Ceramic World Review India 2016

R eview

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System Group

reveals consolidated year - end turnover of more than 440 million euros System Group expects to follow up the 20% rise in turnover of 2014 with further 15% growth in 2015 to reach a year-end figure of between 440 and 460 million euros. The goal for 2016 is 530 million euros. Announced by chairman Franco Stefani and CEO Luigi Panzetti during the year-end press conference, these results were achieved through the efforts of all divisions in the group, which consists of 35 companies with 1,730 employees in 25 countries, and constant investments in R&D (5% of annual turnover).

The System Ceramics owes much of its success to the excellent performance of the revolutionary Lamina process in conjunction with the GEA press for the production of large porcelain panels, as well as the Creadigit digital printing system which has established itself as an industry standard the world over. A total of 600 machines have been sold in the 30 months since the printer’s launch, including 80 in China in 2015 alone. “This shows that process and service quality are key factors despite the approximately 40% higher prices compared to Chinese-made printers,” commented Franco Stefani, who also announced that a major new machine in this segment will be unveiled in 2016.System Group has also reported excellent results in the field of ceramic industry automation, a sector in which the Group is a world leader.

The most dynamic markets in 2015 were Italy, Brazil, Spain, Mexico, China and Egypt. The support centre in Tennessee (USA) and the new branch in Tehran are due to begin operation in 2016, while 10 million euros of investments are planned to expand the Nuova Era business unit facility in Casalgrande (Reggio Emilia). The System Logistics division has also performed well

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and has maintained its strong growth. Since 2008 the number of employees has risen from 92 to 512 and turnover has grown from 30 to 136 million euros (including 18% year-on-year growth in 2015), while the goal for 2016 is more than 200 million euros. On 1 January 2016 the two divisions “Impianti” (custom solutions and large plants) and “Modula” (tray type automatic vertical warehouses) were transformed into two separate joint stock companies. After investing 10 million euros to increase output at the facility in Salvaterra (Reggio Emilia) and 10 million dollars to open the factory in Maine (USA) in August 2015, in 2016 Modula will be opening its first production unit in India, a market where 40 vertical warehouses have been installed this year. More than 1200 Modula units are currently installed worldwide (up 93% in the two years 2013-2014 alone).

At the press conference, System also announced the purchase of the Kale Italia production facility in Borgotaro (Parma) by Laminam, the group company which manufactures large ceramic panels headed by CEO Alberto Selmi.

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Tecnargilla 2016:

an increasingly international event This year once again, Tecnargilla will be a must for all those in the ceramic and brick sector.

For 2016, event organisers Rimini Fiera and Acimac are working hard to increase the already high level of internationalization, with 40% of the exhibitors coming from abroad, along with half of the visitors, who attended the 2014 edition from more than 100 countries. For the next edition, set to take place in Rimini from 26 to 30 September 2016, 80% of the exhibition space is already booked out, with increasing numbers from Germany, Spain, France, Turkey and Greece, alongside confirmed reservations from leading Italian firms.

The high international profile of the event has allowed it to be included in the special plan for promotion of the national exhibition programme, funded by the Ministry of Economic Development through ICE-Agenzia.

Thanks to funding, Tecnargilla 2016 will be able to push its international promotional activities to the next level. Several delegations of buyers will be invited from North Africa, South America, Eastern Europe, Russia and former CIS republics, Iran, Turkey, India, South East Asia and Sub-Saharan Africa.

The international advertising campaign in major sector publications has also been extended, spread across more than 120 adverts and on and offline communication campaigns. To support communication with sector operators, the event’s totally new website is online at www.tecnargilla.it. Available in three languages (Italian, English and German) and with reduced versions in Chinese, Russian, Spanish, Turkish, French and Portuguese, it is more dynamic, social and responsive for mobile devices.

Tecnofiliere and the Indian market Tecnofiliere has long been a leading supplier to the Indian market and recently developed a TFE model 1-exit die with a single internal and external braking system for the production of an innovative interlocking block for loadbearing masonry (400x200 mm) for one of the most important companies in the country. Because this block does not require the use of concrete structures, it allows for savings in terms of both construction costs and timeframes for buildings up to three floors in height. Another of the product’s key strengths is its excellent thermal and acoustic insulation. Made from natural clay, it is ideal for creating healthy, comfortable and totally pollutantfree living spaces without sacrificing thermal efficiency. Furthermore, the properties of low moisture retention and rapid drying ensure optimal thermal protection, while

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the gradual release of stored passive solar energy reduces the building’s thermal management costs. To build the die, Tecnofiliere designed a special core holder to optimise the flow of clay in spite of the small dimensions of the internal walls. The liner and cores are made of highthickness chrome-plated steel to cope with the high rate of wear the die is subjected to during the extrusion process. Tecnofiliere’s strong interest in the Indian market is also confirmed by its participation in the exhibition Indian Ceramics, where it is showcasing its wide range of equipment for heavy clay extrusion.

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Portobello

renews its trust in

A total of 7 Gamma 98 XD digital systems from Durst have been installed and started up in recent months in Portobello factories in Brazil. Three of these are at the facility in Tijucas (Santa Catarina), the other four at the new Pointer plant in the state of Alagoas, in the northeast of the country. Launched last April and officially opened in September, the new plant has a production capacity of 20 million square metres/year of competitively priced floor and wall tiles for sale on the domestic market (under the ViaSeca brand) and for export (Pointer brand).

The Brazilian group’s decision to use the same Gamma 98 XD digital printing systems with up to 8 colours for both the premium and mass market lines reflects its intention to offer Pointer customers the same quality for which Portobello is renowned. With its special greyscale function, Gamma 98 XD is able to achieve an original resolution of between 300 and 1000 dpi and produce drops of different sizes up to

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than 55 new sold worldwide

EKO

Sacmi has sold more than 55 EKO kilns to leading ceramic tile manufacturers in 10 countries, 70% of which have already been started up successfully. Key strengths of the new machines include a 20% reduction in fume volumes compared to conventional kilns and record low levels of consumption. Also important are their design characteristics which enable them to meet today’s production requirements, including frequent size changeovers and the need to handle increasingly small production batches. As well as reducing kiln consumption by more than 25% during pauses in production, the EKO kiln features firing curve monitoring and control systems to minimise temperature variations inside the firing chamber

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Durst

200 pl directly on the nozzle bar.

The printers also have a high level of productivity, “enabling us to achieve high volumes reliably and without any malfunctions within a few weeks of installation”, noted Stefano Galli, the Brazilian group’s head of design and development. Another key factor is the Gamma 98 XD’s integrated self-maintenance capability, which enables it to perform routine maintenance automatically.

