said: "We're delighted the LEP is prioritising the Ceramic Valley bid as part of the high growth agenda for the city and the wider area."

The second bid is looking to improve existing business parks – including at Meaford, Stafford, Uttoxeter and Keele – by creating a further 9,000 jobs. New businesses will benefit from superfast broadband and better transport links.

County council leader Philip Atkins said: "We believe we have two strong submissions. There is no reason why an area should not try for more than one Enterprise Zone.

"This will be an extremely competitive bidding process." Government officials will rule on the bids later this year.

The growth of technical ceramics, and the resurgence of one of Europe’s formerly principal manufacturing centres, can only be good for the future of the industry in general and for a serious focus on reducing import dependence on the Far East and improving the overall EU economy for exports into the bargain.

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october 2015

Asian Ceramics (ISSN: 1476-1467), is published by Bowhead Media Ltd, registered in the UK no: 6127651

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TOTO plans sales and marketing expansion • RAK Ceramics opens new subsidiary • Beijing Trend leads way for third tier cities • HSIL allegations “thrown out” by commission • Clay Craft opts for “green” energy • Macksons to by 70% • Shining Star all ready to go • Lampang feels the heat • Cera plans premium raid • Unicera gears for 20 THAILAND

SINGAPORE

TOTO plans sales and marketing expansion

RAK Ceramics opens new subsidiary

TOTO Group plans to expand its sales network in Bangkok and other key cities as a part of its marketing strategy to establish itself as a high-grade brand and achieve a contribution of 158 billion yen (Bt47 billion) from overseas by 2017.

"Thailand is among the big four Asian markets, excluding China. The others are India, Indonesia and Vietnam. Sales in Asian markets represented 21 per cent of the total of last year's turnover," said Hiromoto Harano, assistant general manager for Toto's international business coordinating division.

Toto has set up both factories and sales and marketing offices in those countries to enable it to serve the different needs in each market.

In Thailand, after selling its shares in two joint ventures with Siam Cement Group - Siam Sanitary Ware and Siam Sanitary Fittings - two years ago, Toto Group now has its own factory in Saraburi province and manages its own sales network.

Tsuyoshi Morita, vice president and general manager for sales and marketing at Toto (Thailand), said that on top of building brand awareness in the Kingdom, the Bangkok office would focus on creating a sales network in highpotential provinces and continue to promote the company's Washlet line-up of toilets and accessories.

"We expect to see 20-per-cent annual growth on average until 2017. We also [plan] to create our brand image as high-end products that target big upscale projects like Central Embassy, Okura Prestige Bangkok hotel and Le Meridien Bangkok hotel," Morita said.

From 2018 onwards, the company will penetrate the

The office, a wholly owned subsidiary of RAK Ceramics, will be led by Carmen Herrada, vice president Asia, who was appointed in July 2015.

The opening of RAK Ceramics’ Singapore office is part of the company’s value creation plan, a re-focused strategy to streamline global businesses and pursue the most profitable operations.

From Singapore, RAK Ceramics will be strategically positioned to serve the Asia Pacific region, the fastestgrowing region in the ceramic tiles market globally, both in terms of production and consumption.

Abdallah Massaad, CEO of RAK Ceramics said: “The launch of our new regional office in Singapore is a step towards fully leveraging the significant

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medium market through expansion of distribution channels in the provinces and continue to promote Washlet, he said.

Toto wants to promote its Washlet water-saving toilets across the globe in the near future. The company expects its water-saving toilets to account for 80 per cent of its total exports within two years, up from 54 per cent now. The rest are standard models.

As of July, it had exported a total of 40 million Washlet units.

Under the "Toto Global Environmental Vision", the company aims to support a comfortable living environment for customers through its products while continuing to lower the burden on the environment through its hygienic technology such as self-cleansing "ewater+" (electrolysed water) and selfsanitising "Actilight" (lightactivated technology).

Toto plans to produce and sell its sanitary ware with Actilight technology in Thailand next year.

To mark its 100th anniversary, Toto Group targets net sales of 650 billion yen and operating income of 61 billion yen in its 2017 fiscal year. Of total net sales, 455 billion yen will come from housing business in Japan, 158 billion yen from overseas business and 37 billion yen from new business - advanced ceramics and green buildings.

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october 2015

growth potential of the Asia Pacific region. As the ceramics market continues to benefit from higher per capita income and increased spending in the region, RAK Ceramics will be well positioned to understand and satisfy the local demands of our customers.”

“We look forward to solidifying our partnerships and distribution channels in high growth and high demand markets around the world, and we view Asia Pacific as a critical market to help achieve this,” Massaad added.

Having a presence in Asia Pacific through the Singapore office is part of RAK Ceramics’ strategy to meet evolving client demands wherever the company operates and to add value to its increasing database of stakeholders.

CHINA

Beijing Trend leads way for roof tiles Beijing Trend Industrial Ceramics Co., LTD. is a world leader in the manufacture of cordierite kiln furniture, with a turnover of well over €20 million.

Already a leading supplier to the sanitary and tableware industry, it has emphasized with the delivery 65,000 H-cassettes to a new plant for clay roof tiles of European design in Foshan, China, the desire to play a similarly significant role in the future in the heavy clay industry. With the exception of a successful first installation of U-cassettes in 2013, Beijing Trend has so far focused exclusively on the H and U cassettes spare parts business.

In this current project, in

addition to the H-cassettes, Beijing Trend also designed and delivered the tunnel kiln car base. This emphasized the importance of optimization of the interface between the cassettes and their support structure on the car deck, harmonizing design, execution and materials. The H-cassette itself was developed by the design office at Beijing Trend’s site in south-east Beijing, using the latest FE-design and simulation programs for two different roofing tiles, verified and qualified in a timely manner with the aid of rapid prototyping, the order was shipped within four months of the contract date.

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roof tiles• RAK strategy shift gains momentum • Roca sees major growth in o expand capacity • RAK unveils investment programme • Al Fanar improves 016 • Fine china gains from integration UAE

RAK strategy shift gains momentum RAK Ceramics’ change of strategy to focus on high-growth markets in the GCC, India and Bangladesh, and lifting its capacity to produce more highmargin products can result in boosting its share price, an analyst has said.

The company, which produces sanitary ware and tiles, overhauled its business last year after Samena Capital, a private equity firm, acquired a 31.7 per cent stake from the ruling family of Ras Al Khaimah.

The Securities and Investment Company (Sico) in Bahrain has a target price of Dh4.20 for RAK Ceramics shares, a 25 per cent premium on the stock’s closing price of Dh3.35 yesterday in Abu Dhabi.

Anoop Fernandes, a Sico analyst, said RAK Ceramics was capable of achieving earnings growth of about 8 per cent a year over the next five years. He cited improvements

to its product mix and falling energy and transport costs.

Fuel costs usually make up 4 to 5 per cent of RAK Ceramics’ product prices, but they fell to 2.2 per cent in the second quarter this year. RAK Ceramics’ daily production of sanitary ware is set to increase 32 per cent to 5.9 million items by the end of next year.

Mr Fernandes said he was expecting demand in the UAE to grow about 7 per cent a year because of more building completions in the retail, hospitality and residential sectors.

He was also expecting RAK Ceramics to achieve better results in Saudi Arabia, where it has lost sales volume over the past two years because labour issues have caused stoppages of projects.

The firm recently changed its distribution approach in the kingdom.

It has taken direct control of bids to supply governmentrelated work, while instructing distributors to concentrate on sales to retailers.

As a result, it plans to increase business-to-business sales in the kingdom from 35 to 40 per cent currently to its peer average of 55 to 60 per cent.

“That’s not built into my estimate, because I’d rather wait for them to do that,” Mr Fernandes said.

In the first six months of the year, net profit for RAK Ceramics fell 2.4 per cent year-on-year to Dh146.4 million on flat revenue of Dh1.55 billion.

Mr Fernandes expects fullyear revenue this year to dip 1 per cent to Dh3.1bn, but he forecasts a 10 per cent rise in net profit to Dh305m. RAK Ceramics has divested noncore businesses such as textiles and pharmaceuticals, as well as a loss-making business in

­Sudan.

The firm may also sell a shuttered Chinese business unit with a book value of Dh88m and a big piece of land on Ras Al Khaimah’s waterfront that it has valued at Dh900m.

Mr Fernandes said RAK Ceramics’ shares were likely to rise further if international sanctions on Iran were lifted soon. The shares are up 15 per cent this year.

The company has a ceramic tile factory in Iran that needs investment of about US$2m, but it is capable of producing much cheaper tiles because of the relatively lower cost of gas there.

“The problem is that they are not able to repatriate the cash,” said Mr Fernandes, adding that it could take some time for RAK Ceramics to compete in Iran’s domestic market because there were several established players there.

CHINA

Roca sees major growth in third tier cities Roca Sanitario SA, the Spanish sanitaryware manufacturer, said the number of outlets selling its products in China are expanding at the rate of around 50 a year, mostly in third-tier cities.

Emilio Salazar, its national managing director, said the quickly expanding operation in China now represents a little more than 10 percent of group revenue, and that is expected to grow as the standards of living continue to rise.

Salazar admitted, however, that this year its sales forecast had been cut, due to delayed completion dates at some major housing projects.

"We expect the property market

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to pick up during the second half of 2015. I currently estimate we have a 12 percent market share of the higher end of the sanitaryware sector," he said.

One of the company's focuses at the moment is the shift in demand by customers for what the industry calls "smart sanitaryware".

"The bathroom space is under a great transformation, just as almost everything around us is. Electronic products are becoming more important in the bathroom and Roca has gone to great lengths to adjust to that and provide consumers with products that meet their needs," he said.

"We are completely renewing our Multiclin (advance shower toilet) product line this year with 19 new models, and are already starting to see the fruits of this great effort in terms of orders.

"During the first half there was a big increase in demand for electronic products and we are already increasing capacity at our factory in Taiwan to match that."

Roca has 10 factories in China and this year Salazar said it has invested in the expansion of two, in Tangshan, Hebei province, and Suzhou, Jiangsu province.

Next year the company also plans to start work on a new shower-enclosure factory in

Suzhou, as well as open a Rocabranded showroom in Beijing.

Roca sanitaryware has actually been sold in China for years, but its customer base has changed dramatically in recent times.

"Over the past decade, we have mainly been offering our products to wealthy consumers who were buying a new home.

They were normally more than 45 years old, and appreciated European brands and European designs because they had traveled there," he said "But in recent years our end of the market has been expanding fast, and increasingly it's younger couples or newly weds in their early 30s."

october 2015

asian ceramics

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News

INDIA

INDIA

HSIL allegations “thrown Clay Craft opts for out” by commission “green” energy The Fair trade regulator CCI has rejected allegations of unfair business practices made against Hindustan Sanitaryware and Industries Ltd (HSIL) with regard to a dealership in Madhya Pradesh.

The complaint was filed by Shubham Sanitarywares -- a partnership firm engaged in the dealership business of sanitary ware, faucet ware and tiles of various brands in Indore.

The entity's earlier complaint against HSIL was also rejected by the CCI. The anti-trust regulator said the entity has not placed any new evidence to substantiate its allegations of violation of competition norms by HSIL. "Moreover, the issues raised by the informant (Shubham Sanitarywares) in the instant case have already been considered by the Commission in its previous order in case no.

99 of 2013," the watchdog said in an order dated September 9.

Rejecting the allegations, the commission said there is "no prima facie case" of violation of competition norms.

For the latest case, Competition Commission of India (CCI) considered the market of branded ceramic sanitary wares and bathroom fittings in India as the relevant one.

According to Shubham Sanitarywares, HSIL stopped supply of products to it since February 2013. It was alleged that HSIL had sent communications to its dealers/ distributors that discounts more than the limit stipulated by it should not be given to the customers.

"Until and unless regulation of discounts leads to appreciable adverse effect on competition, such practices do not become anti-competitive per se," the Commission said.

Among others, it was alleged that HSIL engaged in the practice of tie-in arrangement by asking its dealers to purchase products along with

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those sourced from other manufacturers.

"As far as the allegation of tie-in arrangement is concerned, the commission after considering the product range has found that complete set of bathroom fittings consist of ceramic and non-ceramic products are sold together as a set by companies dealing with branded products in organised industry of ceramics.

"Though individual units are also sold, consumers always have a choice to go for a complete set or different units from different manufacturers," the order said.

NEWS IN BRIEF Italy's ceramics sector is set to expand by four percent this due to fuelling of exports and an expected turn over of 5 billion euros (about USD 5.5 billion), according to its main business association, Confindustria Ceramica."The most dynamic part of the market is exports, which now amount to over 80 percent of turnover and were worth 2.23 billion euros in the first six months of the year," said Confindustria Ceramica President Emilio Mussini.

He made the announcement while speaking on the opening day of the 33rd International Exhibition of Ceramic Tile and Bathroom Furnishings, in the city of Bologna. "The globalisation of the sector's production means this will reach some 480 million square metres worldwide," he said.The US and Asia, where exports climbed 32.4 percent and by 11.2 percent respectively, were especially buoyant markets, Mussini said."All the main export markets have performed strongly," he stated.

october 2015

One of the largest manufacturer and retailer of fine bone china and ceramic tableware, Clay Craft India has roped in Su-Kam Power Systems to set Rajasthan's first 200 KW rooftop grid tied solar photovoltaic power plant for captive consumption at company's manufacturing facility.

With this, Clay Craft India has become the first company to use renewable energy in VKI, Jaipur. In the second phase with an installation of an additional 100 KW rooftop solar PV systems it will become Rajasthan's first manufacturing company using 200 KW rooftop solar PV systems in total.

Mr. Rajesh Agarwal, Director, Clay Craft India Pvt. Ltd. said, "Clay Craft is having India's largest automatic manufacturing plant of bone china and ceramic tableware in Rajasthan. Being the largest on production side, we need uninterrupted power supply to fulfill the committed domestic and export demand. Using renewable energy is industry's first initiative in the state. This step has made us completely independent for using own power systems which will also save nearly Rs. 24.48 Lakhs of operational cost annually."

Inaugural function of the first phased 100 KW rooftop solar PV Plant, was graced

by Mr. Pushpendra Singh, Hon'ble State Energy Minister, Government of Rajasthan and Mr. B. K. Doshi, MD of Rajasthan Renewable Energy Corporation (RREC).

Su-Kam Power Systems Ltd.'s business associate Sky Solar's Shree Gajendra said, "Clay Craft India is a unique case study for us in Rajasthan. Based on our power consumption study made on this company it requires approximate power energy of 10 lakhs units annually. With new set-up of solar power energy systems it will be able to save 2.72 lakhs of units every year."

The company offers superior quality fine bone china crockery & ceramic tableware for all purposes. Su-Kam was given the overall responsibility of designing, supplying, testing and commissioning of the solar power plant.

Clay Craft that claims of using environment-friendly kilns and machines to manufacturing their products were very forthcoming when it came to going for an alternative source of energy that is both environment friendly and money saving. It further looks to invest in R&D for enhancing its product quality and capacity by using industry's best fuel efficient technology.

The entire system consists of two string inverters of 50 KW each and 400 solar PV panels of 250 watt each. The power generated from the solar system will suffice part of their energy requirement to run the heavy machineries like furnaces, printers, air conditioners, computers etc.

The surplus energy required will be fulfilled by the energy supplied through the utility.

Spread across 35,000 square meter area, Clay Craft's stateof-art production facility has a production capacity of 110,000 pieces per day for Bone China and Ceramic Tableware and 80,000 pieces per day for Plastic-ware. The main production line is tuned to handle large volumes of Bone China crockery in a variety of shapes and combinations.

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News

SRI LANKA

BANGLADESH

Macksons to expand capacity RAK unveils investment programme Sri Lanka based Macksons Tiles Pvt Limited is set to expand its installed capacity in the first half of 2016. Based at Bandargama, Macksons Tiles is a relatively new entrant in the growing Sri Lankan ceramic industry. The company which commenced commercial production of glazed ceramic floor tiles a couple of years back has received a great reception for its products in the domestic market. This process has an exceeding rate. Currently, Macksons Tiles has an installed capacity to produce 6000 sqm of glazed floor tiles for residential and commercial applications.

Speaking to Asian Ceramics Macksons Tiles Limited’s General Manager, Thajitha Perera told “ With a limited number of ceramic tile production in Sri Lanka there is a significant opportunity for domestic manufacturing.

Currently, a major part of total demand is imported into the country from China, India and Thailand. We aim to replace some portion of the import by setting up a state of the art manufacturing plant for production of vitrified tiles at our Lankan facility.”

Speaking on the availability of raw materials needed for ceramic tile production he says “It is a fact that the raw materials available in Sri Lanka, when it comes to producing floor tiles, is world class and is comparable to that of Italy or Spain. As such, the material in Sri Lanka can be defined as the best. And we are happy that we have strived to use good quality Sri Lankan minerals to bring and change the total spectrum of how tiles should be offered to the Sri Lankan consumer.”

Macksons is in the process of finalsition of production equipments for the production of vitrified tiles at its upcoming plant.

Macksons Tiles Lanka (Pvt) Ltd was established in 2012 with a fully automated state-ofthe-art Italian production facility that manufactures tiles under the brand name of Macktiles.

Macksons Tiles Lanka is the third ceramic tile producer in the Sri Lankan market.

Macktiles parent company,

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Macksons Holdings was established in 1970 by its founder Chairman, A. W. M. Makeen. Its first business venture was the City Trading Company, which traded building materials and paints.

From its humble beginnings, the paint company has grown to the top paint manufacturers in the country and also Sri Lanka’s largest paint exporter under the brand name of ‘Multilac’.

SAUDI ARABIA

Al Fanar improves by 70% A major manufacturing company based in the Saudi capital of Riyadh, the Al Fanar Group recently completed a significant investment in Sacmisupplied technological and plant engineering solutions, leading to a production increase of no less than 70% if compared to the beginning of 2014.

This order included a precrushing and raw material handling system, downstream from which there are two continuous MTC 088 mills and two ATM 110 spray dryers. At the heart of the line there are four PH 3020 presses with an inter-column clearance of 2,250 mm (these join the three already installed by Sacmi) and four 14.12-metre horizontal ECP dryers which join the two existing ECP units.

Completing the picture is the firing department with three kilns (with an effective inlet width of 3150 mm) designed to manage porcelain tiles too.

Together, these provide a total firing length of 327.6 metres.

A long-standing partner of Sacmi - which, in 2011, provided the Saudi company with a production line that tripled the existing output - Al Fanar has, with this latest investment decision, moved closer to its goal of becoming a major player in the Saudi ceramic industry and has opened up new market prospects involving the entire Middle East.

october 2015

RAK Ceramics, one of the world’s largest manufacturers of ceramic tiles and sanitaryware with a distribution network that spans 160 countries worldwide, has added two new casting machines and a state-of-theart kiln to its Bangladesh plant.

The Sacmi-developed high pressure casting technology, which is now used extensively within the industry, includes two battery-type casting machines for two-part moulds and a new Riedhammer HWS kiln, which has an output capacity of 706.5 pieces per cycle.

RAK Ceramics Bangladesh plant is one of the most modern and highly automated facilities in the region. The Dhaka site is also fitted with glazing robots supplied by Sacmi and thanks to this new investment will benefit from increased output capacity, in the region of 200,000 pieces per year.

Key features of the Sacmisupplied casting line include excellent finished product quality, user-friendliness

and optimisation of space.

Designed to carry out both firing and re-firing, the Riedhammer kiln is characterised by high quality output, reduced energy consumption and lower emissions.

RAK Ceramics, which has a global annual production capacity of over 4.6 million units in sanitaryware alone, has always had a strong focus on environmental and economical sustainability and their ongoing partnership with Sacmi solutions providing high-efficiency and lowconsumption technology clearly demonstrate this.

Abdallah Massaad, CEO of RAK Ceramics said, “We are very pleased to have installed this new technology in our RAK Bangladesh plant. We continue to invest heavily in research, development and the latest technologies to ensure that we remain at the cutting edge of ceramics’ production.

We have a strong partnership with Sacmi and a long-term commitment to maintain our status as an industry leader.”

BANGLADESH

Shining Star all ready to go Star Ceramics, one of Bangladesh’s most important manufacturers of floor and wall tiles, porcelain and ceramic sanitaryware, has now extended and enhanced its product range thanks to a new sanitaryware production facility, entirely built using Sacmi’s plant engineering and technological know-how.

Already delivered and successfully installed, this plant has an output capacity of 200,000 pieces/year and features the very best Sacmi pressure casting and firing technology. Even at this initial stage, a part of the new production line is already equipped with singlemould casting modules for various articles that employ two-part moulds (ADM

series). Then, of course, there is the Riedhammersupplied HWS kiln for firing and re-firing; designed to ensure the very best product quality, it is equipped with a full complement of heat recovery systems to optimise consumption and reduce emissions.

Modern and efficient, this new plant will be the jewel in the crown of the Star Group, which is looking to increase market shares both in Bangladesh and the main Asian countries where the Group operates.

This latest production plant joins the already-operational tile manufacturing one, which has allowed the company to strengthen and broaden its position on the ceramics market.

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THAILAND

INDIA

Lampang feels the heat Cera plans premium raid Tableware producers in Lampang cluster in Thailand are feeling the heat of general slowdown in the region. About 150 odd small and mid size tableware producer based in Lampang cluster have craved a niche for quality tableware production at affordable prices in domestic and exports markets in recent years.

Speaking to Asian Ceramics, one manufacturer explained that in the last 18 months the economic slowdown has affected the region, particularly because of Europe. On an average tableware producers from Lampang cluster exports about 30- 35 % of their output to Europe, but the slowdown has resulted in this figure coming down to about 25 %.”

He further said “ Besides the European slowdown, tableware producers in the the cluster have been forced to operate much below their optimum capacities, as a lot of China made ceramic tableware are increasingly making inroads in Thai and other ASEAN markets due to anti dumping duties on Chinese products in European Union.”

Lampang is famous for its ceramic industry, where there are approximately 200 ceramic factories. Most of these tableware producers are original

equipment manufacturers which mostly receive orders from Europe, the United States and Japan. OEMs in Lampang are well known by foreign traders due to high skill manufacturing and low production cost. The population of this province is about 700 000 and about 150 000 of them work in the ceramic factories.

Lampang ceramic cluster is a privately initiated cluster established by SMEs in a geographical area similar to many successful clusters in foreign countries. In the past, ceramic manufacturers focused mainly on reducing the cost of products rather than product quality development.

The prices of ceramic products decreased due to a price war between m anufacturers. Thus, manufacturers tried to solve this problem together by establishing the Lampang ceramic association. This collaboration helped manufacturers to survive the strong competition.

Later, the government established a ceramic centre in this area which supported information, knowledge and technology for manufacturers and product development.

In 2014, this ceramic cluster generated revenue of about 340 million Euros.

TURKEY

Unicera gears for 2016 UNICERA International Ceramic, Bathroom and Kitchen Fair, Turkey's gateway to Eurasia in the ceramic, bathroom and kitchen industries, is preparing to open its doors for the 28th time.

Held by Tüyap in association with the Ceramics Federation of Turkey (TSF) and the Association of Plumbing and Construction Materials Suppliers (TİMDER), the UNICERA International Ceramic, Bathroom and Kitchen Fair prepares for the 28th meeting of the industry with a wide range of exhibits and the CERAMICTECH Ceramic Processing Technologies specialty section.

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Being one of the top trade shows in the world with a consistently improving performance, UNICERA will cover 11 halls and 98,000 m2 of indoor exhibition space this year as well. UNICERA keeps growing and reinventing itself year after year, and served 68,051 professional visitors in 2015. This represented an increase of 10% in domestic and 28% in foreign professional visitors. In addition to the increase in the number of visitors, 16 new countries were represented in the fair this year, achieving 8.8% increase in country diversity. With the keen interest of sector’s brand names

october 2015

Cera Sanitaryware Ltd is preparing to take a plunge into premium sanitaryware market.

Backed up by an Italian tie-up, the BSE-listed firm is to take on global brands that dominate the premium segment in India.

The Rs.822 crore Cera will be launching a slew of premium products of Italy-based global sanitaryware brand ISVEA, with which it has forged an exclusive tie-up, next month. These products are expected to be priced upwards of Rs.15,000.

After strengthening its presence in the mass and mid-market segments, Cera seeks to make its presence felt in the highly-competitive premium segment. With its luxury sanitaryware products, Cera will be competing with global brands like Kohler, Roca and Duravit. “We will be launching ISVEA products by mid-September. Our initial focus will be on 3-4 markets where we

have strong presence. Within a year, we intend to go pan-India,” Atul Sanghvi, Executive Director, Cera Sanitaryware told The Hindu.

He said ISVEA, founded in 1962, was known for its design in premium sanitaryware and Cera would work with the Italian firm to come out with new designs that would be suited for the local market. Cera has started bringing consignments from Italy and is also in the processing of appointing some exclusive dealers for its premium foray.

While the organized sanitary market is growing at 15 per cent, the premium category, which accounts for about 10 per cent of the market, has been growing at 30 per cent plus.Global brands have been aggressive in targeting brand conscious high networth customers and continue to dominate the premium sanitaryware market.

Asian Ceramics

Get the AC advantage… subscribe today at www.asianceramics.com www.asianceramics.com the fair marked a 7.3 % growth in number of exhibitors and also targets to bring together more than 70 thousand professional visitors with the sector.

UNICERA will be serving the needs of all exhibitors and visitors with a wide range of products and countless business opportunities between February 23rd and 27th, 2016 at the Tüyap Fair and Convention Center, Istanbul.

Being Turkey's gateway to the Eurasia in the sector, UNICERA makes excellent use of its geostrategic location to play an active part in forming new cooperative opportunities and effective strategies. With the

industry becoming a strong and key player in rapidly-developing global markets, a consistently growing manufacturing capacity, state-of-the-art technology investments, and the benefits of high quality help to increase competitive strength across the globe.

The industry has some of the largest integrated production plants in the world, and develops innovative products through advanced technology and excellence in design to become a key supply hub. UNICERA continues to leverage global brands to add momentum to the industry.

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News

THAILAND

Fine china gains from integration Home Pottery, a Thai manufacturer of fine-china tableware and kitchenware products, is looking to expand its Asean export market to cash in on regional integration. The Asean Economic Community, to be effective by the end of this year, will allow zero-tariff benefits for export of such products within the region.

Niran Chourkittisopon, managing director of Home Pottery, said the company currently exported about 98 per cent of its total production to many markets around the world, including the United States, Spain, Italy, Australia and New Zealand. But Asean accounts for only 1-2 per cent of its total exports.

"We will maintain our export proportion at 98 per cent over the next five years. However, we want to increase the contribution from AEC markets to between 5 and 8 per cent" over that period, he said.

Niran said the company currently exported its products directly to business clients, comprising restaurants and hotels, in South Korea only.

"We plan to expand our exports into new AEC markets, especially [high] potential countries such as Myanmar, Singapore, South Korea … and Cambodia. We are also looking to promote our product availability in many retail channels, aiming to reach individual consumers in the near future."

He said the company expected annual growth of 10-15 per cent over the next five years.

Home Pottery posted total revenues, from both domestic and export sales, of Bt132 million last year, down from Bt134 million in 2013 because of economic difficulties both in the US and Europe.

In 2014, Thailand's ceramictableware exports enjoyed robust growth, jumping 27 per cent to Bt3 billion. This year,

Home Pottery forecasts its total sales reaching Bt150 million, up 15 per cent.

Niran said his family started out by manufacturing chicken bowls for sale in Lampang.

He set up his own company, Home Pottery, in 2001, inspired by a visit to England. At that time, he found that English china factories had started to shut down as production costs became unmanageable.

Niran saw great potential from manufacturing such products himself mainly for export.

Home Pottery recently announced its latest brand of fine-china table and kitchenware products. Pe'tye will target three-to-five-star hotels and restaurants as its major business customers.

Nijawan Chourkittisopon, marketing director of Home Pottery, said: "We want to consolidate all our existing brands, comprising Heart@ Home, One, and Hotel & Heart,

into only one Pe'tye brand, so we will able to focus on one brand to be promoted around the world."

She said Pe'tye was positioned as an outstanding tableware brand in terms of quality and attractive design. It utilises advanced "low-profile glazed foot" technology from England, which keeps the bottom of the product from rubbing against a table and makes it more durable.

"We will invest Bt80 million between now and 2019 to increase production capacity for tableware at our factory in Lampang. The factory has reached its full production capacity at about 1,200 tonnes per annum," Nijawan said.

"With the expansion, we will be able to raise the production capacity at the factory by 10 per cent by the end of this year.

Production capacity will be increased by 80 per cent over the next five years," she said.

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october 2015

and creativity of the projects interact with the rigour and purity of the exhibition spaces.

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News

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News

International News Fiskars restructuring hits jobs Finland

T

he Fiskars group is set to cut more than a hundred jobs after announcing it would move production abroad. Lay-off talks were undertaken in September, shortly after the government announced a raft of measures designed to improve Finnish competitiveness.

Finland’s efforts to improve competitiveness and secure jobs got off to a bad start on Wednesday, when Fiskars announced plans to shed some 130 jobs. The consumer products company is to close one ceramics factory in Helsinki and move production abroad.

The move is part of a restructuring programme aimed at streamlining production and distribution, according to the firm’s communications chief Maija Taimi.

The factory’s shop steward said that the news came as a surprise, despite the lack of orders in recent months.

Fiskars’ history dates back to 1649, when it was established as an ironworks in a village of the same name. Since then it has grown to employ 8,600 people in 30 countries, selling products in more than a hundred countries.

The move is seen as part of a restructuring program to continue to optimize its global supply chain network in Europe and Asia. The planned Supply Chain 2017 -program aims to

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improve the competitiveness of Fiskars manufacturing operations and distribution network.

The total costs of the planned program are approximately EUR 20 million in 2015–2017, which are planned to be recorded as non-recurring charges. The targeted annual cost savings are approximately EUR 8 million, subject to the full implementation of the program.

The targeted cost savings would be achieved gradually, and the majority of the savings are expected to materialize in the Group’s results after the program is completed, which is estimated to be by the end of 2017. The estimated cost savings targets are based on the potential to reduce complexity and increase

october 2015

competitiveness in Fiskars’ manufacturing operations and distribution network. Planned measures will be negotiated and communicated locally in each country when they become more concrete.

The integration planning with WWRD is in its initial stages and the Supply Chain 2017 -program is only focused on Fiskars manufacturing operations and distribution network prior to the WWRD acquisition.

“Our current restructuring programs are progressing well and we expect to complete them on schedule. We believe that there are opportunities to further improve our competitiveness.

We will continue to optimize our operations and identify areas

where we can be more effective.

Fiskars is consistently building a platform to be a global consumer goods company”, said Kari Kauniskangas, President and CEO of Fiskars Corporation.

Fiskars’ current programs are progressing according to their planned schedules. The investment program launched in 2010 in Europe aims to ensure competitiveness through wellfunctioning processes and systems which enable shared functions and structures. The costs and investments related to the program are estimated at EUR 65 million, of which approximately EUR 55 million had been recorded by the end of 2014. As communicated before, the implementation period is running till the end of 2016.

In 2013, Fiskars launched a restructuring program to optimize operations and sales units in Europe. The EMEA 2015 program will be completed by the end of this year. The total cost of the program will be approximately EUR 25 million, four million euro less than originally estimated at the time of the program launch.

The targeted annual cost savings of the program are approximately EUR 13 million and exceed the previously announced estimate of EUR 9–11 million. The majority of the savings are expected to materialize in the Group’s results as of the end of 2015, once the program is fully implemented.

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News

Steelite expansion creates new jobs United Kingdom

P

ottery giant Steelite is to create more than 100 jobs after major plans for a new factory were given the goahead.

The tableware firm is to build the manufacturing plant on its Middleport site to keep up with soaring international demand for its products.

And the investment is being hailed as the best example yet of the revival of Stoke-on-Trent's ceramics industry.

Jane Gratton, deputy chief executive of the Staffordshire Chambers of Commerce, said: "Steelite really is one of Stoke-onTrent's big success stories.

"The expansion of its factory and the jobs that will be created are great news for the city and the local economy."

Stoke-on-Trent City Council passed the expansion proposals, expected to bring 112 jobs, at a meeting yesterday.

It comes after Steelite – which employs more than 1,000 people – announced record sales with global markets including Europe,

North America and the Middle East all performing well.

And the firm will be able to produce an extra 100,000 pieces a week following the construction of its new factory.

The company has been granted permission to build a production base, with offices and car parking, at its site in Middleport.

Group company secretary Philip Ray said Steelite was committed to manufacturing in Stokeon-Trent, and the new factory was needed to meet increasing demand.

He said: "During the past few years we have been extremely successful in developing the business throughout the world. We have seen sales grow which has left us with a number of business capacity constraints at our site.

"The new facility will allow the production of an extra 100,000 pieces of flatware per week up from 500,000, which is desperately needed to allow us to keep up with demand and give us the capacity to innovate and bring new products into the

marketplace.

"This will allow us to maintain manufacture in Stoke-on-Trent."

Steelite, which employs 1,000 people, turned over £94 million in 2014, up from £89.6 million the previous year, making it the fifth year running that it had smashed its sales record.

The Sentinel revealed this year Steelite had hoped to create 65 jobs but that figure has since been revised to 112.

Stoke-on-Trent City Council's development management committee granted planning permission for the 5,300 square metre factory at a meeting yesterday.

However, Steelite – which exports 80 per cent of its goods to 140 countries – confirmed no date had been set for work on the new building to begin, but it will take between 10 and 12 months to complete.

Families living near the site had objected to the plans.

Addressing the committee, nurse Yvonne Hof, of Newcastle Street, said: "We had to put up

with the dirt and the dust from the previous extension. I don't feel consideration has been given to local residents."

Councillor Ross Irving, chairman of the committee, said: "I think the scheme as a whole is very good.

But I would ask that the applicant liaise with residents. It would be the behaviour of a good neighbour to set up a liaison group so if residents have complaints it can be quickly sorted out."

Mr Ray assured the committee that Steelite was keen to communicate with residents and said: "We would be willing to enter into negotiations to see what we could do to mitigate, within reason."

Jane Gratton, deputy chief executive of the Staffordshire Chambers of Commerce, welcomed the expansion.

She said: "This expansion further underlines the resurgence of manufacturing in North Staffordshire and Steelite's position as a world-class business that is going from strength to strength."

Briqueterie Irdjen chooses Bongioanni Algeria

A

couple of hours’ drive from Algiers, at the foot of the big dam of Tizi Ouzou is located the Company Briqueterie Irdjen.

The ownership has committed to the skilful hands of Bongioanni Macchine the renovation of the clay preparation line and of the bricks and tiles shaping. The production, after the renewal will be of 250.000 ton/year, which corresponds to more than 800 ton/day The manufacturer of Fossano has supplied at the beginning of the preparation line the new Primary Crusher 612FR, a machine with big performances (≥ 200ton/hr) suitable to receive big blocks of clay even with very high hardness.

The primary crusher has been placed outside the hangars and feeds one of the two box feeders which prepare the production mixture.

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The size of the blocks of clay is furtherly reduced passing through a clay disintegrator 13LD and a roughing roller mill LE810. Before entering in the silo the clay is mixed by a wetting mixer MIX 710I. The storage area has not been modified by Bongioanni Macchine. The clay picking up is done through a mechanic paddle that feeds the box feeder of the production line, consisting of a refining roller mill LI1012, a machine featured by an hydraulic safety system which sleeves are made of thermally treated alloy steel with a hardness of 60-62 HRC The extruder installed is the model TECNO 750M equipped with de-airing mixer MIX 710D, which well known strengths are: the reduction unit with parallel axis widely dimensioned and having a weight of approx. 6 ton.; the big

october 2015

vacuum chamber that ensures an excellent degassing of the clay, the optimized pitch of the augers for big productions at a reduced number of turns.

The electric control board supplied as per Bongioanni Macchine standard, foresees the system to control the speed R.A.V.®, to self-manage the turns of the machine (extruder), in order that the filling of the auger is always optimal, thus granting a constant quantity of push and, as a consequence, an increase of the quality of the extruded products To complete the whole, the customer has commissioned the supply of pressure head and dies to Bongioanni Stampi.

The pressure head with different cone-shapes has been dimensioned to use the dies B8 with 5 exits and B12 with 3 exits.

For what concerns the dies the customer has chosen the

top of the range and ordered to Bongioanni Stampi the Omega models, a type of dies that can be modulated with single lubricate braking system with outside adjustment, bridge support corns sectioned for single exit and with all the components that touch the clay, protected by abrasion proof inserts that can be completely disassembled. This kind of stateof-the-art die has been purposely designed to meet the customer’s requirements both in terms of easiness of use and savings.

Corns and frame are made of enbloc Tungsten Carbon with a thickness of 15mm. Anticorrosive dusts are used to realize these pieces.

The bridge is made with a new abrasion proof steel with a hardness of 40 HRC, furtherly protect by a chromium-plating characterised by a hard thickness of chrome.

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News

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Raw Materials News

Technical ceramic focus drives loans Dudson secures new funding United Kingdom

United Kingdom

A

Birmingham-based engineering company that specialises in the production of technical ceramics has boosted its product range and increased its workforce with support from Clydesdale and Yorkshire Banks.

Precision Ceramics is part of the McGeoch Technology group and creates bespoke technical ceramic components resistant to heat, wear and corrosion. They are primarily used in the aerospace, nuclear power, electronics and oil & gas sectors.

The six-figure package was provided by Clydesdale and Yorkshire Bank’s Birmingham

business and private banking team.

As a result, the group has invested in equipment, allowing it to expand its product range and increase staff numbers by 20 per cent.

Steve Swallow, managing director of Precision Ceramics, said: "Our parts can now be found on three planets – Earth, Mercury and Mars and in a wide range of applications from satellites to Formula 1 cars.

"Clydesdale and Yorkshire Banks have been crucial to developing our business. With support from their experienced staff we have been developing components with increased tolerance and are now able to offer ceramics that we previously could not."

A

215-year-old ceramics maker in Staffordshire, which supplies the likes of Nando's and Virgin Trains, has secured a new funding package worth £10m.

Dudson is headquartered in Stoke-on-Trent and makes ceramics for high-profile clients in the leisure sector. The new facility, which comprises invoice discounting, stock finance, a term loan, and plant and machinery finance was provided by the Birmingham office of Leumi ABL. The business has experienced recent sales growth after launching ranges in the UK, US and Australia, which is expected

to create 20 jobs in Stoke.