“The closest Durst Service Point is more than 4 hours by plane from the Pointer factory and it’s crucial for us that the printers remain operational 24/7,” Galli explained. Portobello has been using Durst technology since 2011, including six Gamma 75 and 120 series printers which have improved productivity and brought significant savings in terms of downtime along with very high final quality. These advantages have contributed to the company’s steady growth. Portobello closed 2014 with a turnover of approximately $ 320 million and a production volume of over 30 million sq.m.

kilns

(less than 2°C). This results in highprecision material yields regardless of size or thickness as well as minimal waste. Kiln consumption data are available to ceramic companies to enable them to monitor kiln performance in real time by means of an advanced, userfriendly interface. The integrated supervision system used on Sacmi machines provides all essential system information and can be interfaced with external control tools, a crucial factor in effective management of modern manufacturing facilities.

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LB

starts up in I ndia

LB Group (Fiorano, Italy), which is exhibiting at Indian Ceramics 2016, is pleased to announce the opening of its first business unit in India, with legal domicile in Mumbai and headquarters in Gujarat. New technical and sales staff, properly trained by LB, will join the local collaborators who have been working in India for a number years.

India is one of the most lucrative markets for the Italian group and together China and Brazil makes up 25% of its export turnover. Exports account for 75% of the group’s total turnover, with further major supply contracts in the USA, Russia and Iran.

LB Group has announced excellent 2015 results, including 20% growth in consolidated turnover with respect to 2014 to around 38 million euros. The parent company LB, a leading manufacturer of plants for the production of technical and glazed porcelain and for dry grinding with microgranulation, likewise estimates 20% year-onyear turnover growth to around 28 million euros. These good results follow a radical corporate restructure and a threeyear period of continuous investments of 10% of turnover in

human resources and R&D projects, leading to the development of Divario (press feeding system) in 2013, Easy Color Boost (dry raw materials colouring system) in 2014 and Freestile in 2015.

Freestyle combines two previous systems and is able to create unique ceramic products while cutting costs by rationalising production layouts.

“In 2016 we will embark on a process of lean production,” announced the group’s CEO Emilio Benedetti. “We plan to cut delivery times by 30%, eliminate pockets of inefficiency, reduce general costs and improve the overall quality of processes and products.”

LB Group, which also includes the subsidiaries Sitec and Sermat, currently has around 115 employees (plus 180 workers for outsourced operations) and an R&D team made up of 9 professionals including chemists, geologists, technologists and product managers with many years of experience in the ceramic sector.

ICF-Welko supplies kilns for large - format tile and The System Lamina lines for the production of large ceramic panels in sizes up to 1600x4800 mm and a variable thickness from 3 to 30 mm use special kilns with System-ICF-Welko technology for the firing stage. The two Indian companies Simpolo and Qutone have adopted these highly innovative production lines, which will come on stream this spring. For the drying lines, Simpolo has adopted a ICF-Welko 5-layer dryer (width 2950 mm and length 40 metres) and an ICF-Welko kiln (width 2950 mm and length 210 metres). Qutone has opted for a 5-layer dryer (width 2950 mm

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panel firing to I ndia

and length 30 metres) and a kiln of 190 metre length and width 2950 mm. Both companies will produce up to 1600 x 4800 mm size panels and 800x800 mm size tiles with thicknesses of between 8 and 12 mm. Both the kilns and the dryers feature cutting-edge technological solutions that have previously been tested on other installations used for the same types of products and are equipped with the most advanced monitoring and production management systems.

C era mic W o rld Review India 2016

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Operation “Star Porcelain”: the KMG G roup chooses S acmi KMG (Khater Massaad Group) has successfully started up the new Star Porcelain Pty plant in the Hobiganj district in Bangladesh, one of the country’s most modern plants for the production of high-end hard porcelain.

The complete line, built in collaboration with the Sacmi Group, covers everything from body preparation using certified high quality raw materials through to the dry pressing station. It also features pressure casting solutions (based on traditional mechanised or plastic moulding systems). A key factor in the company’s investment decisions was the range of high efficiency isostatic pressing solutions produced by Sacmi, complete with robotised finishing systems, which Star Porcelain now uses for most of its output.

Siti B&T

strengthens its presence in I ndia

Siti B&T Group has recently started up a new complete line for one of its longstanding customers, the ceramic manufacturer Comet India based in Morbi (Gujarat). The new plant has helped the Indian company secure significant shares of the domestic and international markets by substantially raising production capacity and improving product quality. The line supplied by Siti B&T includes an EVO press, a vertical dryer and a latest generation Greenfire® kiln.

The EVO 5008 press has a maximum pressing force of 5,000 tons and a free clearance between columns of 1,900 mm. It is ideal for the production of 60x120 cm and 90x90 cm sizes and is extremely reliable thanks to its steel

Smalticeram India

structure which guarantees high shaping precision. To optimise factory spaces, a vertical dryer has been installed after the press to ensure extremely uniform drying.

Equipped with a cutting-edge combustion and heat recovery system based on the innovative Siti B&T burners, the Greenfire® kiln has a length of 166 metres and a width of 2950 mm. It can produce sizes of 60x60 cm and 80x80 cm and delivers high productivity, quality and energy efficiency.

starts up

Building on its more than 45 years of experience in the sector, Smalticeram is intensifying

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Completing the order is a robotised dip-glazing station and a tunnel kiln for firing in a reducing atmosphere built by Riedhammer.

This innovative kiln has been designed specifically for the tableware industry and is equipped with fully automated control systems. This first stage of the investment plan will boost Star Porcelain’s output to 15 million pieces a year. The company is also preparing to install decoration solutions for most of its output, both by hand and using decals, while new tableware collections will feature modern aesthetics by some of Europe’s leading artists.

its presence in the world’s most important ceramic districts. For this purpose, a few months ago

Cera mic W o rld Review India 2016

it opened a new branch in the Morbi district in Gujarat called Smalticeram India, which joins the branches already operating in Italy, Indonesia, Brazil, Spain and the USA. The role of Smalticeram India is to provide technical and graphics support to ceramic companies operating in the Indian market through local personnel coordinated by expert Italian technologists. The Indian branch will therefore strengthen partnerships with local cli-

entele and offer the market the latest new products from the Italian glaze and colour producer.

These include sophisticated digital technologies (SJ-SD-D3.0), special glazes with very high colour intensity (HD-HDG), materials for double filling (Smaltipress) and technical grits (GF-GS).

Marazzi Group Italia adopts new digital technologies from P rojecta E ngineering Marazzi Group has adopted the two latest new digital products from Siti B&T Group member company Projecta Engineering for use at its facilities in Fiorano and Sassuolo: G5, the new generation of digital decorating machines launched in June 2015, and Evo7 (Hybrid Model).