Chris Davies, group finance director at Dudson, said: "We had a number of different offers when we went through the refinancing process. What attracted us to Leumi was their flexibility of approach and a willingness to find solutions that suited both parties.

"The due diligence and paperwork process can be quite onerous but Jason Holland at Leumi ABL was always on hand to provide advice and guidance which actually made it very straightforward."

Last year, the Business Growth Fund provided Dudson with a long-term loan worth £3m.

Raw Material News

IRAN CHINA CLAY “BULLISH” ABOUT ASEAN ASEAN // Kaolin

Raw material producer and supplier to ceramic company, Iran China Clay company is bullish about prospectus of South East Asian ceramic industry.

The Iranian company is increasingly targeting ceramic producers of South East Asian countries with its quality kaolin offerings.

Speaking to Asian Ceramics during the ASEAN Ceramics exhibition in Bangkok, Thailand, Iran China Clay’s Marketing Manager, Mohammed Ahmadi told “We produce some of the best quality Kaolin at our Jolfa ( Northern Iran) based plant. With an installed capacity of 150,000 tons of Kaolin per annum, we export about 30- 35 % of our total output to other Asian countries.”

Speaking on the importance of South East Asian market, he further says “

South East Asian countries doesn’t have ample natural resources of some of the raw materials needed for ceramic production, particularly Kaolin. With increased focus on quality of finished products, South East Asia based producers have started paying more attention to quality of raw material.

This has resulted in increased demand for quality products like ours.”

Iran China Clay Industries Company is a leading Iranian manufacture and exporter of different types of kaolin in crushed, micronized and washed noodle form as raw material for production of sanitary ware, porcelain and tableware, ceramic and tiles and glaze applications. So far, the company has exported its products to several countries such as Turkey, Oman, UAE, Pakistan, Armenia, India, Bangladesh and Syria.

CHINESE COMPANIES MOVE FOR LICENSES Ethiopia // Kaolin Ministry of Mines (MoM) has extended its first mining survey license for Kaolin to China Communications Constructions Company Ltd (CCCC), Addis Fortune has reported.

Kaolin is found in Amhara, Oromia and Southern Regional States (principally in Debretabor, Hosaena and Hadiya areas) of Ethiopia.

Ethiopia Bedacha, Public Relations & Communications Deputy Director of MoM said the company will be given a license for exploration rights after surveying is completed for three to 10 years based on the amount of deposit.

Afterwards, the company will be awarded with mining license for 10 to 20 years.

Limited studies on the geological location and deposit of the mine, limited knowledge on the type of the mine and its benefits and inadequate promotion are the causes for the absence of exploration of Kaolin mineral, said Ethiopia.

CCCC is a state owned company and engaged in the construction and design of roads and transportation infrastructure.

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october 2015

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News Anaylsis

News

32

Back from the dead?

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asian ceramics

ocal reports from the Stoke Sentinel are indicating that the once defunct UK ceramic manufacturing sector is heading for a significant upturn in fortunes.

More than 150 years after the heyday of the British ceramics industry, things are looking more positive than for some time.

Stoke’s old industrial district is looking much healthier than it did a decade ago, when it appeared in danger of collapsing altogether. Ceramics in Stoke and the surrounding Staffordshire area includes everything from dinner sets and vases to bricks and industrial tiles for roofs. Most of the revival has been in table and giftware, where exports have risen by 36% between 2009 and 2014, and with another strong performance recorded in the first six months of this year, they are set to rise again.

The district has benefited from substantial new investment in both technology and factories in recent years, with distinguished names such as Waterford Wedgwood Royal Doulton, Wade and the hotel-ware specialists Steelite leading the way.

Numerous companies are hiring, such as Emma Bridgewater, which has become renowned for its polkadot designs and other motif drawings using techniques that date back more than 200 years.

There has been a resurgence in small and medium-sized firms, with new arrivals such as Dimbleby Ceramics joining the likes of more established designers such as The New English and Anita Harris in carving out new market niches.

Back in the 19th century, the local industry employed more than 100,000 people. Even in 1979 around 52,700 people still worked in the ceramics factories which dominated the city’s industrial landscape. Since then, the UK industry experienced a long decline as recession and globalisation took their toll. Several high-profile factories closed in Stoke and in the 1990s some manufacturers outsourced production to South-East Asia as firms sought to take advantage of lower labour costs.

This “hollowing out” had a dramatic

october 2015

effect upon both the local skills base and employment, which fell to around 10,000 in 2008. Yet since then, employment has stabilised and recently begun to rise as firms have started recruiting again. There is increasing optimism and the latest data shows that in table and giftware gross value-added, which is an indicator of profitability, rose from £125m to £181m between 2009 and 2013. In short, the sector got around 45% richer over the period.

So what has changed? The first factor is global demand, where particularly US and Japanese consumers have become increasingly averse to purchasing premium wares manufactured cheaply in Asia (especially China) but sold under one of the branded names from the English Potteries.

With Stoke wares still perceived to be among the highest quality in the world, the “Made in England” backstamp is an increasingly important marketing tool.

China has also become less attractive as a manufacturing location due to rising labour and energy costs, anti-dumping duties and logistical problems.

Some firms, including Waterford Wedgwood, have begun to bring some of their production back to the district as a result.

We’ve also seen the more successful district firms upgrading their product lines to adapt to globalisation by paying more attention to designs and wider marketing activities. This has enabled them to carve out specific market niches, avoid cut-throat low-cost competition and instead command premium prices. Notable examples include Emma Bridgewater and, at the very high end, Moorcroft, whose wares are largely marketed upon their unique designs and being handcrafted within the district.

Companies that provide services to the big players have been pursuing similar strategies. A good example is Times Square, which prints designs on to ceramics. Known in the trade as decals, the lower and medium-end work in these designs had become susceptible to Asian competition. So Times Square began investing in a higher-quality and

more complex set of decals, which are difficult to imitate and appeal to higher-value clients.

Times Square has also started using these techniques in related sectors including glass, fine-art reproduction and high-end photographic posters.

Other players are going to greater limits, with ceramics technologies now being used in anything from bio-inserts and bone transplants to drug delivery systems and mobile transmitters.

Finally there has been a big change of attitude within the district. There was a tendency for the management of family firms to pass from one generation to the next, which sometimes reinforced rigid practices and closed thinking.

Recent managerial appointments have tended to draw from across manufacturing and other sectors.

As well as the shift away from the mass market, this has led to wider engagement with consumers and more emphasis on marketing and technology.

Local firms and institutions such as the British Ceramic Confederation, industry testing centre Lucid-eon and the local chamber of commerce have also made greater efforts to encourage networking and collaboration. We’re seeing producers benchmarking their products and manufacturing processes and visiting one another’s factories. Not only have they been sharing knowledge and ideas, some leading firms have been informally advising and supporting smaller ones. For instance Steelite’s new factory has incubator units for start-ups. There has also been greater collaboration among firms on industry-wide issues such as improving energy efficiency and local skills development.

The net result has been that an industry that looked to be on its last legs a few years ago has reinvented itself. No one is predicting a return to the mass employment of yesteryear, but there appears to be a renewed vigour that is helping to ensure that there is at least a future for the sector. It demonstrates that there is nothing inevitable about decline, and that old traditional manufacturing districts are capable of enjoying a renaissance.

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Analysis: Bricks

Build it…they ASEAN brick makers look forward

Yogender Malik looks at how the brick industries of South East Asia have adapted to modern manufacturing techniques and are gearing for the future.…

W

ith a population of more than 600 million, ASEAN countries is one of the largest and diversified markets in Asia. Region’s brick industry is a huge sector with a production in excess of 100 billion bricks per year. Growing ASEAN economies, population growth and rapid urbanization have caused a boom in construction activities in these countries. Since, there is a very strong correlation between these three factors and demand for bricks, this segment of ceramic industry is reaping rich dividends from the rapid economic and construction growth of these countries.

Since the 1970s and 1980s, governments in ASEAN countries have taken several steps in varying degrees to modernize and industrialise the brick industry through the introduction of machines and new technologies such as the tunnel kiln. Several brick-making processes have been mechanized and it is unthinkable to find hand-moulded bricks in the medium and large scale brick production entities of the region. This has created very strong incentives for improved brick technologies and has also paved the way for technologically advanced and much superior hollow bricks in the region.

However, improved building techniques and practices such as using rat-trap bond in place of traditional English bond masonry for constructing walls has reduced the number of bricks and mortar required per square meter of wall construction in recent years.

Markedly different from the brick industry of China, South Asia and Middle East ( largest brick production countries in world), ASEAN brick industry is more modern and has embraced technology in a big way. Rapid economic growth of 1990’s was the main factor behind rapid automation and birth of large brick making enterprises, instead of smaller entities, which dot most of the China and South Asian countries. Vietnam is the only country, which has a brick industry similar to Chinese and South Asian brick industry. However, even in Vietnam, ratio of production and usage of hollow bricks to traditional bricks is far higher than China and South Asian countries.

Alternate building materials such as cement blocks and concrete masonry units have created a market for themselves replacing traditional bricks in many of the constructions in Thailand, Malaysia and Indonesia.

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Vietnam

There are some about 12,000 operational kilns in brick making segment in Vietnam which vary considerably in size, shape, and production process. Brick making process varies throughout the country depending on regulation, fuel availability, and geography.

The majority of the brick making enterprises are located in Vietnam's South in the Mekong Delta. Region’s vast network of rivers lends well to the transport of bulky clay, fuel, and fired brick. The South is characterized by generally smaller, traditional kilns fueled by rice husk- an agricultural waste. In the Mekong Delta, majority of brick production is concentrated in An Giang, Dong Thap, and Vinh Long provinces. The central and northern kilns have less uniformity in process and design. They may use a traditional, vertical shaft, or tunnel kiln design, and are much more likely to be fed off of coal than agricultural waste. As brick making in the North is generally closer to population centers, it has run into more trouble with the authorities.

Vietnam brick industry is a mix of unorganized and organized units. Organized sector has both private and public sector units.

Opposed to most of the production units in South Asia, brick production factories in Vietnam operate year round. In 2001, the first vertical shaft continuous kiln (VSCK) was introduced in Vietnam. The successful application of the first VSCK in Hung Yen province created a boost for the quick replication of VSCKs in many provinces of Vietnam in later years. Currently, more than 1000 VSCKs are operational in the country.

“Vertical shaft continuous kiln has helped us deal with the problems of the high energy cost, scarcity of firewood and environmental pollution. In comparison with traditional kiln, the operation of the new kiln is easier and simpler. With this success, we plan to replace the remaining ones with this new technology.

By doing this, production cost will be considerably reduced,” says Vuong Huy Dao , General Manager of Anh Dao Brick Making enterprise.

One of the most important distinguishing feature of the Vietnamese brick industry is the complete absence of the practice of manual brick-moulding and the use of simple brick-making machinery.

Even the smallest brick-making plant uses a simple extruder for brick moulding. Over the last 10-15 years, handmade bricks have

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Analysis: Bricks

y will come Brick Production in ASEAN

LOCALLY MADE EXTRUDERS ARE NOW COMMON IN MOST BRICK MANUFACTURING FACILITIES/PLANTS been non-existent to a large extent. Locally made extruders are now common in most brick manufacturing facilities/plants. These extruders range from very simple with a low output, to a basic extruder with a relatively larger output.

The other distinguishing feature in Vietnam is the pro-active, even interventionist, role played by the government in shaping the policy for the sector. Vietnam has a separate Department of Building Materials in the Ministry of Construction at the national level and Departments of Construction at the provincial level. Besides, there is a significant public sector presence in brick-manufacturing through SOEs (State Owned Enterprises) and VIGLACERA (Vietnam Construction Glass and Ceramic Corporation). Apart from this, the Vietnamese government has also incorporated institutional capacity building programmes through various R&D and training institutions such as the Vietnam Institute for Building Science and Technology (ISBT) and the Vietnam Institute for Building Materials Science and Technology (IBMST). Training programme are devised to look for alternative more energy-efficient brick making. Provincial associations of brick makers are formed to make it easier to share new technology with even the small brick making unit of rural areas. Capacity and training is provided to ensure Ambient Air Monitoring at brick kiln sites and their vicinity to streamline environment-related dispute settlement by local authorities.

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m na et Vi

nd la Th

ay al M

ai

si

a si ne do In

The Government of Vietnam issued a decision to ban the traditional brick making production within the urban perimeter, which will take full effect in the entire country by 2017. Most of the provinces issued regulations to ban the use of agricultural soil, soil of some special land such as historical, heritage sites, soil of dams and irrigating works. Earlier in 2012, Vietnamese Prime Ministerâ&#x20AC;&#x2122;s office had issued a directive aimed to boost use of unbaked building materials and restrict production and use of baked clay bricks.

a

Ban on Traditional Brick Making

Bricks/Year (In Billion)

october 2015

asian ceramics

37

Analysis: Bricks

By putting the policy of replacing all baked building materials, including clay bricks, with alternative building materials strictly by 2020 in place, the government has been able to exert pressure on the informal sector to phase out use of burnt clay bricks. The policy further provides for the use of about 15-20 million tonnes of industrial waste such as thermoelectric ash, blast furnace slag, etc., in the production of building material.

Malaysia

Malaysian brick making industry is most modern among its ASEAN peers. Country’s brick production is dominated by three dozen big and small scale manufacturing units. In last 10-15 years, alternative construction materials like cement blocks have replaced brick usage to a large extent. On per capita basis, Malaysian usage of traditional bricks is far less as compared to South Asian countries.

Last year was a tough time for the Malaysian bricks manufacturing industry. All the major producers struggled due to the rising operation and production costs. At the beginning of the 2014, electricity tariff went up by nearly 19% in the country, To mitigate the adverse impact of this abrupt rise in the production costs, all major producers intensified their effort to achieve greater efficiency in manufacturing processes.

Claybricks & Tiles Sdn. Bhd. (Claybricks)

Located at Kota Tinggi, Johor, Claybricks state of the art plant has an annual production capacity of 300,000 metric tonnes of fired products in wide variety of colors and textures. Occupying an area of more than 10 hectares, the company also owns about 80 hectares of clay quarry to ensure consistency in quality of raw material supply. Kota Tinggi is a historical town well-known for its abundant reserve of quality clays for ceramic and heavy clay industries.

The company claims that rich clay deposit in the proximity enables it to produce a wide varieties of products with texture ranging from smooth face, rock face, sandblast, cobble and tumble; while the color ranges from white, cream, granite, red, purple, brown and many other combinations of shades and tones. Company also produces brick accessories and bricks of special shapes to fulfill the pursuance of perfection by some architects or designers.

Claybricks & Tiles claims that about 90% of its products are exported to Japan, Taiwan, Hong Kong, Singapore and the Middle East.

Table- Major Brick Producers in Malaysia S. No.

Company

Location

1

Cheras Brickworks Sdn Bhd

Selangor

2

Galian Brick Industries Sdn Bhd

Kuala Langat

3

Kilang Batu Hap Kee Sdn Bhd

Kuala Lumpur

4

LDV Batubata Kerlin Sdn Bhd

Selangor

5

Qiristar Bricks Contractor Sdn Bhd

Serendah

6

Selendang Delima Bricks Manufacturer Sdn Bhd

Kajang

7

Sentosa Brickworks Sdn Bhd

Rawang

8

Wira Bricks Sdn Bhd

Shah Alam

9

Yap Khay Cheong Brick Works Sdn Bhd

Kuala Lumpur

10

Yap Teck Heng & Sons Bricks Industry Sdn Bhd

Kuala Lumpur

11

Original Clay Industries Sdn Bhd

Johor

12

Kimtee Brickworks Sdn Bhd

Selangor

13

Kilang Batu Bata KYH Sdn Bhd

Pahang

14

Parksim Bricks Sdn Bhd

Pahang

15

Brick Dotcom Sdn Bhd

Kuala Lumpur

16

Deluxe Brickworks Sdn Bhd

Klang

17

Thai Huat Brickworks Sdn Bhd

Kula Lumpur

18

Malaysian Red Bricks Factor Sdn Bhd

Kuala Lumpur

19

Sin Heap Fatt Brickworks Sdn Bhd

Kuala Lumpur

Kia Lim

Public company, Kia Lim is one of the largest and most modern clay brick manufacturer in Malaysia. The company is engaged in the production of clay common bricks, facing bricks, block bricks, brick tiles, chamfered paving bricks, and H-shape pavers, as well as roofing tiles.

With an installed production capability of approximately 180 million pieces of bricks per annum (approximately 400,000 tons of clay bricks), the company has installed new European production lines for facing bricks and pavers. Kia Lim claims that it has a 30% market share in Johor and Malacca. The company markets 80% of its products locally and exports the rest to Singapore, Taiwan, Hong Kong, Japan and the Middle Eastern countries.

Managing director Dr Tang Hai Chiang says, “In the last 10 years there were about 400 common brick manufacturers in the country but 70% of them had since closed down due to stiff competition. In Johor there are only 10 left now.”

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Unity Brick Works Sdn Bhd

Incorporated in Mar 2010 at Pekan Tehel, Melaka, Unity Brick Works Sdn Bhd is a new brick producer in Malaysia. Company’s first factory in Pekan Tehel, Melaka has a production capacity of 2 Millions clay bricks per month. Its second brick manufacturing operations at Benta, Pahang commenced in 2014 with a production capacity of 1.5 Millions clay bricks per month.

The company claims that is looking for further expansion of its manufacturing capacity in coming years as more and more development take place in Malaysian construction industry.

Indonesia

Most of the brick production in Indonesia is located in Java. A major part of the total brick production is carried out by cottage and village industries, which account for 20% and 43% of total production,

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Analysis: Bricks

respectively. The remaining 37% is produced by relatively large scale brick plants. These cottage and village producers can vary from 60,000 to 400,000 bricks a year, with the average output of the cottage industry being around 70,000, and the village industry around 250,000.

Clay is either dug up from the owners' land or from fields that have been rented from neighbours. Clay is often not transported. This is particularly valid for small scale units, which produce bricks near the clay pit. The dry bricks are either transported to the kiln or are fired in a temporary kiln built on the site. Bricks weigh from 1.3 to 2.2 kg. per piece, depending on the size, and are usually made by small teams of people, with 5 people being able to dig, mix and mould 1000 bricks a day. Small production units normally use their own labour and only occasionally employ hired labour, while progressively larger units often rely on hired labour. Nearly all units, probably with the exception of the smaller units, have drying sheds as well as covered kilns and, in principle, they can produce most of the year round. However, during the rainy season and during harvesting time, owners of brick factories find it difficult to attract sufficient labour because the wages they offer tend to be low. As a result, production is often seasonal.

Updraft kilns in the form of clamps (mostly scoved clamps) and scotch kilns, are used to fire the bricks but large producers use Hoffman or Tunnel kilns. Some brick makers do not own a kiln but rent one from another producer or sell the unfired bricks to another brick producer. Fuel wood and or rice husks are the main fuel types being used, with rice husks becoming the dominant fuel for many smaller units, while the somewhat larger units use both fuel wood and rice husks, depending on availability. The continuous kilns normally use oil or coal.

Fuel availability is becoming a significant problem for those enterprises that are burning wood. Rice husks therefore become more and more important, but the main drawback with this fuel is that during the firing process very little control can be exerted, which is not the case with fuel wood. Using rice husks as fuel instead of wood can be financially attractive because 1.5-2 times the amount of useful energy can be generated for the same price even when the very low conversion efficiency for rice husk firing is taken into account.