The first completely modular digital decoration system, G5 covers the entire glazing process and further improves all digital technologies developed to date.

For the facility in Fiorano, Marazzi has chosen a G5 with a 915 mm printing width and 6 colour bars equipped with

new Seiko printheads. The Evo7 (Hybrid Model) installed in the Sassuolo facility has a printing width of 1120 mm with 6 colour bars, again fitted with Seiko printheads.

With these latest-generation installations, Projecta Engineering further strengthens its close collaboration with the Marazzi Italia Group, which once again is focusing on technological innovation as the key to success and to increasing its competitiveness.

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Sabino Menduni - s.menduni@tiledizioni.it

Kajaria continues to grow With the aim of reaching an output of 100 million sq.m/year by March 2018, the largest Indian ceramic tile manufacturer Kajaria is following apace its planned investment programme which started a couple of years ago.

The group ended the year 2014 with a production capacity of 54 million sq.m and a real production of 50 million sq.m (10 million more than the previous year, +26%), but both figures have already changed in the first 9 months of 2015 following the start-up of new production sites in Rajasthan and Gujarat.

Even more astonishing was the 37% increase in turnover registered in 2014, which reached approximately 327 million euros.

We met Mr. Ashok Kajaria, who updated us on the latest operations and described the future steps in his agenda.

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CWR: Kajaria achieved excellent growth last year. What can you tell us about this?

Ashok Kajaria: That’s true, we have posted a healthy uptick in both revenue (+19%) and profitability (+41%). We are looking forward to good opportunities over the next five years as the

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Cera mic W o rld Review INDIA 2016

Ashok Kajaria

government has launched a comprehensive social housing project called “Housing for all by 2022”. An estimated 60 million houses will need to be built to achieve this goal. The government has also launched “Swatch Bharat Abhiyan” (Clean India initiative), which aims to build 60 million toilets across the country by 2019.

CWR: In just a year you have increased the number of your tile plants from 7 to 10. What’s next in your expansion programme?

A. Kajaria: A new floor tile line with a capacity of 3 million sq.m/year will begin production at the existing location in Gailpur in September/October this year. Our JV partner Taurus Tiles Private Limited commissioned a 5 million square metre polished vitrified tile facility in Morbi in June 2015. We will also start up a 6.5 million square metre polished vitrified tile greenfield facility in Rajasthan by December 2015.

With this expansion we will reach a tile capacity of around 69 million sq.m/year by the end of this calendar year, registering growth of 28% over 2014.

We have also entered into a new JV with Floera Ceramics Pvt Ltd involving the construction of a 5.7 million square metre polished vitrified tile facility in Andhra Pradesh, which will come on stream in 2016.

CWR: What technologies do you use?

A. Kajaria: There is nothing new as far as technology is concerned, but a few new machines have been installed to make bigger tiles including a 6500 PH press and a 273 metre kiln from Sacmi, one of the longest in India. We are also the first in India and the second in the world to have adopted the new Divario press feeding system from LB. CWR: Besides producing bigger volumes, to what extent are you improving the quality of your products?

A. Kajaria: Exposure to international home buying trends and the impact of surging markets has changed the face of the modern urban landscape.

Now the affluent, cosmopolitan and discerning consumer demands premium products and services and has ample knowledge of the choices available. This is the reality of the modern Indian tile market. To cater to the expectations of

Ce r am i c W or ld R e vi e w I N D I A 2 0 16

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the discerning buyer, it’s important for us to keep a tab on the quality of our new ranges and large format sizes such as 80x120 cm, 60x120 cm and 80x80 cm in glazed porcelain and polished porcelain for niche customers, along with volume driven sizes like 30x60 cm and 30x45 cm. We are also planning to launch slim tiles in a large format very soon.

CWR: How did the market respond to your recent entry into the sanitaryware and faucet sector?

A. Kajaria: Tiles, sanitaryware and faucets are complementary products sold in the same stores, so this was an opportunity for Kajaria.

Moreover, our dealers mentioned that an increasing number of customers were asking for complete bathroom furnishing solutions.

We decided to enter the sanitaryware and faucet verticals through our subsidiary Kajaria Bathware Pvt Ltd. The 700,000 piece sanitaryware facility at Morbi, Gujarat will reach the optimum production level in the current fiscal year. The product range comprises 100 SKUs catering for diverse customer requirements.

Similarly, the 1 million piece faucet facility at Gailpur (Rajasthan) will also optimize capacity utilization in the second half of this fiscal year.

CWR: How do you expect demand for tiles to evolve in India?

A. Kajaria: India is ranked third in world ceramic tile production after China and Brazil and is growing annually at 11-12% as a result of urbanization and replacement of natural stone.

A majority of India’s ceramic producers are located in Morbi (Gujarat), possibly the second largest tile cluster in the world accounting for more than 60% of the country’s total production.

Although India is one of the top consumers of tiles globally, it is also one of the lowest in terms of per capita consumption.

But despite some sluggishness in the real estate sector, I believe that demand for tiles will continue to grow. The most important reason for this is that technological advancements have strengthened the aesthetic appeal of tiles, making them an integral home improvement component. And as I said, in this segment tiles are replacing a lot of low/high end marble.

The replacement market is growing as people aspire to better products which are now available in India at very affordable prices.

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Cera mic W o rld Review INDIA 2016

The new Government’s push for housing, sanitation and building smart cities along with growing urbanization and easy availability of housing finance are some of the other developments that will impact demand positively.

CWR: With such a high local demand to satisfy, is there space to focus on export markets?

A. Kajaria: We do export ceramic tiles to the Gulf countries and have begun exporting glazed porcelain tiles to Europe, Australia, Taiwan and the USA, but it is still very low as a pro portion of our domestic sales.

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Paola Giacomini - p.giacomini@tiledizioni.it

Emilceramica starts up in India with Simpolo India is the country that Emilceramica has chosen for the international expansion of its manufacturing operations.

As in the case of Zeus Ceramica in Ukraine, the formula chosen by the Italian ceramic group for its Indian start-up is a new 50-50 joint venture with the Indian tile and sanitaryware producer Simpolo, a group owned by the Aghara family and operating in the state of Gujarat.

The goal of the new company, called Simpolo Emilceramica Pvt Ltd, is to commence production of large-format ceramic tiles and panels by next spring using Gea technology from System.

An ultra-modern new facility is already under construction as part of an investment of more than 20 million euros.