Bricks produced in the smaller units are are generally solid, e .g., without any perforations or cavities and are of inferior quality. However, despite low quality, these bricks are accepted on the market because of their comparatively low prices. With the establishment of quality standards by Indonesian government a few years ago, many of these small scale producers are finding it tough to sell their products. These bricks are mainly supplied to the private construction market and only to some minor extent to the public sector which is increasingly turning to alternative building materials such as cement blocks.

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Thailand

Along with Malaysia, Thailand brick production underwent a metamorphosis during 1990â&#x20AC;&#x2122;s. Small and mid scale brick production units, which was the norm in the country started disappearing at a fast rate. The process of transformation came to a halt during the economic difficult years of 1998- 2002. In the past, a large part of brick production in Thailand came from a mixture of clay and husk that was pressed into shape, sun dried, and then burned to make it stronger. Even today, bricks (typically cheaper) used in non-loaded bearing walls are still made using the same method. The husks from rice fields are added to reduce weight. After burning, the husks provide good bonding and also act as a heat-insulator. The local brick is used for the lower-cost projects in each local area and are usually made with locally produced raw materials.

In the rapidly decreasing un-organized brick sector in the country, bricks are produced at the cottage, village and rural enterprise levels with production technologies which vary with the size and scale of the producer. At the cottage and village levels, the technology, in general, is simple; bricks are handmolded, sun dried and then fired in a pit or clamp kiln. The thermal efficiency of the firing is low as is the quality.

At the other end of the range of available technologies are those such as mechanical clay mixing and extrusion, automatic wet brick handling systems, controlled drying and continuous firing systems. However the latter are only used at the level of large rural enterprises which in general, a§re located near urban centers. In between the simple and the advanced methods of making bricks, are a range of intermediate technologies.

In Thailand, Concrete Masonry Units (CMU) and cement blocks are also known as concrete blocks and are usually bigger than clay bricks and light-weight concrete block or Autoclaved Aerated Concrete (AAC) have replaced the traditional bricks in a major way.

Technologies

A wide variety of brick making technologies are used throughout the ASEAN countries. These vary from very simple manual operations which use age old clamp or stove kilns, to the sophisticated mechanized, and nowadays computerized technologies which utilize tunnel kilns. The latter, have made rapid progress in some of the ASEAN countries in last few years. However, in between these two extremes lies the semi mechanized factories, which use extruders and more sophisticated kilns. Each technique has its benefits and corresponding cost.

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Analysis: Indonesia

It’s a gas….

Indonesia hit by rising fuel costs

Jahir Ahmed concludes his analysis of Indonesia by focusing on how the country’s tableware and sanitaryware industries are being impacted by rising gas prices.

A

sudden exorbitant increase of natural gas price has destabilized Indonesian ceramic production, forcing the manufacturers of tiles, sanitarywares and tablewares and become uncompetitive in the domestic and export markets. Indonesian Ceramic Industry Association (ASAKI) believes if the government fails to revise the prices of natural gas, supplied by the state-run PT Perusahaan Gas Negara (PGN), on urgent basis, the industry will face serious consequences, even many of the production units may collapse.

When the government of President Joko Widodo is strengthening its efforts of earning higher revenue for better management of the economy in a situation of slowdown, the ceramic manufacturers are suggesting price revision as better way for maximizing revenue and improve the management of the economy. The manufacturers asked the government to drastically reduce the gas price to let them become competitive and help boost up revenue of the state. They are demanding competitive prices of the state supplied natural gas, a policy already adopted by the other competing neighbouring ASEAN countries.

"The prices of gas for the ceramic industry in Indonesia were already too high, before the price increase in August. The previous price of US$8.7 per mmbtu in North Sumatra and a little lower rates in the main ceramic producing gas-rich region of Java were much higher, compared to other ASEAN countries. With that previous higher price the ceramic sector was gasping for breath, because, the Indonesian ceramic manufacturers lost their competitive edge,” said ASAKI Chairman Elisa Sinaga.

“After repeated appeals for revision in the past, finally in the first half of this year, the government was supposed to reduce the price as was indicated. But to the surprise of all, what happened was just the opposite. A sudden massive price increase from

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August has flattened the industry," said Elisa added.

“The prices of natural gas for the ceramic industry in North Sumatra province is now around US$14 per mmbtu, while for the ceramic industry in East and West Java zones it is US$8.7 and US$9.2 per mmbtu,” he said.

ASAKI made it clear to the government that the gas price is unbearable to the ceramic industry all over the country.

Indonesian ceramic markets at home and abroad will be in unmanageable trouble or totally lost to other countries where the average price is less than US$6 per mmbtu.

“The price of gas in industry in Singapore is only US$5 per mmbtu. In Malaysia even less than US$5 per mmbtu. We propose a competitive price, US$ 5-6 per mmbtu," said Elisa.

Currently ASAKI has 76 member-companies which manufacture tiles, sanitarywares and tablewares.

Efficiency gaps

The government knows gas price increases will make Indonesian ceramic wares expensive both at home and on the world market, resulting in grabbing market shares by the products of the competing countries where production cost would be comparatively much lower. But the government wants the Indonesian manufacturers beat the alien competitors with innovation and higher efficiency in minimizing production cost, suggested the officials in the Ministry of Industry.

“The impact will ultimately reduce sales of the Indonesian companies and force them cut down utilization of production capacity, as the efficiency could not be raised immediately with the existing plants and production systems, some of which technically could be totally obsolete when it comes to upgrading efficiency,” said Elisa.

Achmad Safiun, Chairman of the Indonesian Forum of Industrial

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Analysis: Indonesia

Gas Users (FIPGB), said industrial gas users are now beginning decline in production. “Symptoms of decline in production began to be seen in line with the decrease in domestic demand and the increasingly high price of gas industry. As the ceramic industry was already down 20-30 percent now," said Safiun.

FIPGB noted that prices of gas for industries sold by PGN and its principal PT Pertamina (Persero) is currently up to around US$9.3 per mmbtu. The fuel is much more expensive than the price of gas in a number of ASEAN countries, such as Singapore where the price is about US$4-5 per mmbtu, in Malaysia US$4.47 per mmbtu, in Philippines US$5.43 per mmbtu and in Vietnam around US$7 5 per mmbtu.

"The condition of the Indonesian industry is vulnerable because of rising energy and raw material prices, weaker export, and due to these the product competitiveness has hampered," said Safiun.

"The sales of the products are depended on the domestic market, but the higher priced local products are facing difficulties to compete with imported products. The exports have not been able to compete since losing of competitiveness. The exports are likely to be stagnant at some 11 percent despite efforts for improvement in export shipments," said Elisa.

"The ceramic industry did not demand subsidies, but competitive prices of gas to save the national industries, the country’s economy, and workers’ employment," he asserted.

According to ASAKI, a de-industrialization situation has almost happened. With the condition of the domestic market being down, ASAKI is under severe pressure from the member industries to open up overseas markets. “To boost exports,” said Elisa, “ASAKI experienced the need of production and export incentives from the government as most essential.”

The ASAKI chief told Asian Ceramics the annual production capacity of the ceramic floor and wall tile industry in Indonesia is currently 500 million sq meters, in sanitaryware sector the capacity is 5.5 million pieces a year, in tableware the capacity is 300 million pieces per year, while the annual production capacity of roofing tile is more than 130 million pieces.

Earlier, Indonesian ceramic industry was expected to achieve a double digit growth in 2015 following continued expansion of the country’s economy by near about six percent in 2014 and expected seven percent in 2015. Particularly, the tile industry has poised to grow substantially to 43 trillion Indonesian rupiahs, or US$3.6 billion, in sales revenue in 2015, from the projected Rp36 trillion in 2014, according to ASAKI.

Turnover issues

ASAKI recorded a production volume of ceramic tiles in Indonesia

THE GOVERNMENT KNOWS GAS PRICE INCREASES WILL MAKE INDONESIAN CERAMIC WARES EXPENSIVE BOTH AT HOME AND ON THE WORLD MARKET last year at about 480 million sq meters, with a turnover value reached Rp30 trillion. The achievement was increased by approximately 10 percent compared with the achievements of 2013, and were slightly better.

Elisa assess the current situation amid sluggish domestic market and burdensome for the ceramics industry can grow. A number of attempts to divert sales to the export market is also not easy given the competitiveness of the ceramic industry less when compared with similar industrial origin neighboring countries in the region.

ASAKI is continuously trying to convince the government for a revision of the price increase to save the energy-intensive ceramic industry, while the government argues that the ceramic industry needs increase of efficiency in cost effective production to make profit and such condition also prevails in other high gasuser industrial sectors like, glass, steel, petrochemical, fertilizer, etc. The Ministry of Industry explained the government actions, supporting the gas price increase, and said this will move ahead the national economy in a gas-short situation and gas should earn better prices from the industrial users.

In a latest move the government has, however, indicated to revise the gas prices if the high gas-user industries cannot absorb the increase in face of competition with the other ASEAN countries which enjoy duty-free or liberalized access to the Indonesian markets.

Among the most affected ceramic sectors in latest gas price increase are sanitarywares and tablewares who consider natural gas as their raw material equivalent. Both the sanitaryware and

Indonesia’s exports of ceramic tablewares and other household porcelain/non-porcelain articles, in value Indonesia’s exports of ceramic tableware, kitchenware, of porcelain/china and non-porcelain, under HS Code 6911 and 6912, in value, in million US dollars HS Code

Indonesian ceramic tableware exports in value Product label

691110

Tableware and kitchenware of porcelain or china

691190

Household articles nes & toilet articles of porcelain or china

691200

Ceramic tableware, kitchenware, other household & toilet articles nes

www.asianceramics.com

Exported value in million US$ in 2010

Exported value in million US$ in 2011

Exported value in million US$ in 2012

Exported value in million US$ in 2013

Exported value in million US$ in 2014

80.910

90.172

82.384

97.515

108.303

1.167

1.292

1.391

1.407

0.643

25.560

31.397

33.261

27.161

27.651

october 2015

asian ceramics

43

Analysis: Indonesia Indonesia’s exports of ceramic tablewares and other household porcelain/non-porcelain articles, in quantity Indonesia’s exports of ceramic tableware, kitchenware, of porcelain/china and non-porcelain, under HS Code 6911 and 6912, in quantity,

HS Code

Indonesian ceramic tableware exports in quantity Product label

691110

Tableware and kitchenware of porcelain or china

691190

Household articles nes & toilet articles of porcelain or china

691200

Ceramic tableware, kitchenware, other household & toilet articles nes, other than porcelain/china

2010

2011

2012

2013

2014

Exported quantity in Tons

Exported quantity in Tons

Exported quantity in Tons

Exported quantity in Tons

Exported quantity in Tons

14,472

14,934

13,565

18,250

21,568

256

268

375

300

273

17,673

17,092

16,636

13,337

11,466

Indonesia’s exports of ceramic sanitarywares in value Indonesia’s exports of ceramic sanitarywares, including, sink, wash basin, bath, bidet & similar sanitary fixture, under HS Code 6910, in value, in million US dollars HS Code

Indonesian ceramic sanitaryware exports in value Product label

691010

Ceramic sinks, wash basins etc & sim sanitary fixtures of porcelain/china

691090

Ceramic sinks, wash basins etc & similar sanitary fixtures nes

Exported value in million US$ in 2010

tableware factories in Indonesia are fully dependent on cheaper and undisrupted supply of gas.

As the government is determined to earn higher revenues from gas sales and has limited capacity to mobilize resources for gas transmission and development of distribution according to the consumer demand, the sanitaryware and tableware factories are under pressure to improve efficiency to minimise cost of production.

Japanese influence

In Indonesian sanitaryware markets, the Japanese are the dominating players. All three major operators are Japanese owned joint venture investments. The companies include, PT Surya Toto Indonesia Tbk (TOTO), American Standard Indonesia PT, and PT INAX International (INA Sanitaryware).

Due to change of hands, American Standard is now owned by the Japanese company LIXIL Corporation, which also owns INAX International in Indonesia. LIXIL with its two plants in the country has a substantial influence in both the domestic markets and exports of Indonesia. All three companies are expanding operations in Indonesia both for domestic and export markets.

Among the three, TOTO is now implementing major expansions. Its ongoing expansion projects are upgrading its Indonesian markets. The upgrading is aimed at attracting new segments as Indonesian consumers are spending more or improved bathrooms and toilets. This expansion of production and upgrading segments with value added products will consolidate TOTO’s secured markets in Indonesia and abroad further, in line with production and marketing strategies followed in other ASEAN countries where it is one of the biggest manufacturers of sanitarywares.

Industry sources observe TOTO is giving priority in developing Indonesian operations as its regional hub in South East Asia both for regional consumption and exports to other countries. The company says it has best production efficiency in South East Asia which is unbeatable by any competitor, for which, in a free market situation it will continuously have better edge in competition.

TOTO’s operation is expected to remain as much potential in any event of cost escalation as its export is strategically supportive

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Exported value in million US$ in 2011

Exported value in million US$ in 2012

Exported value in million US$ in 2013

Exported value in million US$ in 2014

19.272

18.258

18.228

17.066

20.857

5.612

5.656

3.021

1.971

1.656

with one thirds of the production going to high-end markets of different countries including Japan. TOTO said this helps overcome the negative impacts of weakening of the Indonesian currency, Rupiah.

Under ongoing expansions, TOTO has brought a seventh production line in Indonesia into stream last year. It claims to have some 65-70 percent market shares, by applying a vast distribution channel operated by its associate PT Surya Pertiwi. Some 3,500 dealers operate its distribution in some 15 hubs all over the country. The company said it will have 10 production lines with total capacity of 4,800,000 pieces per year.

Upgrade

In the coming years, TOTO will have further opportunities in the Indonesian market with expanded production of value added water closets, when the country’s consumption will upgrade from the existing 60 percent toilets’ usage of squat systems, said the company.

US based American Standard is now part of the global group LIXIL Corporation. American Standard and LIXIL both provide bathroom fixtures with various variants and different characters, which can be selected and combined according to taste and character of the consumer.

Like that of TOTO, LIXIL Corporation and American Standard Indonesia, along with INAX International, with the support of their global productions and distribution networks and research skills and designs, will provide diverse solutions for the Indonesian markets.

Already LIXIL, through INAX and American Standard, has established itself as a highly acceptable quality sanitarywaresolution provider in the domestic market of Indonesia. Since long American Standard also provides after sale services and supplies accessories and spare parts. It continues to make improvements in the use of natural resources such as water.

With reported sales growth of 15-25 percent each year, American Standard has to face stiff competition in the sanitary ware business. Besides, local prominent rivals, many imported industry players are involved in the competition in the Indonesian sanitaryware markets.

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Analysis: Indonesia

About a half of American Standard products are sold by the retailers. One fifth of the products are consumed by the lower middle-scale segments. The products have double digit growth in sales.

Housing starts

Indonesia’s ceramic sanitarware production has increased to an estimated 5.4 million pieces in 2014 from 4.7 million pieces in 2012, according to ASAKI. Political stability and economic growth have pushed ahead the Indonesian house building construction prompting higher demand for sanitarywares. ASAKI Chairman Elisa Sinaga observed, as the country’s economic growth has stabilized despite occasional slower consumption, the housing sector will consume a huge quantity of sanitarywares and tiles offering opportunities for new investments. The existing capacity will fall short of market demand for versatility of the consumer requirements, he suggests.

Due to a large population of about 260 million and indigenous rawmaterials as well as energy sources, Indonesia has plenty of opportunities to develop the local sanitaryware industry. ASAKI said the current trend of consumption will expand the domestic market greatly in Indonesia where per capita consumption is still much lower than those of Malaysia, Thailand and Vietnam. “But the rising cost of energy has been reducing profit margin,” he added.

Dining options

Indonesia is famous since long for tablewares. The products are dominating worldwide among the imported dinnerwares and kitchenwares. Ceramic and glass tablewares both are attractive worldwide. Almost all major Western stores have Indonesian ceramic tablewares for a diverse range of customers. The ceramic tablewares, dinnerwares and hotelwares produced in Indonesia have many manufacturing features including designs, in all forms of product categories, porcelain, bone china, stoneware and earthen ware, and have export demands globally.

Compared to the sanitarywares and tiles, the tableware sector of Indonesia has more players, because of presence of small and medium entrepreneurs (SMEs), as well as several global brands as direct manufacturers or using local contract manufacturers for OEMs. At least three dozen tableware factories are efficient manufacturers with potentials for exports. Some of them are quite large and globally reputed.

Japanese technologies have best influence on the Indonesian tableware markets. Some of the major operators are foreign investors. They include manufacturers of famous brands.

All large-scale manufacturers are exporters to the principal destinations, Europe and North America, for premium prices.

Among them, the leading operators are PT Sango Ceramics Indonesia, PT Wedgwood Royal Doulton Indonesia, PT Narumi Indonesia, PT Hankook Ceramic Indonesia, PT Lucky Indah Keramik Indonesia, PT Indo Porcelain. Manufacturers like PT Kedaung Oriental Porcelain Industry (KOPIN), IKAD Ceramics and KIG Group have several manufacturers under combined marketing for shipments of their goods to worldwide export markets.

Organised sector

P.T. Surya TOTO Indonesia Location: Tangerang, Indonesia Products: Ceramic sanitarywares Markets: Domestic and export markets Others: P.T. Surya TOTO Indonesia is TOTO’s first overseas factory. Its products include water closets, urinals, bathtubs, washbasins, bidets, sanitarywares with bathroom cabinets and fixtures, etc. The products are exported worldwide.

American Standard Indonesia PT Location: Cileungsi, Cibinong 16820, Jawa Barat, Indonesia Products: Ceramic sanitarywares Markets: Domestic and export markets Others: American Standard Indonesia PT is a major sanitaryware manufacturer in Indonesia to cater the domestic markets and for exports.

PT INAX International (INA Sanitaryware) Location: Semarang 50121, Indonesia Products: Ceramic sanitarywares Markets: Domestic and export markets Others: INAX is the leading Indonesia based ceramic sanitaryware manufacturer, founded decades ago.

PT Sango Ceramics Indonesia Location: Semarang, Indonesia Products: Porcelain, stoneware and bone china hotelware and household tablewares Markets: Domestic and export markets Others: PT Sango’s porcelain, stoneware and bone china hotelwares are meeting domestic demands and exporting to many countries. Its bone chine plant is producing, specially white ranges, for the hotel and restaurant industries.

PT Hankook Ceramic Indonesia Location: Pasar Kemis, Tangerang, Indonesia Products: Porcelain and fine bone china hotelwares and household tablewares Markets: Domestic and export markets Others: PT Hankook Ceramic Indonesia is a leading quality manufacturer of tablewares with a production capacity of one million pieces per month. It produces bone china, vitrified fine china, porcelain and stoneware dinnerwares and gift items.

PT Lucky Indah Keramik Indonesia Location: Jakarta, Indonesia Products: Ceramic stoneware dinnerwares Markets: Domestic and export markets Others: Lucky Indah Keramik produces ceramic stone dinnerwares. Deep plates, bowls, flat plates, cups and saucers with different sizes. Also handpainted items, white wares, decorated items, soup plate with embossed designs on brown body, etc.