We met Emilceramica Group’s CEO Luca Majocchi, who has just returned from Morbi where together with chairman William Tioli he took part in the cornerstone laying ceremony and the traditional blessing of the new production site.

“We had the privilege to attend a very moving ceremony that saw the intense participation of the whole Aghara family and the local community,” he said.

Luca Majocchi

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CWR: This is another first for Emilceramica: it was the first Italian company to begin production in Ukraine and is now the first to set up a production site in India. How did this project come into being?

Luca Majocchi: Emilceramica group operates in the high end of the tile sector with brands Emilceramica, Provenza, Ergon and Viva. It has an annual production capacity of 9 million sq.m, plus the 4 million sq.m of the Zeus factory in Ukraine, and revenues of more than 180 million euros, 90% of which are generated abroad.

We already have a strong presence in Europe - which is effectively our domestic market - and in the United States, a strategic market where we operate through Emilamerica distribution centres. However, it is simply not possible to envisage furLuca Majocchi and Jitendra Aghara, together with William Tioli, Sergio Sassi and close associates after signing the joint venture agreement ther growth and develop-

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Cera mic W o r l d Review INDIA 2016

The Simpolo and Emilceramica stand at Acetech Mumbai, October 2014

ment without establishing a presence in the enormous Asian market. We believe that the best and most effective way of doing this is to set up a local production facility.

We began working on this project in November 2012, initially looking into the opportunities in China. However, we abandoned the idea due to the language barrier and the asymmetries between foreign and local investors, which mean there is no guarantee of a company of our size being able to operate successfully.

India on the other hand offers many advantages. It has a large and growing domestic market driven by a population with a high percentage of young people, expanding urbanisation and a severe infrastructural deficit that still needs to be filled. The economy is expected to grow by 7% this year. India is also a good platform for foreign investors, who enjoy the same legal rights as local companies, while the heritage of the colonial past includes not just the English language but also a British style legal system.

CWR: And then you met Simpolo.

L. Majocchi: Right from the start, our aim was to export to India a factory model that would be capable of achieving Italian levels of quality. With this in mind, our search for a local partner focused on finding a company already positioned in the high end of the Indian market led by an entrepreneur who shares our values and goals and with whom we could establish a relationship based on mutual trust.

Amongst the many things that India has taught us is that business deals are not made between companies but between people with affinity and a shared outlook.

This was exactly what happened with Mr. Jitendra Aghara, chairman of Simpolo, a family-run company that was set up in 1977 for the production of clay roof tiles. Today Simpolo has one factory for the production of sanitaryware and three factories for the production of glazed and unglazed (double filled) porcelain tiles.

All facilities are located in Morbi, Gujarat, a relatively sparsely populated state with around 100 million inhabitants which is also well managed and has good infrastructures and road links.

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CWR: When was the joint venture set up?

L. Majocchi: The first agreements were signed in October 2014, but the new company - Simpolo Emilceramica Pvt Ltd - was legally incorporated in July this year when the first stone of the future plant was laid. The Chairman of the joint venture is Jitendra Aghara.

In reality our two teams have been working together since the spring of 2014. During the ensuing year and a half we have observed a close affinity with the management of Simpolo regarding this project, which is essential to ensure that facilities function effectively and thereby guarantee the success of the operation.

During this period of time both parties have had the chance to get to know the other’s respective areas of technical expertise and strengths which can be further developed in the future. For example, we realised that Simpolo has a high level of skill and expertise in the production of polished tiles, a kind of product that is very expensive to make in Italy.

CWR: Where will the new Simpolo Emilceramica Pvt Ltd factory be located and what will it produce?

L. Majocchi: The factory will be built in Morbi, not far from the Simpolo plant. It will produce both traditional products and large-format panels using Gea technology from System, specifically the Gea 44000 line in the advanced highproductivity 2.0 version.

The plant will have an initial production capacity of 3.5 million sq.m/year, but the factory is designed to accommodate future expansion. Along with the Gea press, it will also have a 191 metre ICF kiln and a dryer of the same length.

The porcelain panels will be handled using machinery produced by System to ensure complete control over the product.

These technological choices clearly show that our decision to set up in India wasn’t solely to benefit from low labour and production costs. In fact we aim to produce highquality ceramic surfaces capable of meeting Asian de-

The cornerstone laying ceremony and the blessing of the new facility in Morbi

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Cera mic W o rld Review INDIA 2016

I.C.F. & WelkoS.p.A. VIA SICILIA,10 41053 MARANELLO (MODENA) ITALY TEL.+39-0536240811 FAX +39-0536240888 icf-welko@icf-welko.it www.icf-welko.it

mand, which would simply be too costly to produce and export from Italy. Operators need a high degree of training in order to use such innovative technology effectively, but I’m convinced that collaboration between our technical staff already working in Morbi and Simpolo personnel will give the expected results.

Due to the operating characteristics of Gea technology, we are confident that we will be able to produce high-quality materials at the Indian facility.

CWR: When is the plant due to begin operation and what kinds of large-format panels will you produce?

L. Majocchi: The anticipated lead time is 9 months from the laying of the first stone, so we’re expecting to begin production by April 2016. We will initially produce panels with thicknesses of 8.5 and 10 mm, but an further 6 mm thickness will be added in the future.

The Gea 44000 press is able to produce 1600x4800 mm panels and is perfectly equipped to produce the sizes we’re interested in, especially large-format panels whose quality is guaranteed by the total absence of surface stresses during pressing. All collections will consist of glazed porcelain, and from 2016 onwards Simpolo will produce glazed products in the new factory, freeing up capacity in its own facilities for the production of unglazed full-body porcelain.

CWR: Will product design be entirely Italian?

L. Majocchi: Of course. The mission of the joint venture is to offer local consumers Italian design and quality at Indian prices. All products will be decorated using latest-generation Creadigit digital technology. This is another highly sophisticated technology that requires specific technical expertise and professionalism. In view of these characteristics, I really don’t believe that digital printing is responsible for a potential levelling of the market as has so often been claimed.

CWR: How will Simpolo Emilceramica products be marketed?

L. Majocchi: The joint venture will be responsible for sales in the domestic market, where Simpolo has a strong position and where it has already shown an excellent capacity to introduce innovative products. For example, it was the first company to successfully market extra-thick tiles. Emilceramica will take care of sales in all foreign markets in accordance with a jointly agreed strategy. The Simpolo Emilceramica Pvt. Ltd sales network will also look after Indian market distribution of high-end products manufactured in Italy by Emilceramica.

As an initial exercise in joint promotion of the two brands in the Indian market, Emilceramica was present at the Simpolo stand at the Acetech Mumbai trade fair held in October 2014 and the initiative will be repeated this year.

CWR: What does “exporting the Italian factory model to India” mean in practice?

L. Majocchi: Along with the crucial ability to produce high quality I have already mentioned, it means building a flexible factory that is able to provide a high standard of customer service. Emilceramica has already transformed the management of its Italian facilities in accordance with a company model capable of meeting market demand on a just-in-time basis. Whereas companies focused on high outputs have to maintain maximum efficiency to achieve cost competitiveness, Emilceramica - which operates in the high-end product niche - has a plant layout and management approach based on a balance between quality, level of service and in dustrial costs.

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i ta

l SO

LUT I ONS

M I CAL SPEC I AL T

di g

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IES

E AR S A NITA RY WARE & TABLE W

Milena Bernardi - m.bernardi@tiledizioni.it

Uncle Ceramics chooses dry preparation processes Uncle Ceramics is a young Indian company, founded in 2014 by Jayantilal P. Bhoraniya, a manager with 25 years of experience in the ceramic industry. The company specialises in the production of so-called parking tiles, highly technical floor tiles of size 30x30 cm designed for use in high-traffic areas.

Started up in May 2015, the new Uncle Ceramics production plant is equipped with Italian technology and is the first facility in Gujarat to adopt dry raw material preparation technology supplied by Manfredini & Schianchi. The Dry Tech plant has a production capacity of more than 8 tons/hour and is designed to be extremely flexible. It can be used for both the floor tile and the double-fired wall tile production lines.

We met Jayantilal P Bhoraniya to find out more about the company and its objectives.

CWR: What was the idea behind Uncle Ceramics?

Jayantilal P. Bhoraniya: The basic idea is that in order to deal with the fierce market competition, it is necessary to adopt a new approach to technology by designing plants that deliver high levels of efficiency, lower costs and high quality finished products. The best results can only be achieved by using cutting-edge technology and abandoning production models based on the now obsolete conventional technology which is still widely used in India.

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CWR: What kind of products do you manufacture specifically?

J.P. Bhoraniya: We specialise in the production of exterior tiles for high-traffic areas, which in India we call “parking tiles”. Market demand for these products is very high in India and is increasing day by day. They are produced with vitrified body and have high load-bearing strength and low water absorption (0.5%). We produce them in a 30x30 cm size and with thicknesses ranging from 9 to 12 mm.

CWR: When did you start producing these tiles and where have you begun marketing them?

J.P. Bhoraniya: The plant began production in May 2015 with an output capacity of 5,000 sq.m/day.

We have a dealer network that already covers the areas of the country with the biggest levels of consumption. Our

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C era mic W o rld Review INDIA 2016

Overview of M&S dry grinding plant in operation at Uncle Ceramics

target markets include residential projects, industrial units and government projects.

As we have only just started production we do not currently export, but our marketing team is exploring the opportunities.

CWR: Could you describe the production plant?

J.P. Bhoraniya: We have adopted advanced Italian technologies including dry process raw materials preparation technology from Manfredini & Schianchi, double layer kiln technology from Sacmi and digital printing technology from Durst. We opted for high levels of automation to make the production process increasingly efficient.

Our strong focus on the environment is reflected in our choice of a dry preparation process with zero water consumption (and therefore zero risk of water pollution), and very low or zero emissions. The plant also has a dust collection system with environmental filters for recycling fine dust and reusing it as a raw material.

CWR: What benefits have you observed with the use of dry preparation technology during these first few months of production?

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J.P. Bhoraniya: Above all the simplicity of the process, as well as its efficiency and eco-friendliness compared to spray dryer technology. It is also very flexible and allows us to switch rapidly between different products. In these first few months we have seen exceptional results in terms of both performance and tile quality. We have lower reject rates and higher output efficiency, as well as huge savings in terms of fuel, labour, material and electric power costs.

CWR: Does the plant allow you to recycle polishing waste?

Storage silos for dry grinding plant J.P. Bhoraniya: Yes it does, which is a major economic and environmental advantage. Recovering polishing waste as a raw material overcomes the need for disposal, which is a big problem here in Morbi.

Another factor is that this waste is available in abundance in Morbi due to the presence of a large number of polished vitrified tile manufacturing units. This reduces production costs depending on the product we want to make.This can only be done with dry preparation technology. In wet processes, waste recovery is severely limited as the economic benefits are outweighed by the increased costs of fuel and additives (such as STPP, sodium tripolyphosphate). Finished product quality is also adversely affected.

CWR: What are your next goals?

J.P. Bhoraniya: We aim to double our output within a year through new investments to expand production capacity. At the same time we intend to expand our range of floor and wall tiles.

CWR: Could you give us a general overview of the Indian ceramic industry?

J.P. Bhoraniya: The Indian ceramic industry has enormous growth potential. Due to increasing demand and the booming economy, dozens of new manufacturing units have come into production this year alone.

The outlook is very promising for the future, but the industry is now at a turning point. It is hungry for innovation and more efficient technology capable of cutting costs and improving competitiveness in what is often a price-oriented market. I believe the Indian ceramic industry is ready to take this big step forward.

ď œ

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Detail of the humidification-granulation zone with Forgia MS38-F

The state of the art of System’s full digital process

Rita Cagnoli, System

The Creadigit digital decoration machine produced by System now sets the standard in the ceramic digital decoration sector in terms of reliability, print quality and versatility.

More than 300 machines were sold in 2015, bringing to 600 the total number of units sold in the 27 months since the machine was first launched.

While maintaining the identity of the original model, Creadigit has been adapted to the needs of ceramic clients over the years, becoming longer and wider and incorporating improved software and electronics. Its potential has been steadily enhanced without sacrificing its characteristics of extremely high productivity (in terms both output and top quality yield), absence of banding due to clogged nozzles, and robustness of the hardware and software.

The following are the main characteristics that set Creadigit apart in the market: 1. optical printhead alignment: 2. optimised hydraulic circuit with three recirculation loops; 3. attention to construction details; 4. proprietary electronics, mechanics, software and RIP developed through ongoing partnerships.

To meet these specifications, Creadigit undergoes continuous development and modification and upgrades are always available. The result is an extremely reliable digital printer which functions with 100% of nozzles in operation.

Creadigit’s success owes much to the integrated printhead. For years now System has been using SG1024 printing technology from Fujifilm Dimatix.