PT Indo Porcelain Location: Tangerang, Indonesia Products: Porcelain hotelwares and household tablewares Markets: Domestic and export markets Others: Decades old Indo Porcelain is one of Indonesia’s major manufacturers of hotelwares and household tablewares. Its white porcelain products are on the market offering a broad choice of shapes, glazes and decorations. It also manufactures OEM for many of the world’s leading tableware brands.

Larger organised tableware manufacturers have annual production capacity of about 300 million pieces of high quality tablewares,

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Analysis: Indonesia

said ASAKI. In 2014, Indonesia shipped more than US$136 million worth of ceramic tablewares, including, porcelain, bone china and stoneware products for the world markets, according to the Geneva based International Trade Centre (ITC). Major destinations include European Union, USA, Middle East, Japan, Thailand, South Korea and Australia-New Zealand.

Indonesia also imports a few million US dollars worth of tablewares per year mostly from China.

Despite Indonesia’s presence as a good tableware producer and supplier to the world market, the country’s potentiality yet to be explored by the global investors in the sector, according to the industry sources. Currently, investment in this sector remains slow because of shortage of natural gas and high prices of gas.

Indonesia has almost all raw material sources domestically and the mining sector also has potential for development as the country is vastly unexploited. In addition to that, indigenous natural gas and cheaper local labours are available in plenty.

However, higher economic growth of Indonesia has greatly increased the domestic market demand for quality tablewares.

Existing foreign operators like UK’s Wedgwood Royal Doulton Indonesia, Japan’s Narumi Indonesia and South Korea’s Hankook Ceramic exploit the opportunities in Indonesia substantially and cater the global markets with products shipped from their factories in Indonesia under their world famous brands.

The Gas War

"Gas prices contributed substantially in component production costs. In ceramic industry, components of the price of gas has its share of 30 percent of the cost of production; in glass, 30-35 percent of production cost; in steel, 30-35 percent, and 80 percent of the fertilizer industry. There are many other huge gas users like petrochemicals, etc. If the efficiency of the gas price can be given, the competitiveness of these industries will certainly increase, "explained Franky Sibarani, Chairman of Indonesia Investment Coordinating Board (BKPM).

BKPM is an one-stop investment promotion agency mandated to boost domestic and foreign quality direct investment through creating a conducive investment climate and reporting directly to the President of Indonesia. The agency, chaired by Franciscus M.A Sibarani, (known as Franky Sibarani) with a ministerial status since last year, works as a ‘proactive advocate’ for investments as well as a matchmaker for investors.

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PT Wedgwood Royal Doulton Indonesia Location: Tangerang, Banten, near Jakarta, Indonesia Products: Porcelain hotelwares and household tablewares under the Royal Doulton and Wedgwood brands.

Markets: Domestic and world markets Others: Nearly whole of the outputs are exported worldwide.

PT Narumi Indonesia Location: EJIP Industrial Park, Cikarang Selatan, Bekasi 17550, Indonesia Products: Bone china hotelwares and household tablewares Markets: Domestic and export markets Others: The hotelwares produced in the Indonesian plant of the Japanese Narumi are supplied to the hoteliers worldwide.

PT Kedaung Oriental Porcelain Industry (KOPIN) (also IKAD Ceramics and KIG) Location: Pasir Kamis, Tangerang, West Java, Indonesia and Kampung Poglar, Kedaung Kaliangke, Jakarta Barat, Indonesia Products: Porcelain and stoneware tablewares Markets: Domestic and export markets Others: KOPIN, IKAD and KIG, under KIG Group of several manufacturers, produce on-glazed quality and decorated porcelain and stoneware tablewares since decades. Most of the high-end products are exported to the main targeted markets in Europe and North America, mostly for retail superstores.

Sibarani, who previously served as Chairman of the Indonesian Employers Association (APINDO) and Vice Chairman of the Standing Committee of Domestic Trade, and Secretary General of the Indonesian Food and Beverage Association (GAPMMI), has been involved in the development of national industry, states, the efficiency of gas prices is one component that can be considered as one of the incentives given to improve the competitiveness of the existing industries.

"The focus of BKPM, in addition to attracting investment and improving the realization of the investment, is to keep existing investments did not stop or leave," said Sibarani, in an official statement early September, when the industrial manufacturers were showing their anger against the forced unilateral price increase without taking other ASEAN countries’ lower gas prices into consideration, specially, in ASEAN free market economic region.

“BKPM proactively communicate with industry to discuss

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Analysis: Indonesia

Indonesia’s exports of ceramic sanitarywares in quantity Indonesia’s exports of ceramic sanitarywares, including, sink, wash basins, etc, & sim sanitary fixtures of porcelain/china, under HS Code 691010 and 691090, in quantity, in kilograms HS Code

Indonesian ceramic sanitaryware exports in quantity Product label

691010

Ceramic sinks, wash basins etc & sim sanitary fixtures of porcelain/china

691090

Ceramic sinks, wash basins, wash basin of other than porcelain/china

2010

2011

2012

2013

2014

Exported quantity in Kilograms

Exported quantity in Kilograms

Exported quantity in Kilograms

Exported quantity in Kilograms

Exported quantity in Kilograms

8,065,572

6,356,265

7,825,492

6,844,763

8,536,128

2,710,389

2,517,391

1,428,661

1,048,555

1,255,062

Indonesia’s imports of ceramic tablewares and other household porcelain/non-porcelain articles, in value Indonesia’s imports of ceramic tableware, kitchenware, of porcelain/china and non-porcelain, under HS Code 6911 and 6912, in value, in million US dollars HS Code

Indonesian ceramic tableware imports in value Product label

691110

Tableware and kitchenware of porcelain or china

691190 691200

Imported value in million US$ in 2010

Imported value in million US$ in 2012

Imported value in million US$ in 2013

Imported value in million US$ in 2014

11.022

11,570

11,114

4,002

3,472

Household articles nes & toilet articles of porcelain or china

0.115

0.139

0.751

0.147

0.038

Ceramic tableware, kitchenware, other household & toilet articles nes, other than porcelain/china

1.343

1.371

2.023

0.295

0.649

efforts to improve their competitiveness amid growing economy slows,” he continued. Sibarani said when he had interaction at a meeting with the members of the Forum of Industrial Gas Users at the end of August, one of the issues raised in the meeting was the potential for improving the competitiveness of the industry through the efficiency of the price of gas for the industry. He stated, BKPM will examine more deeply impact the efficiency of gas prices on the competitiveness of the industry as well as the mechanism that allows the efficiency to do.

Sumatra’s stepchildren

"The increase in gas prices to double makes the cost of production jumped significantly, especially for ceramic industries that require a lot of gas," said Johan Brien, chairman of Apigas, the association of the gas users of North Sumatra.

Industrial gas users in North Sumatra states experiencing difficulties in carrying out operations due to increase of gas prices to US$14 per mmbtu from US$8.7 per mmbtu, since August 1.

Apigas members allege the industrial consumers in North Sumatra province seems

50

Imported value in million US$ in 2011

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october 2015

stepchildren in the family in determining the issue of price of gas by the government.

The price of gas in West Java and the surrounding areas is only US$9 per mmbtu, East Java US$6.5/mmbtu, Batam US$6.0/ mmbtu. North Sumatra’s nearest neighbour Singapore charges US$3.87/mmbtu, while in Malaysia it is US$3:58/mmbtu.

Apigas Chairman Brien said the industrial employers have no alternative but to use gas from PGN; besides, the employer objected because they can not switch to other energy sources for industrial machines were designed to use natural gas and existing gas pipeline infrastructure.

"PGN get gas supply from Pertamina EP and the Arun LNG through Pertagas. Then, they distribute it to us. They are the only company that distributes to us. Infrastructure also has them, so our position is weak in the pricing of gas,” said Brien.

Apigas requested the consuming industries for suspension of the bill. If PGN does not stop the supply of gas, Apigas only willing to make payments according to the price prior to the adjustment.

Sources in ASAKI, Apigas and Sumatran ceramic industry believe that once an equal gas price

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Analysis: Indonesia

Indonesia’s imports of ceramic tablewares and other household porcelain/non-porcelain articles, in quantity Indonesia’s imports of ceramic tableware, kitchenware, of porcelain/china and non-porcelain, under HS Code 6911 and 6912, in quantity, 2010

2011

2012

2013

2014

Imported quantity in Tons

Imported quantity in Tons

Imported quantity in Tons

Imported quantity in Tons

Imported quantity in Tons

24,416

21,646

20,449

10,102

12,183

68

126

367

6

6

1,064

817

1,540

188

166

Indonesian ceramic tableware imports in quantity HS Code Product label

691110

Tableware and kitchenware of porcelain or china

691190

Household articles nes & toilet articles of porcelain or china

691200

Ceramic tableware, kitchenware, other household & toilet articles nes, other than porcelain/china

Sources: International Trade Centre (ITC), Geneva, calculated estimates based on UN COMTRADE statistics.

Indonesia’s imports of ceramic sanitarywares in value Indonesia’s imports of ceramic sanitarywares, including, sink, wash basin, bath, bidet & similar sanitary fixture, under HS Code 6910, in value, in million US dollars HS Code

Indonesian ceramic sanitaryware imports in value Product label

691010

Ceramic sinks, wash basins etc & sim sanitary fixtures of porcelain/china

691090

Ceramic sinks, wash basins etc & similar sanitary fixtures nes

Imported value in million US$ in 2010

is introduced in comparison to nearby West Java, the region of North Sumatra will be future location for several ceramic manufacturers because of its growing consumers, specially in its flourishing capital city of Medan, as well as the best proximity to Malaysian and southern Thailand’s wholesale and retail markets and global shipping hub of Singapore. North Sumatra with a population of 14 million is the most populous Indonesian province outside of Java, and its capital Medan with a population of over 2 million is the fourth largest city in Indonesia, and the largest Indonesian city outside Java.

Garuda Tile

Already there exist some ceramic producers including the region’s major one, PT Jui Shin Indonesia (SAI Global ISO 9001-2008, ISO 130062010 and SIRIM QAS Malaysia standard certified) Jui Shin Indonesia’s brand name is ‘Garuda Tile,’ which was established in 2001and located in KIM II, Medan, North Sumatra, with an initial production capacity of 12 million sq meters of quality tiles per year, as the first ceramic atile factory in Sumatra. It aims on providing affordable good quality products and professional services to Sumatra market. Its product sizes include 300mmx600mm, 600mmx600mm and 800mmx800mm.

The company began operations with 3 production lines of glazed ceramic tiles in 2002, and had successfully grown its capacity to 11 kilns, 8 production lines, and 3 specialized in producing porcelain tiles and 4 production lines of granite tiles. Strong efficiency commitment has enabled Jui Shin to sustain the company's future growth and profitability with 2 more production lines of granite tiles to begin operation in full swing by the third quarter of 2015.

Jui Shin has the complete production facilities, from clean processing environment for raw materials, milling, advanced world class pressing machines, well controlled temperature firing kiln, Nano technology polishing machines, packing machines, and well organized warehouse. Jui Shin owners expect fair treatment and

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Imported value in million US$ in 2011

Imported value in million US$ in 2012

Imported value in million US$ in 2013

Imported value in million US$ in 2014

6.838

9.050

15.072

8.249

9.802

2.033

2.720

3.519

3.633

3.027

balance in nation’s business and industrial growth in all regions.

MoI maths….

The Ministry of Industry had reportedly compiled four gas price reduction schemes for the industry in April. In the schemes, the highest price was US$9.05 per mmbtu which could lead to potential loss of 8.15 trillion Indonesian Rupiah of government, but it can add economic output amounting to Rp72.4 trillion, admitted the Ministry officials.

While the scheme was the maximum decline in natural gas prices by 40 percent so that the gas price was estimated to be at US$6.3 per mmbtu. With that prices, the potential shortfall in government revenue was estimated to be Rp32.6 trillion, but could contribute to the increase in Gross Domestic Product (GDP) amounting to Rp289.7 trillion.

"If gas is seen as auxiliary raw materials, perhaps later could cost US$7 to US$8 per mmbtu. In that case, the price should be US$5 per mmbtu, because, it is the main raw material," said Muhammad Khayam, Director of Basic Chemical Industry, Directorate General of Manufacturing Based Industry, Ministry of Industry.

At that time, before current increase, the price of natural gas as a feedstock in Indonesia was the highest in Southeast Asia, in particular, in the ASEAN countries. Domestic gas price of US$ 9.3 per mmbtu was higher than Singapore’s US$4-US$5 per mmbtu, Malaysia’s US$4.47 per mmbtu, and that of US$5.47 per mmbtu in the Philippines and US$7.5 per mmbtu in Vietnam.

Project failures?

Industrial Gas Users Forum questioned the Rp10 trillion GresikCirebon gas transmission project's completion of pipeline from Gresik, East Java to Cirebon, West Java, that remains dormant for 10 years. If the construction of the gas pipeline is completed, the price disparity of

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Analysis: Indonesia

Indonesiaâ&#x20AC;&#x2122;s imports of ceramic sanitarywares in quantity Indonesiaâ&#x20AC;&#x2122;s imports of ceramic sanitarywares, including, sink, wash basins, etc, & sim sanitary fixtures of porcelain/china, under HS Code 691010 and 691090, in quantity, in kilograms 2010

2011

2012

2013

2014

Imported quantity in Kilograms

Imported quantity in Kilograms

Imported quantity in Kilograms

Imported quantity in Kilograms

Imported quantity in Kilograms

HS Code

Indonesian ceramic sanitaryware imports in quantity Product label

691010

Ceramic sinks, wash basins etc & sim sanitary fixtures of porcelain/china

8,100,192

10,454,254

14,818,931

8,050,603

10,076,336

691090

Ceramic sinks, wash basins, wash basin of other than porcelain/china

1,540,832

2,143,014

2,769,379

2,705,274

2,247,836

Indonesian ceramic tableware and sanitaryware production capacity Ceramic commodities

2012 in million

2013 in million

2014 est. in million

Tableware

275 pcs

275 pcs

290 pcs

Sanitaryware

4.7 pcs

5.1 pcs

5.4 pcs

Tile

390 m2

410-420 m2

420-490 m2

Roofing tile

120 pcs

120 pcs

130 pcs

Source: ASAKI compiled

natural gas in East Java and West Java can be suppressed, said Elisa Sinaga, Chairman of Indonesia Ceramic Industry Association (ASAKI).

He said, the 700-800 km project is planned to transmit gas from Gresik to Cirebon for PT Pertamina.

New development

In a latest development in mid September, Industry Minister Saleh Husin suggested, competitive gas prices have a direct impact on improving the efficiency, industrial competitiveness and productivity of

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industrial gas users. In addition, a more competitive gas prices also boost the utility of factories, increased employment, and increase state revenues.

The minister was echoed by Achmad Widjaja, chairman of the coordinating committee for the gas industry of the Indonesian Chamber of Commerce and Industry (Kadin). According to him, if the price of gas for industry is higher, it could threaten the position of the national industry in a free market of Asean or the Asean Economic Community (AEC).

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SP

R

AY I N G M AC HI N ES -F OR

636,443.14

711,890.32

1,857.19 14,687.17

981.96

Other 18 countries

682.29

371.43

11,776.27

10,348.08

139.72

3.73

22.22

18,232.70

701.74

Philippine

Sub-total

417.56

16,131.45

Thailand

China

Source: Sucofindo-Surveryor Indonesia (through ASAKI)

Total

Sanitary wares, porcelain (691010) and non-porcelain ceramics (691090)

96.99

Other 21 countries

23,031.32

21.27

South Korea

Sub-total

59.99

AN Y

SH

AP

E

757,258.37

11,175.12

1,244.11

390.86

689.12

8,851.03

13,453.81

223.88

-

40.21

191.13

18.89

1.54

1.18

1.14

15.02

13.24

0.58

0.15

0.26

155.16

11.46

1.68

1.17

0.90

7.71

3.23

0.09

0.03

0.11

TS

Thailand

3.00

UC

12.25

OD

13,189.72

PR

10,182.40

D

22,853.07

UN

China

RO

Tablewares and kitchenwares, porcelain (691110 and 691190) and non porcelain ceramics (691200)

OR

2014 (Est.)

167.13

17.91

2.12

0.65

1.42

13.72

3.54

0.07

-

0.21

3.26

-F

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ES

2013

N

2012

HI

2014

AC

2013

M

2012

G

Value in million US$

N

Volume in tons

SI

Country of origin

ES

Commodities

PR

Indonesian imports of ceramic tablewares and sanitarywares during 2011-2014, from the main sources

Analysis: Indonesia Do you produce or spray ceramics?

We make the machines.

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55

Analysis: Jiangxi

Province Profile:

Jiangxi production climbs as incentives rise In the next of our series of Province Profiles, we turn to tile industry expansions taking place in Jiangxi.

T

here are134 ceramic enterprises and 342 production lines (including western roof tile lines) in Jiangxi, with the ceramic tile (excluding western roof tile) daily capacity of 4,608,900m2/d and that of western roof tile 6,080,000pcs/d. Among which, there are 78 polished tile lines with capacity of 1,259,000m2/d; 55 interior wall tile lines with capacity of 1,137,000m2/d, 48 rustic tile lines with capacity of 691,500m2/d, 44 fully polished glazed tile lines with capacity of 411,300m2/d, 43 exterior wall tile lines with capacity of 626,000m2/d, 18 small floor tile lines with capacity of 317,000m2/d, 16 other tile lines (including crystal tile, microcrystalline tile, ceramic panel and wall skirting tile) with capacity of 167,100m2/d and 40 western roof tile lines with capacity of 6,080,000pcs/d.

In Jiangxi, there are 36 tile lines under construction and 49 inkjet printers in operation and 8 ordered.

Jiangxi not only takes the lead in ceramic tile manufacturing, ranking fourth nationwide on ceramic tile capacity, but also acts as a large consumer. As much as 70% of product sales center on local market and neighboring provinces. Since 2007, the provincial ceramic tile industry, supported by the policy of “Eastern ceramic enterprises to the west and Southern ones to the north”, has come a long way.

Facilitated by local abundant clay resources, convenient logistics, Gao’an, Jingdezhen, Fengcheng and Pingxiang have raised to be four large ceramic production bases. The positioning varies from to base due to distinctive industrial background, for instance, Gao’an is mainly ceramic tile production bases; Jingdezhen, known as ceramic town for thousands of years, is home to household ceramic; Fengcheng focuses on premium ceramics; Pingxiang utilizes the existing industrial ceramics to establish industrial ceramic base.

From the original plans of the governments we know all have a clear positioning in the industry. After seven years’ development, however, many insiders found that to promote economic growth, local governments seem to have forgotten about the original plan.

Such ceramic tile enterprises as Kito, Tidiy and Ryowa settled in Jingdezhen, household ceramic base, while Cimic, Dongpeng and Wonderful settled down in Fengcheng, the premium ceramic base.

Cutthroat competition remains between four production bases.

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Enterprises haven't enjoyed well development in these planned areas except for Gao’an. It is more disappointing that these brands, which originated in and built marketing center in Guangdong, merely regarded Jiangxi just as production base. In such case, they failed to bring about the local brand building, with no scale effect present in local ceramic tile industry Based on the latest statistics released to AC, nevertheless, the ceramic tile industry in Jiangxi scatters in 18 cities, counties and districts. Besides the four planned key production bases, Shanggao and Yifeng, following Gao’an, are large production regions with relatively concentrated distribution, while the rest majority places are home to 1 to 5 ceramic enterprises. As regards capital composition, Gao’an capital tops the list. Most of the enterprises in Gao’an, Shanggao and Yifeng are owned by Gao’an bosses. Moreover, a great deal of capital is from Guangdong and Wenzhou and Wenzhou bosses are mainly involved in interior wall tile manufacturing.