The printhead is available in three different versions according to the native drop size. It has a resolution of 400 dpi, an internal recirculation loop and a high-resistance metal

CREADIGIT: TECHNICAL CHARACTERISTICS Print width (mm)

Machine length (mm)

Machine width (mm)

Belt height (mm)

Max. number of colours

Max. number of printheads

Max. speed at 400x400dpi (m/min)

STD

710

3500

1800

1000/1200

6

11

40

E

710

4450

1800

1000/1200

8

11

40

XL

1161

3600/6000

2250

1000/1200

6

18

35

XLE

1032

4580

2126

1050/1200

8

16

48

XXL

1355

4580/6000

2446

1050/1200

8

21

25

XXL HS

1355

4580/6000

2446

1050/1200

8

21

40

BS

1806

6000

3500

1000/1200

6

28

25

Creadigit

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focus on digital glazing & decoration

plate, and can be completely reconditioned.

CREADIGIT: 3 DIFFERENT PRINTHEAD VERSIONS

System has established Printhead Model Native drop size (pL) a leadership position in the field of large size tile SG 1024-SC 10 printing with the two versions XXL and BS, SG 1024-MC 30 which have printing 80 widths of 1355 mm and SG 1024-LC 1806 mm respectively.

The enormous versatility of Creadigit has led to the development of various full digital lines, a ceramic process in which all decoration steps are performed digitally, from glazing through to final protection. To date a total of 7 lines with the multicreadigit system have been installed worldwide.

In the near future System will be introducing two important innovations which will further improve the technology: • the possibility of using a new printhead to discharge large quantities of material, • the possibility of using a new software function which allows printhead discharge to be controlled without having to either increase the print resolution or change the working waveform.

These are just two of the many new features that are constantly being tested and implemented in the System laboratories.

Use

Inks Inks/Materials Materials

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New developments in digitalisation of the ceramic production process Alessandro Ferrari, Esmalglass-Itaca Group The introduction of inkjet digital technology has prompted one of the biggest changes in the history of industrial ceramic tile production, resulting in highly diversified products that enjoy a stronger position in the global marketplace.

Digital technology has grown enormously since 2008. It is estimated that out of a total of approximately 9,000 glazing lines in operation all over the world, the conversion rate from traditional to digital technology stands at around 72%, with peaks of more than 90% in some countries such as Spain and Italy. This trend indicates that digital technology has in effect become the dominant decoration method in the ceramic sector and is the technological segment attracting the greatest investments in terms of research and development.

However, this progress in terms of technology and products prompts a new question: “What can be done to further diversify finished products and make them more competitive in the global marketplace?� Esmalglass-Itaca has attempted to answer this question through the digital application of material with the ultimate goal of digitalising the entire glazing line.

To do this, two new families of digitally applied materials have been developed: Digital Effects and Digital Materials. These two families complement the Digital Inks range which for years has been a point of reference in the digital ceramic world.

The Digital Effects series products are oil-based submicronic materials (based on the same medium as the Digital Inks) and can be used with existing printheads. Due to their strictly controlled particle size, these products maintain a very high level of stability both in the printing circuit and in the printheads. Digital Materials series products are micronic water-based materials that can be used exclusively in new-generation printheads capable of discharging high application weights (from 50 g/m2 to 800 g/m2). These products are water-based and have a particle size of above 3

Digital Materials: Crystalline

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Digital Materials: Matt

focus on digital glazing & decoration

Digital effects: Metallised

Digital effects: Lustre

Âľm. Due to this large particle size compared to submicronic products, these materials produce a typically ceramic effect and can be applied digitally in the same quantities as with conventional techniques such as bell applicators, flat screen printing machines, rollers and fumĂŠ devices.

The Digital Materials range also includes the Digital Powders family, which consists of spray-dried powders, grits, grains, etc. with particle size and flow properties suitable for application with dedicated dry inkjet printheads.

The fact that the Digital Solutions family from Esmalglass-Itaca not only performs digital decoration with pigmented inks but also applies layers of material digitally gives ceramic manufacturers and designers the opportunity to create highly differentiated products using a completely digital process. This brings numerous advantages, including improvements to the finished product, the production process and cost management. In terms of aesthetics it will be possible to create new finishes and textures and synchronise graphic designs so as to achieve unique and very natural looking effects. From the standpoint of production and management, it will be possible to reduce the typical defects of conventional applications, increase flexibility and speed in changing models and in developing prototypes, reduce warehouse stock and consequently improve the company’s working capital.

Digital Materials: Clear matt

Digital effects: Glue + Dry

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Continua+ for decoration of large sizes Dante Biserni , Sacmi Imola

The recent introduction of Continua+ marked a major step forward in the industrial production of extremely large size ceramic tiles and panels and laid the foundations for new plant engineering solutions.

After being unveiled in its standard configuration at Tecnargilla 2014, numerous lines have now been installed and are giving excellent results in terms of sizes, thicknesses and textures, combining perfectly with the outstanding potential of Italian ceramic design.

In particular, Continua+ offers exceptional opportunities for full integration between the various digital decoration techniques, including those that can be performed dry prior to pressing and subsequent inkjet applications of inks and glazes. It is a simple, compact and flexible solution that combines low energy consumption with an ability to produce highly fashionable large sizes while enhancing technical and aesthetic qualities. The Continua+ line performs the following steps in the production of large-format tiles and panels: • use of one or more DDD (Digital Dry Decoration) machines for dry decoration with spray-dried powders of coloured bodies and glazes; • tile forming by means of the PCR2000 compactor using steel belts, which can either be smooth or surfaced with the desired texture; • high-dEfinition inkjet decoration using the wide range of available DHD printers.

To achieve full integration between the graphic designs and textures, the starting point is a source image, usually acquired in high dEfinition using various acquisition techniques. From this image, three types of files are produced: • 100 dpi (medium dEfinition) .tif or .psd graphic files for each colour bar on the DDD dry decorating machine; • 360 dpi (high dEfinition) greyscale .tif files to create the texture on the belt by means of a patented digital resin-coating process; • 360 dpi (high dEfinition) RGB .psb or .psd files for the DHD inkjet decorating machine.

The really new aspect here is that all stages in decoration can be performed starting out from an initial image so as to create a fully digital line.

The following devices use digital graphic information on the Continua+ line.

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Continua+ with DDD and DHS

DDD Each machine can apply up to 4 colours in multichannel mode.

Depending on the degree of coverage of the graphic design, each bar can deposit up to 1200 g of powder, granules or flakes and/or their mixtures. The materials are suitable for a wide range of uses in terms of flow rate, particle size and moisture content. The maximum useful dimensions of the designs are a length of 200 metres and a width of 1900 mm.

PCR2000 The continuous compactor can be fitted with smooth and textured belts with a length of 7500 mm and useful widths from 1000 to 1900 mm. The belt change operation takes just half an hour. In the event a texture needs to be used, Sacmi has patented a belt preparation system in which the texture file is transferred to the belt directly without the need for a mould.

DHD The digital inkjet decoration machines suitable for use with large-format tiles and panels are DHD1408 (with max. decoration width of 1390 mm for a fired size of width 1200 mm) and DHD1808 (with max. decoration width of 1882 mm, for fired sizes of width up to 1600 mm). Each model can be fitted with up to 8 colour bars for the application of inks and/or glossy/matt glazes.

The combination of different dry and wet digital decoration techniques allows for the production of very natural looking ceramic surfaces that are far more than mere photographic reproductions and stand apart from the highly standardised decorated tiles that are now commonplace in the market. Continua+ technology today allows for fully digital production of large-format ceramic panels, making it possible to programme every aspect of the process from shaping to decoration, diversification of sizes and management of finished products. This kind of approach is likely to become increasingly widespread in the ceramic sector over the next few years.

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Colorobbia Digital Space: a step towards the future of ceramics In step with the constant growth in digital technology, Colorobbia has developed and steadily expanded its range of products for digital decoration and glazing in collaboration with various players in the ceramic technology industry.

The result is Colorobbia Digital Space, a complete and wellbalance range made up of five different families: • EHP (Extended Hydrophilic Properties) series - Pigmented inks and effects; • ETR (Extended Temperature Range) series - Pigmented inks and effects; • SPS (Special Particle Size) series - Special-effect inks with special particle sizes; • HQ (High Discharge) series - Engobes and glazes for digital glazing; • DDA (Digital Dry Application) series - Materials for dry digital application.

Colorobbia’s fully integrated solution combines Digital Space series products based on meticulous aesthetic research along with glazes, grits and all other materials that make up a tile. It devotes the utmost attention not just to individual products but to all aspects of tile production. It is the perfect combination of all these factors that brings the best aesthetic results at competitive costs.

ETR and SPS series: colours and effects The ETR and SPS series include a wide range of pigmented inks and special-effect inks that combine high stability with excellent colour strength. The special-effect colours can produce tones, textures and surfaces with unique and exclusive effects.

The ETR series of pigmented inks comes in a wide range of

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Angelo Onorato, Colorobbia

focus on digital glazing & decoration

colours, including 3 different blues, a reddish brown, a yellow, a black, a beige, a reddish beige, a pink and a green. To meet the different needs of the market, Colorobbia recently introduced three new pigmented inks (Honey, Mango Yellow and Carbon Black) which expand the colour space that can be produced using the EHP series.

Within the ETR and SPS series, Colorobbia has also developed an extensive array of effects that can be used either individually or in combinations to produce a great variety of innovative surfaces.

This “multilayer” concept patented by Colorobbia opens up a wide range of possibilities and functions, allowing producers to achieve a high degree of customisation.

In addition to traditional effects (glossy, matt, white and sinking), Colorobbia has also developed a series of inks capable of creating highly unusual effects.

One example is the Hydroactive ink which can be applied over a glaze to create a splendid light relief effect based on the well-known characteristic of water repellency. Another innovative ink that fits in very well with the “multilayer” concept is the so-called Multifunction ink, which not only serves as a substrate and interphase but can also create a high-gloss surface and considerably increase the colour intensity of certain pigmented inks.

The multilayer concept reflects Colorobbia’s approach to digital technology which involves developing products capable of combining effectively with glazes. In the pilot plant installed at the Colorobbia Technology Laboratory, plotters and industrial printers made by various manufacturers are used to test products with the various printheads available on the market.

The research and customer support department also uses the best profiling software and analysis instruments available on the market, from a classic Eye One through to a spectral scanner. This enables Colorobbia to offer a highly professional service that not only studies the products to be delivered to tile manufacturers but also determines their limitations and advantages in industrial conditions.

A few examples of effects

A few examples of products created using the “multilayer” concept

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Ceramics: a strategic sector for Durst and the state of the art Norbert von Aufschnaiter, Durst Phototechnik Ceramics remains a strategic sector for Durst, which in 2015 has strengthened its leadership role in the international digital tile decoration market with more than 60 installations of new Gamma XD systems worldwide.

High image quality, sharp and well dEfined details, full, uniform colours and complete absence of banding are just a few of the advantages of these revolutionary 8-colour modular systems which in the space of just a few months have helped set new standards in the industry.

Due to its high level of innovation, Durst Gamma XD has proved very popular amongst the tile manufacturers that use it all over the world. Many of them have been so pleased with the performance of the first installed machine that they have ordered a second, and in some cases even a third, up to a record number of 7.

The latest-generation technology developed by Durst’s R&D department and implemented on the Gamma XD series sets these machines apart from other printing systems and marks a step forward compared to the company’s previous models.

Quality and productivity Users of Durst Gamma XD have been particularly impressed with the system’s quality. It delivers superior performance and defect-free print results even when applying difficult designs and decorations. This is due to the maximum colour uniformity achieved over the entire printing width, with delicate colour transitions and natural details with plenty of contrast.

The excellent quality is matched by equally high production efficiency. The Gamma XD series printers are immediately ready for production and guarantee total stability of the nozzles, even after long periods of inactivity. The exclusive thickness scanner with anticrash sensor allows for automatic printhead adaptation, avoiding line stoppages and minimising the need for adjustments.

Total Cost of Ownership One outstanding feature of the system is its excellent price to performance ratio, including extremely low support and maintenance costs (Total Cost of Ownership). This advantage is guaranteed by the exclusive self-purge function which ensures high reliability, minimises maintenance frequency and eliminates ink leaks onto the conveyor belt.

The new self-calibrating printheads can be replaced directly by the operator in just 11 minutes, optimising production efficiency and minimising machine downtime. On re-

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focus on digital glazing & decoration

starting, the print quality remains the same without the need for further mechanical adjustments.

One example is a Gamma 98 XD printing system installed in Brazil on 10 April 2015 which has produced more than 2 million sq.m of tiles in just over 6 months, during which time support and maintenance costs amounted to just 483 euros without the need to replace nozzles, filters or printheads.

Flexibility Durst Gamma XD is highly flexible thanks to the innovative DM – Digital Material Printing Technology option which allows for special effect printing using special inks. This is an essential function for creativity and development of highly innovative designs. The innovative conveyor and centring system allows for double-row printing and high productivity even on very small surfaces, assuring excellent results on any kind of tile.

Synchronisation All Durst Gamma XD systems can be perfectly synchronised amongst themselves and with printers from the previous Gamma series, ensuring maximum print quality by separating decorations and special effect printing. Gamma XD systems are also equipped with software for synchronisation with Durst Gamma DG (Digital Glaze, for centralised control of the entire glazing and decoration process). This innovation revolutionises tile production by optimising the production process, increasing efficiency and minimising waste.