Gao’an: major base

Based on statistics derived from visits, there are 181 production lines in Gao’an (including western roof tile lines) with total capacity of 2,616,400m2/d (excluding western roof tile) and 150 inkjet printers in commission.

Not late at the start compared to Foshan, Gao’an also boasts remarkable history of contemporary ceramic industry. In 1978, the first ceramic tile enterprise in Gao’an named Ruijing Ceramics was established, which manufactured the first glazed tile in Jiangxi. Since then, ceramic enterprises prevail in lots of towns and almost each town had some plants, leading to scale effects until middle of 1980s.

When the ceramic industry became the pillar to the local economy, with the output taking up 1/8 of that in China, Gao’an was credited as “kingdom of glazed tile”. However, as its failure to keep up with times, Gao’an was rapidly replaced by Foshan as the leader.

Yet the early beginning and fruitful outcomes have laid a solid foundation for Gao’an, which trained a large number of qualified employees and left ceramic complex in heart of inhabitants, suggesting the re-rise in the years ahead.

In the tide of ceramic industrial transfer, Gao’an first seized the chance. In March, 2007, construction of ceramic tile industrial base

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Analysis: Jiangxi

THE VICE PRESIDENT OF CIMIC (JIANGXI) ZHOU XINRUI BELIEVES THAT THE POLICY HERE RESEMBLES THAT IN SHANGHAI

started. Guangdong New Pearl Ceramics, New Zhongyuan Ceramics and local enterprises settled here in 2007, which promoted the industrial scale to expand miraculously, and the affiliated programs follow suit, including such infrastructure as railway and gas supply, upstream projects machinery and chemicals. In 14th July, 2008, China Building Materials Federation agreed to name Gao’an base as "China Ceramic Tile Industrial Base", the first manufacturer at nation level.

By far, there are more than 120 architectural ceramics enterprises (including those under construction), among which 67 ones are ceramic tile manufacturers, with contracted fund of RMB 20 billion.

181 production lines (including western roof tile lines) have been completed with total capacity achieves 2,616,400m2/d (excluding that of western roof tiles), and over 180 inkjet printers are in commission. As a pillar industry of Gao’an, ceramics contributed 1/6 of the Gao’an government revenue, driving the development of logistics, catering, hotel and real estate, creating jobs for rural residents in adjacent villages and towns as well. The rural economy has been promoted and the indirect economic and social performance cannot be measurable.

tanks. Moreover, most enterprises adopted inkjet devices. The officials are expected to further highlight the elimination of backward production technique, energy conservation and control of pollutants discharge. In March this year, the base has signed an agreement with China Energy Conservation and Environmental Protection Group, supplying gas centrally to enterprises in the base to ease the tension of insufficient natural gas and high cost.

Growth control

Building “flagships”

In 2012, Gao’an government printed and distributed “Suggestions on Accelerating the Implementation of Use of Natural Gas in Ceramic Industrial Base” in accordance with “Suggestions on Accelerating the Implementation of Use of Natural Gas” by provincial authority. According to the Suggestions, natural gas should be adopted by ceramic settlers and supported enterprises signing agreement since January 1st, 2010; after October, 2011, newly-built production lines must employ natural gas as the fuel; before the end of December, 2012, the affiliated enterprises burning coal and oil should change the fuel into natural gas.

Gao’an has made great headway in industrial transfer, giving rise to more requirements of government for environmental protection.

Expansion began to slow down after the threshold of settlement raised in 2010. Some enterprises chose to invest in adjoining villages, towns and prefecture-level cities, such as Shanggao and Yifeng. During three years since then, companies settled in the region were mostly supporting enterprises except for Weichen Ceramics and Lvdao Ceramics. Some enterprises with adequate fund have performed well in scale and brand over the past few years.

According to a staff of Jiangxi ceramic tile industrial base management committee, the committee will work to improve infrastructure and environment in the park. Based on access criteria, the expansion of total scale in ceramics will be regulated stringently and well-known brand is welcome. Efforts should be made in reshaping enterprises and production lines poor in technique, quality and environmental protection. Enterprises are encouraged to cooperate with colleges, universities and National Quality Supervising Test of Architecture & Sanitary Ceramics, speeding up product structural adjustment and promoting products quality to enhance the development of regional brands.

It is learned that all enterprises in Gao’an, obsoleted smelting exhaust furnaces and constructed desulfurizers and activated sludge

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Gao’an authority always gives priority to brand building, which rolled out logo of “Ceramics of Gao’an” whose requirements must be met by manufacturers last year. It is learned that enterprises here have gripped the brand, like “Foshan brand”, “Jingdezhen brand” and “Fujian brand” all the time, lacking its own local brand, with only several enterprises which engaged in exterior wall tile and western roof tile dedicating in proprietary brand.

On the other hand, manufacturers aware of brand importance are energizing relevant effort to build proprietary brand, which is advocated by local officials as well. The President of Jiangxi Taiyang Ceramics Group, Hu Yiheng said repeatedly that it takes supported enterprises and personnel with time, fund, talents and design to build brand. At present, the building ceramic industry, in the development stage, has less brand influence. Enterprises should evolve from survival to development before brand building is commenced.

In order to acquire its reputation, the government made clear the specific task for governments at all levels and functional departments in building up ceramic brands. The list of key enterprises supported was confirmed based on three levels at descended order, “wellknown trademark”, “famous trademark” and “notable trademark”, establishing such graded nurturing model for trademark as “nurture some, support some and apply for some”. In recent years, Gao’an has flexed its muscles in application for “China well-known Trademark”, which was gained by a batch of enterprises here and from Guangdong, including Taiyang of Taiyang Ceramics, Demei from New Pearl Ceramics, Bogesi from Weichen Ceramics, Xinmei from Xingaofeng Ceramics, Oukaluo from Xinzhongying Ceramics, being awarded RMB 500,000 by government. According to management committee of the base, the local government decided to raise the profile of Gao’an ceramic by investing RMB 5 million for advertisements in China Central Television (CCTV) with enterprises.

october 2015

asian ceramics

57

Analysis: Jiangxi

The County line…

Shanggao county and Yifeng county, both bounded by Gao’an city, traditionally are called “Pan-Gao’an Production Region”, because their ceramic industries are affected by Gao’an, with Gao’an capital as well. But why it is necessary to talk about two areas alone? They have surpassed Jingdezhen, Fengcheng and Pingxiang in size and product structure.

The ceramics development in two counties can be traced back to 2008. Only a couple of enterprises were in operation before that, such as Jinniu Ceramics in Shanggao and Jinfo Ceramics in Yifeng, while with the expansion of Gao’an production region , investment promotion policy of the two counties attracted scores of Gao’an local enterprises, which are mainly settled in Shanggao Huangjindui Industrial Park and Yi Feng Lianggang Industrial Park.

There are 22 enterprises in the two counties, with 10 in Shanggao. Adjacent to Gao’an, it is quite convenient for some supported enterprises to settle Gao’an for providing fast and considerable service. That's why there are infrastructures less in the two counties. Via investigation, two areas now have witnessed the stable industrial scale, and policies on environmental protection and taxes are not as stringent as those in Gao’an, which resulted to larger expansion in both counties. A person in charge of Yifeng Jinfo Ceramics said local policies will be matched in parallel those of Gao’an, with more strengthened requirements for environment protection. Besides, Shanggao authority will not introduce ceramic enterprises, setting down more strict standard for environmental protection, with no preferential policy for ceramic enterprises.

Fengcheng: power issues

Since receiving ceramic industrial transfer in 2007, Fengcheng city brought in Cimic, Dongpeng Ceramics and Wonderful (Hemei) one after another, while there are no new settlers at present. Dongpeng established Dongpeng Sanitary in the park and Wonderful injected more fund to new programs. These enterprises, taking Fengcheng as manufacturing base, place the marketing center in Shanghai and Foshan, with no brand effect for local industry.

After seven years' development, nevertheless, the industrial scale didn't expand as scheduled like the foreign-invested enterprises in park. Only Wonderful expanded to nine production lines, with four lines under construction. Cimic (Shanghai), which has moved all production lines to Fengcheng, merely owns 8+1 production lines (with one experiment kiln.).

The Vice President of Cimic (Jiangxi) Zhou Xinrui believes that the policy here resembles that in Shanghai, and logistics and raw materials aren't superior to those in Shanghai and so does labor cost. Kuang Jinchu, a staff of Dongpeng Ceramics (Fengcheng) purchasing division said, the labor cost of Fengcheng is cheaper and its raw materials are relatively rich compared to those in Foshan. However, it lacks the advantage for producing polished tile. At present, the major trouble lies in energy selection, as three enterprises in the park adopted different energies, including natural gas, gas and coking gas. The gas reserve is merely enough for Dongpeng, and coking gas is inclined to contaminate products with ash, which resulted to low-grade products.

Jingdezhen: porcelain relaunched?

With thousands years of history in manufacturing porcelian, Jingdezhen has two local ceramic tile enterprises named Pengfei Ceramics and Mengtexiang Ceramics, while the other enterprises

58

asian ceramics

october 2015

almost raised in industrial transfer, for instance, Kito, Ryowa, Oceano, Icoto and Leter settled down in Sanlong Ceramic Industrial Park.

According to the reporter’s investigation, their is no significant change in production capacity of local ceramic tiles compared to that in 2011. Only Kito and Ryowa from Guangdong newly constructed 1~2 production lines, without new peers settling in the park. As the same as other production regions, Jingdezhen is only production base for them, while the marketing center is in Foshan headquarters . In such context, scale effect failed to emerge in Jingdezhen and the way for local brand is rather tough ahead, for instance, Leter and Pengfei Ceramics have built up marketing center in Foshan and consistently focused on R&D of products and brand promotion, but their pace is slowed by this journey with twists and turns.

General Manager of Kito in Jingdezhen production base points out that the local official stresses environmental protection.

Enterprises originated from Guangdong have changed their energy into natural gas, while local counterparts are requested to finish energy transformation before 2015. All local entrepreneurs felt the high logistic cost and production cost. Specifically, limited industrial scale and backward logistics such as automobile and rail transportation, with expensive purchasing and costly shipment contributed to RMB7 higher of comprehensive cost than that of Foshan. Pengfei, the traditional local enterprise which employs coking gas, doesn't have plan for expansion due to limited land, gaining market through increasing added value and R&D of new products.

Pingxiang City: a new capital?

Ceramic tile enterprises in Pingxiang production region mainly scatters in Xiangdong district industrial park, with the other two enterprises located in Anyuan district. Xiangdong, a municipal district of Pingxiang, is at the edge of Jiangxi and Hunan. Bounded

by Liling city of Hunan province and Youxian county at southwestern part, it is the western gate of Jiangxi, known as “gate of west Jiangxi” and “thoroughfare connecting Wu and Chu area”. In June, 2007, Xiangdong is officially listed into “Ceramic Industrial Base of Pingxiang in Jiangxi” by Jiangxi provincial government, being entitled as “Capital of China Industrial Ceramic” by Xiangdong district in January, 2009.

Xiangdong district, as a vital vehicle for “Capital of China Industrial Ceramic”, is committed to establishing science and technology “highland” and cost “low-lying land” of China industrial ceramic products, building the park into the strongest one integrating with “products production, teaching and experiment, R&D and testing and personnel training”.

As a production region focus on industrial ceramic manufacturing, Pingxiang has small ceramic tile industrial scale, with only seven enterprises possessing 17 production lines, among which Z&D Group ranks No.1 in scale. Therefore, it is no doubt that policy there is more flexible but natural gas in Xiangdong district is still under supervision.

According to the principal of Z&D Group market department, the cost is higher than that in Gao’an although the logistics has been notably upgraded in recent years. The products have advantages in Hunan, Hubei and southwestern markets.

Related facilities in the park need to be improved and related technology service are only available in Gao’an or Foshan. The high-speed rail will far facilitate the technology exchange and employee service.

www.asianceramics.com

60

asian ceramics

october 2015

China Ceramic Tile Industrial Base

Ducheng Town

China Ceramic Tile Industrial Base

Jiangxi New Century Industrial Park

China Ceramic Tile Industrial Base

Jiangxi New Century Industrial Park

China Ceramic Tile Industrial Base

Jiangxi Xinruijing Ceramics Co., Ltd. (No.2 factory)

Jiangxi Shenzhou Ceramics Co., Ltd.

Jiangxi Ruiyuan Ceramics Co., Ltd.

Jiangxi Ruiyang Ceramics Co., Ltd.

Jiangxi Luosifu Ceramics Co., Ltd.

Jiangxi Luonaer Ceramics Co., Ltd.

Jiangxi Jinhuan Ceramics Co., Ltd.

Xinjie Town

China Ceramic Tile Industrial Base

Jiangxi Xinruijing Ceramics Co., Ltd.

Jiangxi Xinzhongying Ceramics Co., Ltd.(Xinjie)

Ducheng Town

Jiangxi Gaoxin Taiyang Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

China Ceramic Tile Industrial Base

Jiangxi Ruixin Ceramics Co., Ltd.

Jiangxi Xinzhongying Ceramics Co., Ltd.

Jiangxi New Century Industrial Park

Jiangxi Taiyang Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

China Ceramic Tile Industrial Base

Jiangxi Hengdali Ceramics Co., Ltd.

Jiangxi Jinkairui Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Weichen Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Ouya Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

China Ceramic Tile Industrial Base

Jiangxi Fuligao Ceramics Co., Ltd.

Jiangxi Pujing Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Location

Jiangxi New Pearl Building Materials Co., Ltd.

Company

Ceramic tile companies in Jiangxi

3 polished tile lines: 40,000m2/d

2 polished tile lines: 31,000m2/d

1 interior wall tile line: 40,000m2/d; 1 polished tile line: 15,000m2/d; 1 fully polished glazed tile line: 15,000m2/d

4 polished tile lines: 72,000m2/d

2 polished tile lines: 26,000m2/d

2 interior wall tile lines: 50,000m2/d; 3 polished tile lines: 64,000m2/d

3 exterior wall tile lines: 45,000m2/d; 1 small floor tile line: 17,000m2/d

5 polished tile lines: 100,000m2/d

3 interior wall tile lines: 75,000m2/d

4 exterior wall tile lines: 60,000m2/d

2 polished tile lines: 26,000m2/d

1 exterior wall tile line: 5,000m2/d; 1 wood tile line: 2,500m2/d

3 rustic tile lines: 39,000m2/d

2 rustic tile lines: 10,000m2/d; 1 exterior wall tile line: 10,000m2/d; 1 small floor tile line: 10,000m2/d

3 exterior wall tile lines: 30,000m2/d; 1 rustic tile line: 10,000m2/d; 1 fully polished glazed tile line: 8,000m2/d

1 interior wall tile line: 25,000m2/d; 1 fully polished glazed tile line: 9,300m2/d

5 polished tile lines: 60,000m2/d; 2 interior wall tile lines: 46,000m2/d; 1 fully polished glazed tile line: 10,000m2/d

2 interior wall tile lines: 45,000m2/d

4 fully polished glazed tile lines: 40,000m2/d

5 fully polished glazed tile lines: 45,000m2/d; 2 interior wall tile lines: 46,000m2/d

Tile line & capacity

40,000m2/d

31,000m2/d

70,000m2/d

72,000m2/d

26,000m2/d

114,000m2/d

62,000m2/d

100,000m2/d

75,000m2/d

60,000m2/d

26,000m2/d

7,500m2/d

39,000m2/d

30,000m2/d

48,000m2/d

34,300m2/d

116,000m2/d

45,000m2/d

40,000m2/d

91,000m2/d

Daily output

7

10

2

12

5

1

1

2

6

5

4

5

1

11

Number of inkjet printer

Jiangxi, near area, export

Jiangxi & near area

Jiangxi, Hunan, Hubei, export, SW

Jiangxi, Hunan, Hubei, Anhui Hebei, SW, NW

Jiangxi, Hunan, Hubei

Jiangxi, Hunan, Hubei, SW, Anhui, Fujian, NW

Jiangxi, Hunan, Hubei, SW, Anhui, Fujian, NW

Nationwide

Jiangxi, Hunan, Hubei, Jiangsu, Zhejiang

Jiangxi, Hunan, Hubei, Fujian, Anhui, SW, NW

Jiangxi, Hunan

Nationwide

Nationwide

Nationwide

Jiangxi, Hunan, Hubei, Fujian, Anhui, SW, NW

Nationwide

Nationwide

Jiangxi, Hunan, Hubei, Anhui

Nationwide

Nationwide

Main Market

2004

2008

2006

2009

2005

2009

2007

2009

2009

2010

2008

1995

2009

2006

2008

2010

2008

2007

2007

2007

Year established

Analysis: Jiangxi

www.asianceramics.com

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62

asian ceramics

october 2015 2 exterior wall tile lines: 40,000m2/d 3 exterior wall tile lines: 45,000m2/d

China Ceramic Tile Industrial Base

China Ceramic Tile Industrial Base

Jiangxi Changcheng Ceram- China Ceramic Tile Industrial Base ics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Hongxin Ceramics Co., Ltd.

Jiangxi Ruifuxiang Ceramics China Ceramic Tile Industrial Base Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Renpai Ceramics Co., Ltd.

Jiangxi Huanbao Ceramics Co., Ltd.

Jiangxi Xinding Ceramics Co., Ltd.

Jiangxi Jintaiyuan Ceramics China Ceramic Tile Industrial Base Co., Ltd.

China Ceramic Tile Industrial Base

2 interior wall tile lines: 44,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Orient Pricess Ceramics Co., Ltd.

Jiangxi Dingguan Ceramics Co., Ltd.

2 interior wall tile lines: 40,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Sanxing Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

2 interior wall tile lines: 45,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Kangerju Ceramics Co., Ltd.

Jiangxi Jingtao Ceramics Co., Ltd.

2 interior wall tile lines: 45,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Zhongpeng Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

1 rustic tile lines: 20,000m2/d; 1 fully polished glazed tile line: 22,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Rongwei Ceramics Co., Ltd.

Jiangxi Hexie Ceramics Co., Ltd.

2 polished tile lines: 44,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Ruixue Ceramics Co., Ltd.

1 polished tile line: 23,000m2/d

2 rustic tile lines: 36,000m2/d

2 polished tile lines: 29,000m2/d

3 interior wall tile lines: 38,000m2/d

1 interior wall tile line: 20,000m2/d; 1 small floor tile line: 13,000m2/d

2 crystal tile lines: 20,000m2/d

2 small floor tile lines: 35,000m2/d

2 polished tile lines: 44,000m2/d

4 polished tile lines: 81,000m2/d

China Ceramic Tile Industrial Base

2 rustic tile lines: 23,000m2/d; 1 fully polished glazed tile line: 7,000m2/d

3 exterior wall tile lines: 48,000m2/d; 2 rustic tile lines: 25,000m2/d

Jiangxi Huashuo Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Xinjingxiang Ceramics Co., Ltd.

2 interior wall tile lines: 35,000m2/d

China Ceramic Tile Industrial Base

Gao'an

Jiangxi Ruipeng Ceramics Co., Ltd.

2 polished tile lines: 35,000m2/d

3 exterior wall tile lines: 27,000m2/d

1 rustic tile line: 8,000m2/d; 1 small floor tile line: 17,000m2/d

Jiangxi Jingcheng Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Henghui Ceramics Co., Ltd.

Jiangxi Jingangshi Ceramics Xinjie Town Co., Ltd. (Xinjie)

Jiangxi Jingangshi Ceramics China Ceramic Tile Industrial Base Co., Ltd.

23,000m2/d

36,000m2/d

29,000m2/d

45,000m2/d

40,000m2/d

44,000m2/d

40,000m2/d

45,000m2/d

45,000m2/d

38,000m2/d

33,000m2/d

20,000m2/d

35,000m2/d

42,000m2/d

44,000m2/d

44,000m2/d

81,000m2/d

30,000m2/d

73,000m2/d

35,000m2/d

35,000m2/d

27,000m2/d

25,000m2/d

2

1

8

8

8

8

5

5

2

2

3

2

3

1

Jiangxi, Hunan

Jiangxi, Hunan

Jiangxi, Hunan, Hubei, SW

Jiangxi, Hunan, SW, NW, Guangdong

Jiangxi, Hunan, Hubei

Jiangxi, Hunan, Hubei, Zhejiang

Jiangxi, Hunan, Hubei, Zhejiang

Jiangxi, Hunan, Hubei, Zhejiang

Hunan, Hubei, Jiangxi, Zhejiang

Jiangxi , near area

Jiangxi , near area

Jiangxi, Hunan

Jiangxi, Hunan, Hubei, SW, NW

Jiangxi , near area

Jiangxi, Hunan, Hubei, Anhui

Jiangxi, Hunan, Hubei, Anhui, Hebei

Nationwide

Jiangxi, export

Jiangxi, Hunan, Hubei, SW, export

Jiangxi, Hunan, Hubei

Jiangxi, Hunan, Hubei

Jiangxi, Hunan, Hubei

Jiangxi, Hunan, Hubei, Anhui

2011

2011

2010

2011

2007

2010

2009

2007

2009

2007

2007

2007

2010

2010

2009

2010

2010

2007

2008

2003

2009

2002

2008

Analysis: Jiangxi

www.asianceramics.com

64

asian ceramics

october 2015

Jiangxi Dongyang Ceramics Taiyang Town Co., Ltd.

Taiyang Town

Jiangxi Xinyang Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Jiayu Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

China Ceramic Tile Industrial Base

Jiangxi Lvdao Sci & Tech Co., Ltd.

Jiangxi Ganhong Ceramics Co., Ltd.

1 water permeable exteriotr wall tile line: 3,000m2/d

China Ceramic Tile Industrial Base

Jiangxi Icoto Ryowa Ceramics Co., Ltd.

1 western roof tile line: 200,000pcs/d; 1 small floor tile line: 18,000m2/d

3 western roof tile lines: 510,000pcs/d

2 western roof tile lines: 200,000pcs/d

3 big western roof tile lines: 600,000pcs/d; 1 small western roof tile line: 340,000pcs/d; 1 western roof tile accessary line: 50,000pcs/d

1 water permeable tile line: 6,000m2/d

1 wall skirting tile line: 8,000m2/d

Jiangxi New Century Industrial Park

Jiangxi Aolisi Ceramics Co., Ltd.

1 wall skirting tile line: 6,000m2/d

1 interior wall tile line: 10,000m2/d; 1 crystal tile line: 11,000m2/d

Jiangxi New Century Industrial Park

Jiangxi Xinsheng Ceramics Co., Ltd.

1 crystal tile line: 12,600m2/d; 1 rustic tile line: 15,000m2/d

Jiangxi New Century Industrial Park

Jiangxi New Century Industrial Park

Jiangxi Jinsheng Ceramics Co., Ltd.

1 small floor tile line: 13,000m2/d

Jiangxi Shengren Ceramics Co., Ltd.

Gao’an

Jiangxi Ruibao Ceramics Co., Ltd.

2 crystal tile lines: 30,000m2/d

1 fully polished glazed tile line: 9,000m2/d; 1 interior wall tile line: 15,000m2/d

Gao’an

Jiangxi Jinisi Ceramics Co., Ltd.

2 fully polished glazed tile lines: 10,000m2/d

2 rustic tile lines: 39,000m2/d; 1 fully polished glazed tile line: 15,000m2/d

Jiangxi Meierkang Ceramics Jiangxi New Century Industrial Park Co., Ltd.

Gao’an

Jiangxi Hongmei Ceramics Co., Ltd.

Jiangxi Jinsanjiao Ceramics Yangxu Town Co., Ltd.

5 polished tile lines: 70,000m2/d

Shinao Town

Jiangxi Xingaofeng Ceramics Co., Ltd.

2 rustic tile lines: 38,000m2/d

2 polished tile lines: 44,000m2/d

3 exterior wall tile lines: 50,000m2/d

Tiannan Industrial Park

Jiangxi Zhongrui Ceramics Co., Ltd.

1 rustic tile line: 23,000m2/d; 1 fully polished glazed tile line: 13,000m2/d

Lanfang Town

Tiannan Industrial Park

Jiangxi Mingrui Ceramics Co., Ltd.

1 western roof tile line: 180,000pcs/d; 1 interior wall tile line: 35,000m2/d

Jiangx Guangxia Ceramics Co., Ltd.

Jianshan Town Industrial Park

Jiangxi Guofeng Ceramics Co., Ltd.

1 small floor tile line: 20,000m2/d; 2 rustic tile lines: 45,000m2/d

Tiannan Industrial Park

Jianshan Town Industrial Park

Jiangxi Jialemei Ceramics Co., Ltd.

1 polished tile line: 23,000m2/d

Jiangxi Jinli Ceramics Co., Ltd.

China Ceramic Tile Industrial Base

Jiangxi Zhongyang Ceramics Co., Ltd.

200,000pcs/d; 18,000m2/d

510,000pcs/d

200,000pcs/d

990,000pcs/d

6,000m2/d

3,000m2/d

8,000m2/d

20,000m2/d

24,000m2/d

6,000m2/d

27,600m2/d

13,000m2/d

30,000m2/d

10,000m2/d

54,000m2/d

70,000m2/d

50,000m2/d

38,000m2/d

44,000m2/d

36,000m2/d

180,000pcs/d; 35,000m2/d

65,000m2/d

23,000m2/d

2

2

2

4

2

2

1

5

2 (ordered)

Jiangxi, Hunan, SW

Jiangxi, Hunan, Hubei, Jiangsu, Zhejiang

Jiangxi, Hunan, Hubei, SW

Jiangxi, Hunan, Hubei, SW, NW

Nationwide, export

Export

Jiangxi

Jiangxi, Hunan, Jiangsu, Zhejiang

Jiangxi, Hunan, Hubei, Jiangsu, Zhejiang

Jiangxi, Hunan

Jiangxi, Hunan

Jiangxi, Hunan

Jiangxi, Hunan

Jiangxi, Hunan, Hubei, SW, Anhui, NW

Jiangxi, near area

Jiangxi, Hunan, Hubei, Jiangsu, Zhejiang

Jiangxi, near area

Jiangxi, Hunan, Hubei, NW

Jiangxi, near area

Jiangxi, Hunan, Hubei, SW

Jiangxi, Hunan

Jiangxi, Hunan

2010

2009

2007

2009

2012

2009

2007

2003

2008

2001

2002

1994

1999

1992

2010

1996

2009

2009

2009

2009

2013

2010

2011

Analysis: Jiangxi

www.asianceramics.com

25 th International exhibition of technology and supplies for the ceramic and brick industries

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26 -30 SEPTEMBER 2016 RIMINI - ITALY th

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66

asian ceramics

october 2015 2 western roof tile lines: 380,000pcs/d; 1 small floor tile line: 20,000m2/d

Huangjindui Industrial Park

Huangjindui Industrial Park

Huangjindui Industrial Park

Huangjindui Industrial Park

Huangjindui Industrial Park

Huangjindui Industrial Park

Huangjindui Industrial Park

Huangjindui Industrial Park

Xujiadu

Luzhou Town

Lianggang Industrial Park

Lianggang Industrial Park

Lianggang Industrial Park

Lianggang Industrial Park

Lianggang Industrial Park

Lianggang Industrial Park

Jiangxi Ruizhou Ceramics Co., Ltd.

Jiangxi Tianrui Ceramics Co., Ltd.

Jiangxi Hefa Ceramics Co., Ltd.

Jiangxi Guoyuan Ceramics Co., Ltd.

Jiangxi Jinweiguan Building Materials Co., Ltd.

Jiangxi Baoqing Ceramics Co., Ltd.

Jiangxi Guanyi Ceramics Co., Ltd.

Jiangxi Jinniu Ceramics Co., Ltd.

Jiangxi Jinliyuan Ceramics Co., Ltd.

Jiangxi Ruipai Ceramics Co., Ltd.

Jiangxi Jinfo Ceramics Co., Ltd.

Jiangxi Ouerma Ceramics Co., Ltd.

Jiangxi Ruiming Ceramics Co., Ltd.

Jiangxi Jinglong Ceramics Co., Ltd.

Jiangxi Jinyang Ceramics Co., Ltd.

Jiangxi Kaiyang Ceramics Co., Ltd.

Jiangxi Lingxian Ceramics Co., Ltd.

Lianggang Industrial Park

Jiangxi Shiji Xingui Ceramics Lianggang Industrial Park Co., Ltd.

2 rustic tile lines: 30,000m2/d

Fengcheng Premium Ceramic Industrial Park

Jiangxi Hemei Ceramics Co., Ltd.

2 polished tile lines: 38,000m2/d

1 rustic tile line: 18,000m2/d; 1 small floor tile line: 22,000m2/d

2 rustic tile lines: 43,000m2/d

3 western roof tile lines: 560,000pcs/d

3 exterior wall tile lines: 60,000m2/d

2 polished tile lines: 40,000m2/d; 1 fully polished glazed tile line: 10,000m2/d

2 polished tile lines: 28,000m2/d

4 polished tile lines: 50,000m2/d; 2 western roof tile lines: 360,000pcs/d

2 wall skirting tile lines: 50,000m2/d

3 polished tile lines: 40,000m2/d

1 rustic tile line: 21,000m2/d; 3 fully polished glazed tile lines: 23,000m2/d; 1 microcrystalline tile line; 5,000m2/d

3 exterior wall tile lines: 60,000m2/d

3 interior wall tile lines: 69,000m3/d

2 small floor tile lines: 32,000m2/d; 1 rustic tile line: 18,000m2/d

2 rustic tile lines: 25,000m3/d; 1 fully polished glazed tile line: 10,000m2/d

4 exterior wall tile lines: 60,000m2/d; 2 small floor tile lines: 45,000m2/d

5 fully polished glazed tile line: 45,000m2/d; 4 interior wall tile lines: 60,000m2/d

4 fully polished glazed tile line: 37,000m2/d

Fengcheng Premium Ceramic Industrial Park

Jiangxi Dongpeng Ceramics Co., Ltd.

5 polished tile lines: 45,000m2/d; 2 interior wall tile lines: 24,000m2/d; 1 fully polished glazed tile line: 8,000m2/d

Fengcheng Premium Ceramic Industrial Park

3 western roof tile lines: 320,000pcs/d

Jiangxi CIMIC Ceramics Co., Ltd.

Jiangxi Xinhongmei Ceram- Gaoâ&#x20AC;&#x2122;an ics Co., Ltd.

38,000m2/d

40,000m2/d

43,000m2/d

560,000pcs/d

60,000m2/d

50,000m2/d

28,000m2/d

50,000m2/d; 360,000pcs/d

50,000m2/d

40,000m2/d

49,000m2/d

60,000m2/d

380,000pcs/d; 20,000m2/d

30,000m2/d

69,000m2/d

50,000m2/d

35,000m2/d

105,000m2/d

105,000m2/d

37,000 m2/d

77,000m2/d

320,000pcs/d

3

2

2

1

4

2

2

1

10

2

3

4

35

4

4

Jiangxi, near area

Jiangxi, near area, Jiangsu, Zhejiang

Jiangxi, near area

Jiangxi, near area, Jiangsu, Zhejiang

Jiangxi, near area, Jiangsu, Zhejiang

Jiangxi, near area, SW, NW

Jiangxi, near area

Jiangxi, near area

Jiangxi, near area

Jiangxi, near area

Jiangxi, near area, SW, NW

Jiangxi, near area, SW

Jiangxi, near area, SW

Jiangxi, near area

Jiangxi, near area

Jiangxi, near area, Jiangsu, Zhejiang

Jiangxi, near area, SW, NW

Jiangxi, near area, SW

Domestic, export

Domestic, export

Domestic, export

Jiangxi, Hunan, Jiangsu, Zhejiang

2010

2010

2011

2009

2009

2009

2008

2001

2010

2011

2003

2010

2010

2009

2009

2008

2009

2008

2007

2007

2006

2002

Analysis: Jiangxi

www.asianceramics.com

68

asian ceramics

october 2015

Xiangdong Ceramic Industrial Base

Xiangdong Ceramic Industrial Base

Jiangxi Guowei Ceramics Co., Ltd.

Jiangxi Baina Ceramics Co., Ltd.

Sanlong Ceramic Industrial Park

Sanlong Ceramic Industrial Park

Sanlong Ceramic Industrial Park

Sanlong Ceramic Industrial Park

Jingdezhn Oceano Ceramics Co., Ltd.

Jingdezhen Hansof Industrial Ceramics Co., Ltd.

Jiangxi Hanjingda Ceramics Co., Ltd.

Jingdezhen Icoto Ryowa Ceramics Co., Ltd.

Lvmeng

Sanlong Ceramic Industrial Park

Jingdezhen Kito Ceramics Co., Ltd.

Jiangxi Kadike Ceramics Co., Ltd.

Sanlong Ceramic Industrial Park

Jiangxi Ryowa Ceramics Co., Ltd.

Jingdezhen Ceramic Industrial Park

Sanlong Ceramic Industrial Park

Jiangxi Leter Ceramics Co., Ltd.

Jiangxi Shengtai Ceramics Co., Ltd.

Gaokeng Industrial Park

Jiangxi Dacheng Ceramics Co., Ltd.

Dingjiazhou

Gaokeng Industrial Park

Jiangxi Lvbao Ceramics Co., Ltd.

Jiangxi Mengtexiang Ceramics Co., Ltd.

Xiangdong Ceramic Industrial Base

Jiangxi Oumeijia Ceramics Co., Ltd.

Jiangxi Xingdaxing Ceramics Xiangdong Ceramic Industrial Base Co., Ltd.

Xiangdong Ceramic Industrial Base

Jiangxi Z & D Ceramics Co., Ltd.

Sanxing Industrial Park

Jiangxi Black & White Ceramics Co., Ltd.

Sanxing Industrial Park

Lianggang Industrial Park

Jiangxi Aobama Ceramics Co., Ltd.

Wanzai Sanjin Ceramics Co., Ltd.

1 small floor tile line: 22,000m2/d

Lianggang Industrial Park

Jiangxi Huangming Ceramics Co., Ltd.

3 western roof tile lines: 300,000pcs/d

2 western roof tile lines: 360,000pcs/d

1 fully polished glazed tile line: 6,000m2/d; 1 western roof tile line: 90,000pcs/d

1 water permeable exteriotr wall tile line: 3,000m2/d

1 interior wall tile line: 20,000m2/d

1 western roof tile line: 200,000pcs/d

2 interior wall tile lines: 32,000m2/d; 1 rustic tile line: 8,000m2/d

3 rustic tile lines: 30,000m2/d

2 interior wall tile lines: 36,000m2/d; 1 rustic tile line: 20,000m2/d;

1 interior wall tile line: 16,000m2/d; 1 rustic tile line: 13,000m2/d

1 fully polished glazed tile line: 10,000m2/d; 1 western roof tile line: 150,000pcs/d

1 interior wall tile line: 15,000m2/d

1 rustic tile line: 10,000m2/d

3 western roof tile lines: 400,000pcs/d

2 polished tile lines: 30,000m2/d

1 interior wall tile line: 35,000m2/d

2 interior wall tile lines: 50,000m2/d; 3 polished tile lines: 41,000m2/d; 1 fully polished glazed tile line: 8,000m2/d

1 small floor tile line: 15,000m2/d

1 fully polished glazed tile line: 6,000m2/d

2 western roof tile lines: 400,000pcs/d

Lianggang Industrial Park

Jiangxi Guanli Ceramics Co., Ltd. (2nd phase)

1 fully polished glazed tile line: 10,000m2/d

Lianggang Industrial Park

Jiangxi Qingyuan Ceramics Co., Ltd.

300,000pcs/d

360,000pcs/d

6,000m2/d; 90,000pcs/d

3,000m2/d

20,000m2/d

200,000pcs/d

40,000m2/d

30,000m2/d

56,000m2/d

29,000m2/d

10,000m2/d; 150,000pcs/d

15,000m2/d

10,000m2/d

400,000pcs/d

30,000m2/d

35,000m2/d

99,000m2/d

15,000m2/d

6,000m2/d

22,000m2/d

400,000pcs/d

10,000m2/d

1

2

7

3

4

3

1

1

5

8

6 (ordered)

1

Jiangxi, near area

Jiangxi, near area

Jiangxi, near area

Export

Jiangxi, near area

Jiangxi, near area

Domestic

Domestic, export

Domestic, export

Jiangxi, near area

Jiangxi, Hunan

Jiangxi, Hunan

Jiangxi

Jiangxi, Hunan, SW

Jiangxi, Hunan

Jiangxi, Hunan

Nationwide

Jiangxi, Hunan

Jiangxi, near area

Jiangxi, near area, Jiangsu, Zhejiang

Jiangxi, near area

2007

2008

2002

2009

2010

2010

2008

2008

2008

2009

2007

2006

2010

2006

2010

2012

2008

2000

2011

2014

2013

2011

2009

Analysis: Jiangxi

www.asianceramics.com

www.asianceramics.com

Yuanshangang Industrial Park

Linchuan

Lushan Yanjiang Industrial Park

Yunshan Development Zone

Xingzi Industrial Park

Jiangxi Hairun Ceramics Co., Ltd.

Jiangxi Hongrui Ceramics Co., Ltd.

Jiujiang Nabel Ceramics Co., Ltd.

Jiangxi Annadu Ceramics Co., Ltd.

Jiangxi Weixin Ceramics Co., Ltd.

october 2015

asian ceramics

Nachang Economic Development Zone

Jiangxi Nanchang Jinisi Ceramics Co., Ltd.

Nanchang Jindadi Ceramics Lushan Zhongdadao, Nanchang Co., Ltd.

Xunwu Industrial Park

Jiangxi Shiwan Huanqiu Ceramics Co., Ltd.

1 crystal tile line: 8,000m2/d

3 rustic tile lines: 42,000m2/d

1 interior wall tile line: 20,000m2/d

Jiangxi Gaoqi Ceramics Co., Ltd.

Chengxi Industrial Park

1 exterior wall tile line: 12,000m2/d

2 polished tile lines: 42,000m2/d

1 pottery panel line: 2,000m2/d

1 exterior wall tile line: 8,000m2/d

2 polished tile lines: 20,000m2/d; 1 microcrystalline tile line: 4,500m2/d; 3 fully polished glazed tile lines: 24,000m2/d; 1 endurable tile line: 5,000m2/d

2 rustic tile lines: 30,000m2/d

2 rustic tile lines: 30,000m2/d

Foshan Henghuayu Ceramic Gucheng Town tile Co., Ltd.

Taiyangsheng Industrial Park

Yuanshangang Industrial Park

Jiangxi Asia Ceramics Co., Ltd.

Jiangxi Xinzhongying Ceramics Co., Ltd.

1 exterior wall tile line: 20,000m2/d

Yuanshangang Industrial Park

Jiangxi Dongtai Ceramics Co., Ltd. 1 polished tile line: 22,000m2/d

2 interior wall tile lines: 65,000m2/d

Jiangxi Xinmingtai Ceramics Yuanshangang Industrial Park Co., Ltd.

2 polished tile lines: 36,000m2/d

8,000m2/d

42,000m2/d

20,000m2/d

12,000m2/d

42,000m2/d

2,000m2/d

8,000m2/d

53,500m2/d

30,000m2/d

30,000m2/d

22,000m2/d

20,000m2/d

65,000m2/d

36,000m2/d 9

2

1

4

1

Jiangxi

Jiangxi, Hunan

Jiangxi, Hunan

Jiangxi, Hunan, Guangdong

Jiangxi, Hunan, Jiangsu, Zhejiang

Domestic, export

Jiangxi, Hunan

Nationwide, export

Domestic, export

Domestic

Jiangxi, near area

Jiangxi, near area

Small cities

Domestic, export

1993

2003

2009

2009

2010

2011

2011

2010

2009

2010

2008

2013

2009

2010

2009

Yuanshangang Industrial Park

Jiangxi, near area, export

Jiangxi Jiajia Ceramics Co., Ltd.

40,000m2/d

2001

2011

2 interior wall tile lines: 40,000m2/d

Jiangxi, near area, Jiangsu, Zhejiang

2007

Xizhen Town Industrial Park

8,000m2/d

Jiangxi, near area, Jiangsu, Zhejiang

2006

2007

2001

Jiangxi Xuantao Ceramics Co., Ltd.

1 interior wall tile line: 8,000m2/d

Nanshancun, Yongfeng Town

Guangfeng Gengen Ceramics Co., Ltd.

29,000m2/d

Jiangxi, near area

Jiangxi, near area

Jiangxi, near area

2014

1 fully polished glazed tile line: 11,000m2/d; 1 small floor tile line: 18,000m2/d

Chengxi Development Zone

Jingdezhen Huatao Ceramics Co., Ltd.

33,000m2/d

380,000pcs/d

100,000pcs/d

20,000m2/d

Jiangxi Best Ceramics Co., Ltd.

2 interior wall tile lines: 33,000m2/d

Shangrao Industrial Park

Jiangxi Best Ceramics Co., Ltd.

1 hand made roof tile line: 100,000pcs/d 2 western roof tile lines: 380,000pcs/d

Taqian Industrial Zone

Jingdezhen Jinshengkai Ceramics Co., Ltd.

2 rustic tile lines: 20,000m2/d

Jingdezhen Jinxiang Ceram- Jineshan Industrial Park ic Tiles Co., Ltd.

Lvmeng

Jiangxi Pengfei Ceramics Co., Ltd.

Analysis: Jiangxi

69

Advertiser feature

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Mechanical Properties

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Viscosity Improvement

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Compositions

Additive Cost Indexed

% Savings

Control 0.2% STPP + 0.35% Acrylic Binder

100

-

0.2% STPP + 0.3% BioKeram 215

89

11%

0.2% STPP + 0.25% BioKeram 215

84

16%

0.3% BioKeram 215 + 0.1% STPP + 0.1 % NaSil

67

33%

0.3% BioKeram 215 + 0.05% STPP + 0.15 % NaSil

55

45%

0.3% BioKeram 215 + 0.03% STPP + 0.08 % NaSil

45

55%

*Columns in the graph represent days after preparation

Potential cost optimization when using BioKeram is obvious: More than 10% savings if Acrylic Binder is replaced by BioKeram 215.

More than 50% savings if STPP dosage is optimized with BioKeram 215 and Sodium Silicate.

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Borregaard South East Asia Pte Ltd Singapore Tel: +65 67780008

www.asianceramics.com

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Talking Shop

Talking Shop

Grespania: driving up sizes In an interview undertaken by El Periódico Mediterráneo, Luis Hernández Sanchis, chairman and managing director of Grespania, SA discusses developments at the company.

EM: What kind of production does Grespania currently generate? Can you describe it in terms of quantities (annual production) and type?

Luis Hernández Sanchis: Grespania has a widely diversified production that meets all of the needs of the ceramic market. We manufacture tiles for covering walls in white paste in a wide range of sizes, colours and designs, as well as porcelain stoneware flooring. We also produce technical porcelain (full body) with different finishes and surfaces and thicknesses suitable for any type of flooring, demanding from a technical point of view, such as commercial areas, transport infrastructures and public areas in general. Our range also includes mosaics and bathroom furniture.

Our Product Engineering Department lends any type of service concerning the use of our products and, in particular, technical applications such as the installation of ventilated façades and raised floors, and also provides tiles with a surface treatment which makes them self-cleaning and bactericidal.

EM: What were your objectives when you started marketing Laminam, and what were the results?

LHS: Three years ago we realised the prospects that the new manufacturing technology of large tiles and reduced thickness opened for the ceramic market, and we decided to include these products in our market, so we established an agreement with Laminam SpA to manufacture our designs.

Since then, the road travelled has not been easy because in the ceramic construction and distribution this product was hardly known, so we had to carry out an extensive work for its promotion and dissemination. Apart from the use of appropriate elements of promotion, we developed numerous courses with architects, installers of tiles and professionals in general, to spread the decorative qualities, applications, handling and installation of this type of product.

The result was satisfactory and, although there is still much to do, we believe it is time to start manufacturing it in our plants».

EM: How did you come to the decision to adopt the System Lamina technology to directly produce the large slabs?

LHS: We believe that the System technology, innovative and provided with a high degree of automation, is highly efficient and productive for the manufacture of this type of products and, in particular, for very thin ones (less than 3.5 mm), which we consider very important.

On the other hand, it was also a logical conclusion of the marketing stage that we have developed so far, since the System technology is that used in the manufacture of the products we are selling.

EM: Your choice is distinguished by an exhaustive search of flexibility in production. Which other formats will you produce with GEA? LHS: Actually, the new technology gives considerable flexibility to the manufacturing process and, although our production will be based on the sizes 100x300 cm and 120x360 cm, we also consider

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Luis Hernandez Sanchis

the production of other formats derived from these by subdivision.

In addition, it will allow us to manufacture different thicknesses, such as the 3 mm, 6 mm and even the 10 mm.

EM: To which geographic markets and segments is the new production addressed?

LHS: Grespania, S.A. exports over 70% of its production, with a high distribution of sales among numerous markets. The new product marketed under the brand Coverlam is aimed at a wide range of countries, although our first impression is that the best reception is from European markets, including Spain, North American and some South-East Asia.

EM: In you one senses a vocation for innovation and quality; what is your policy with respect to environmental protection and, now, energy saving?

LHS: In Grespania, environmental protection has been a priority from the beginning. Back in 1986 we built our second production centre for the manufacture of coating tiles characterised by zero residues. It was an integral plant which included the grinding and fragmentation of raw materials and that recycled 100% of industrial waste, without discharging anything to the outside. Many of the recycling concepts of this plant were subsequently adopted by other companies in the Spanish ceramic sector.

As for energy saving, our plants are installed with co-generation with significant self-consumption of electrical energy generated by us. In addition, we have been pioneers and unique in industrial water purification by reverse osmosis technology and, currently, in our industrial plants we have a high degree of waste purification and recycling. Our company is certified according to ISO14001 and our products are protected by the Environmental Product Declaration (EPD).

www.asianceramics.com

BURTON is now Refratechnik.

The BURTON® brand is here to stay.

BURTON® H-cassette

Thanks to investments in research and development, as well as in the latest production technology, we will continue to set the standards in refractory systems. We supply best quality in order to guarantee you a trouble-free production.

Our strength lies in supplying customised solutions for virtually any application. We also offer state-of-the-art systems for fully automated plants with a strong focus on energy efficiency.

Refratechnik stands for varied product portfolio and a high production capacity.

For our customers, the integration of BURTON into the international Refratechnik Group provides a strong basis for a sustainable and reliable partnership.

With more than 60 years’ experience in the refractory industry, our in-depth expertise boosts our reputation as a supplier of durable and high-performance products that are constantly developed for the future.

History At the traditional location Melle/Buer a brickyard was initially set up in 1887.

After the Second World War, this was converted to the production of refractory systems for the ceramics industry. The refractory products of the company BURTON quickly conquered the world market. Today more than 3500 customers worldwide put their trust in our expertise.

In 2013 BURTON was incorporated into the Refratechnik Group. The Refratechnik Group is in a very strong worldwide position and serves global markets such as cement, steel, aluminium and ceramics industry with advanced refractory concepts and systems.

Learn more: www.burton-is-now-refratechnik.com

Refratechnik Ceramics develops innovative refractory systems that are closely oriented to the technical and economic requirements of the ceramics industry.

In order to provide individual solutions, we develop new formulas, determine maximum operating temperatures, test parameters such cold pressure and cold bending strength, refractoriness, hot bending strength, reversible thermal expansion and the thermal conductivity of the refractory products.

When it comes to the redesign of systems, the intensive knowledge of the operating conditions and the objectives of the kiln operators are the key to a tailor-made offer.

Results in Research & Development at Refratechnik Ceramics in Melle:

Products with highest energy efficiency The site Melle has completely modernised its centre for research and development and brought it to the current state of the art.

Here, high-performance systems for the ceramics industry are developed and tested.

Individual solutions in the material characteristics originate here.

Reduced energy consumption and lower CO2 emissions are central topics in the ceramic industry. The selection of the most suitable tunnel kiln car systems enables energy efficiency to be improved significantly. This not only reduces fuel costs, but also subsequential costs such as the purchase of emission trading certificates.

You can reduce your energy costs by corresponding designs and by material selection. Such highly energy saving products are our innovation REFRATHERM® Eco as well as our BURCOLIGHT® material.

REFRATHERM® Eco: High-end insulation for the tunnel kiln car Biogenic silica (SiO2) is produced through the burning of biomass, the ashes of which mostly contain SiO2. REFRATHERM® Eco is thus based on a naturally renewable resource.

Production The term biogenic silica shows the origin of the product. In modern biomass power plants, subject to quality controls, these raw materials are used as an energy source because they burn CO2 neutrally.

That is, when burned, no more CO2 is released than the plant had previously absorbed from the atmosphere. An aspect which is becoming increasingly important for the raw materials of the future.

Characteristics Biogenic silica is chemically very pure and consists of 94-96% SiO2. The main phases after a special burning process are amorphous silica, tridymite and cristobalite.

Thermal conductivity in W/m·K

Innovation

0.6 0.5 0.4 0.3 0.2 0.1 0

250

REFRATHERM® Eco

600 800 Temperature °C

1000

BUROLIT® 230

BUROLIT® G

Comparison of insulation effect This causes the high melting point of approx.

1650 °C. In production, the volatiles burn but the microporous structure of the SiO2 is maintained.

This structure results in both the extremely low thermal conductivity as well as the low bulk weight.

REFRATHERM® Eco based on microporous silica shows a unique combination of well-defined characteristics such as high insulation, good flow properties, set grain structure. This allows for very low installation heights and thus more usable firing capacity for the brick manufacturer.

The installation time of the insulating layer in the tunnel kiln car can be reduced by about 50% depending on the flow properties set.

Tunnel kiln car with REFRATHERM® Eco insulation

Typical characteristics • Sintering point: 1550 °C • Melting point: 1650 °C • High microporosity and thus excellent insulation • Perfectly optimised flow properties • Low density • Extreme low thermal conductivity

BURCOLIGHT® – Energy saving by weight reduction Kiln car systems equipped with BURCOLIGHT® bricks achieve energy saving by means of weight reduction.

The less mass needs to be heated up, the more energy is saved.

When used for kiln cars, BURCOLIGHT® brick types with a bulk density of ~1.3 to 1.5 kg/dm3 achieve energy savings up to 30% compared with BURCOTOP® brick types (depending on kiln car type and tunnel kiln temperature).

Thanks to these outstanding properties, the total energy savings of the kiln are between 8 and 12%.

BURCOLIGHT® features low mass, excellent thermal shock resistance and low thermal conductivity.

Refratechnik Ceramcis GmbH Barkhausener Str. 55 - 49328 Melle - Germany - Phone +49 5427 81 0 - ceramics@refra.com - www.refra.com

Insight on

BRAZIL Unglazed ceramic tile exports (sq metres)

Unglazed ceramic tile imports (sq metres)

Glazed ceramic tile imports (sq metres)

Glazed ceramic tile exports (sq metres)

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asian ceramics

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www.asianceramics.com

Sanitaryware exports (no. items)

Sanitaryware imports (no. items)

Leading unglazed tile import sources (2014, sq metres)

Leading sanitaryware import sources (2014, no. items)

Leading glazed tile export destinations (2014, sq metres)

Roof tile exports (Kg)

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october 2015

asian ceramics

77

Hunter and the hunted

What happened?

Dear Blog, My previous visit to ASEAN Ceramics in 2013 was full of hope and optimism. There were things that I likes more so than other larger ceramic exhibitions...it felt more egalitarian as there we no huge dominating stands. There were a steady flow of international visitors and pertinently visitors that were decision makers rather than, and I don't want to sound sound elitist, people too much on vacation to really care or too junior in the organization to be able to make decisions.

As ASEAN Ceramics had been in hibernation for a few years it was great to have it back – marvellous to have a South East Asian show that was not dominated by massive Chinese suppliers or frankly speaking by masses of people who like to pick up colourful brochures and samples but rarely can deliver orders.

This, unfortunately, is the case at China Ceramics. Nor was the show too diluted because the show has to cover retail and DIY as we have seen before at Keramika, Indonesia.

ASEAN Ceramics was so good, even I, a somewhat sceptic about exhibitions and the need to exhibit was compelled to consider having a booth; as we did last time. Unfortunately family & business issues meant that could not happen. But I was looking forward to attend if only for two days. For the other advantage of the ASEAN show is that so many of the ceramics family choose to meet up in the evenings that there are great opportunities to discuss all manner of business and gossip in a VERY relaxed environment.

Unfortunately and too much dismay though ASEAN did not deliver as before – but I would suggest it was not the fault of organisers nor of exhibitors. The show had a few more big and international names which was great but the egalitarian size of the booths had more or less been kept which I prefer as it stops the China Ceramics habit of having massive strands that show very little but dominate a third of an exhibition hall. A lot of what was on show was of very good quality – not just local companies and associations but Endeka, Sibelco and Imerys – as well as the always classy Italian stands and agents booths which presented a very good cross section of imported materials and services.

But there were so few attendees there. This was disappointing given the effort actually put into making the show a success so why such a poor turnout?

The first consideration given the new prominence was the bombing at the Erawan Shrine, a popular tourist location in Bangkok city centre. It certainly seems to have scared the Hong Kong authorities into handing out a Red Travel advisory whilst China issued a Level 3 warning; whatever that means. There appeared to be few Chinese visitors though there were Chinese companies exhibiting. It seems somewhat unbelievable that such a relatively small but tragic crime in a tourist area should harm a ceramics trade show and given two other exhibitions in the same BITEC hall looked to be very well attended I'd be tempted to dismiss it. In fact one industry veteran from a multinational company with a significant logo pointed out that none of the visitors from Bangladesh, Sri Lanka or such had even mentioned the bombing. So we can pretty much dismiss terrorism.

The weather then? Hardly – people know what to expect and transport by taxi or Sky Train to the center of the city is very convenient, also the prices and options of hotels and entertainment is about as good as you can get in a major city.

The main reason may well be the near clash with Ceramitec which takes place October 20th to 23rd in Munich. Ceramitec is still possibly the premier show and as it is obviously far larger it also has a very dedicated and very international exhibitor and client list and more than covers materials and machinery. It seems most likely from discussions and review of the websites for each show this is the most likely reason.

It is a pity as there was also a comprehensive list of technical papers presented and briefings by the British Chamber of Commerce and others. The point being that there was little if anything wrong with the show apart from timing.

The problem for the regional shows is that there is only a finite amount of money for companies to spend on marketing and advertising. Many exhibitors know that exhibiting by itself is little more than a flag waving

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www.asianceramics.com

Hunter and the hunted

experience and trade shows have to be followed up with customer visits and that often means more spending. I think the more optimistic exhibitors would suggest that at best an exhibition might create say about 10% sales opportunities no matter how many leads are made. In the case of China Ceramics I'd suggest it is far less.

Exhibitions also compete with a lot of direct marketing and now social media and the multitude of B2B and B2C web sites that abound in various qualities. Virtual trade shows, companies that use their web sites in highly creative & interactive ways never-mind the attentions of agents and distributors doing their daily sales job (hopefully).

Earlier this year, writing about China Ceramics I expressed the view that smaller, niche exhibitions were the way to go for the ceramic industry in Asia and that the very big China Ceramics was of low quality certainly in terms of meaningful leads. So it was disappointing that the ASEAN show struggled for visitors.

Begging the question - do regional shows have a future?

The bigger shows can of course advertise how many visitors and exhibitors they have and quantity they say has a quality all of its own.

But looking at a web site that ranks the supposed Top 100 trade shows in the world - Ambiente makes it to number 30 in the Overall list and there isn't a dedicated ceramic show in the top 100. If we look at industrial shows only and Ceramitec makes it in at number 40. What's big for ceramics isn't especially big in the trade fair world.

Regional co-operation?

So maybe the regional shows need to find some way to cooperate with other industries or associations, organizations to bring in more visitors? This could be especially important given not only the investment made by exhibitors but as with the Thai show the importance to the national economy and development.

Quite a few of the companies exhibiting at ceramics shows appeal also to other industries and their products have more possible applications – could it be trying to make an alliance with connected industries is a way forward – other household products or related industries?

The problem then is the exhibition could lose focus and turn away the very customers and suppliers it is trying to attract. So that is Catch 22; damned if you do and damned if you don't. If the regional show then tried to move locations to keep the exhibition fresh then each nations trade and industry ministries would question what benefit the nations economy would gain given the expense and time needed to coordinate universities, associations and industries with the timing of the show. So again that option seems to further increase the complexity whilst increasing risk and giving little potential gain.

Organizing exhibitions therefore seems to be a herculean task to accomplish successfully. No matter how much time is put into organizing a show and coordinating everything from the web site to the logistics, the booking of the halls the inviting of guests the scheduling of meeting and conferences, having papers submitted, approved, liaising with the media and government departments ultimately the success of failure is counted upon 'Was it busy and who was exhibiting?' So at ASEAN this year it must have been galling for all concerned for so many to stay away.

I hope this doesn't discourage ASEAN Ceramics from continuing. South East Asia does need a good ceramics show and most of the exhibitors want allocation that isn't so big or anonymous that they are swamped by shear numbers. But only visitors supporting such shows will enable them to continue. If we only have the internet and China Ceramics the industry will be duller and less interesting and business contacts will be all the more fickle and fragile.

s t h g t h ou

pe s n't o h “ I i s d oe e t h ou ra g dis c AN m E o r S f A ics m g” a r e C nuin i t n co

Until next time, Your humble servant William Hunter

*The views expressed in this piece reflect those of the author, and not of the magazine or its staff

www.asianceramics.com

october 2015

asian ceramics

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