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The advantages of Efi Ecosystem for the ceramic industry Efi, a world leader in the field of industrial digital printing, has developed the Efi Ecosystem concept which can be applied to any industrial sector, including that of ceramics. It is an integrated solution consisting of the Fiery integral colour management system, a digital printer and inks.

Fiery速 proServer Fiery is the first complete colour management system for ceramic tile decoration. It is able to automate the calibration operations for the graphic design creation process as well as the conversion of designs in the event of changes. It incorporates a channel for special ink application and can print designs on paper with a high degree of fidelity. It is also able to correct for excess ink in manually corrected designs and minimise ink consumption through optimal use of black ink, bringing annual ink savings of between 10% and 30%. Fiery can manage designs with more than 5 colours and it also handles black very effectively for high-contrast images, rapidly correcting small differences in terms of glazes or cycles. It can calibrate a number of machines in order to print with the same colour, in the same process conditions or with a common colour space. It is ideal for companies that have to unify products across multiple manufacturing facilities or which have a single design laboratory.

The Cretaprint printer Along with the Cretaprint P3 printer, the new fourth generation of machines (CS4) was presented in 2015, while new printing widths will be added in 2016. The printhead options have also been expanded. Efi Cretaprint machines are designed to operate with standard discharge and high discharge printheads (Xaar and Toshiba), but they are also able to use the Seiko RC1536 printhead specially developed for the ceramic sector.

They are equipped with a recirculation system and have higher productivity and versatility without sacrificing either resolution or greyscale quality.

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Natalia Martinez, Efi Cretaprint

focus on digital glazing & decoration

A CS4 printer has already been installed in the factory of an Italian ceramic company, which has now ordered a second machine. The CS4 can operate at 42 metres per minute with high quality, without drip issues and with just one machine stop per shift for cleaning.

The electronics on the CS4 are entirely built by Efi and guarantee efficiency thanks to the higher data transmission rate and storage capacity and the DTP 2.0 which allows two different files to be printed at a time with the same printhead.

The Efi electronics minimise the risk of errors and the number of changes and allow for error diagnostics with immediate correction either by the operator or by remote technical support.

The CS4 is a more robust and stable printer suitable for continuous printing of sharp images without tonal variations, even in high frequency conditions, and for the use of inks with a high solids content for full field and/or high discharge applications.

Banding control has been incorporated along with colour uniformity of small drops for pale backgrounds, and a system has been introduced to correct potentially clogged nozzles.

Cretacolor ceramic ink To deliver high-quality ceramic inks, Efi Cretaprint has exploited all the expertise accumulated in more than 20 years of experience at the Efi production sites in the USA. The colours and materials have a wide colour gamut and high intensity ideal for greyscale printing. Strict control of each batch ensures maximum quality with minimum variations in properties and tones. Cretacolors are suitable for all printheads used in the ceramic industry, they are non-toxic for the operator and the containers can be recycled. In particular, Nero HT offers perfect rendering at high temperatures.

Each component of the Efi Ecosystem offers advantages, while the combination of all three guarantees control and high product value in terms of quality and differentiation. The system also ensures high profitability and major production cost savings (up to 50,000 euros/year per line or more).

In any case, the system remains open (Cretaprint offers a third-party ink approval service), modular and customisable, with the following supply options: • Machine + Inks with the loan of a FieryProServer • Inks with the loan of a FieryProServer • Machine + Fiery • Machine • Inks.

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Anti-wear rubber linings.

HTP

horizontal electric centrifugal pump with axial suction

SP

electric centrifugal submerged pump with water cooling

USP

vertical electric centrifugal pump with upper axial suction

LSPM

modular vertical electric centrifugal pump with axial suction on the lower side

Pumps for ceramic slip’s transportation.

Spray driers potentiation systems.

CERTECH S.P.A. con socio unico Via Don Pasquino Borghi, 8/10 C.P. 42013 S. Antonino di Casalgrande (RE) Italy Tel. + 39 0536 824294 Fax +39 0536 824710

www.certech.it - info@certech.it

Big Cover Cover, airless system for big sizes sizes.

March 2 - 4, 2016 / HALL B STAND B-066

CREATECH S.R.L. Via Don Pasquino Borghi, 4 C.P. 42013 S. Antonino di Casalgrande (RE) Italy Tel. +39 0536 823776 Fax +39 0536 812009 www.createch.it - info@createch.it

THE BIGGEST AND THE MOST COMPLETE RANGE of machines for the cooling before the Inkjet digital machine.

La più grande e completa gamma di macchine per il raffreddamento prima della macchina digitale Inkjet.

La mas grande y completa gama de maquinas para el enfriamiento antes de la maquina digital Inkjet.

consumption

8 KW/H

La plus grande et complète gamme de machines pour le refroidissement avant la machine digitale Inkjet.

BASIC

consumption

PREMIUM

CERTECH S.P.A. con socio unico Via Don Pasquino Borghi, 8/10 C.P. 42013 S. Antonino di Casalgrande (RE) Italy Tel. + 39 0536 824294 Fax +39 0536 824710

www.certech.it - info@certech.it

3 KW/H

THE LOWEST OF ITS CATEGORY!

March 2 - 4, 2016 / HALL B STAND B-066

CREATECH S.R.L. Via Don Pasquino Borghi, 4 C.P. 42013 S. Antonino di Casalgrande (RE) Italy Tel. +39 0536 823776 Fax +39 0536 812009 www.createch.it - info@createch.it

Alessandro Bianchini - Siti B&T Group (Formigine, Italy)

Beyond large-format ceramic panels Large-format tiles and panels appear set to become the products of the future in the ceramic sector and are attracting growing interest amongst architects and interior designers the world over. Prompted by market demand for extra-large tiles, Siti B&T Group has now entered the large-format tile segment with its new SUPERA速 technology. Built using the most advanced techniques in the sector, this technology 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 very large sizes.

Extremely high flexibility SUPERA速 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速 has an average production capacity of 9,500 sq.m/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.

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H E R E WE ARE 2016

U.S.A.

Brasil

2014

20 0 0

1998

The first indication of a concrete commitment aimed at ensuring growth and development at international level came in 1973, when it expanded into Spain, entering into a joint venture with the largest Spanish company in the sector and thereafter opening a new branch in Onda-Castellon.

This operation allowed the company to expand its commercial horizons not only in Spain, but also in France, North Africa and the neighbouring Arab countries.

1973

1990

www.smalticeram.com

Spain

Indonesia

Smalticeram is today one of the world’s leading names in the manufacture of products for applications on ceramic materials. The company’s history goes back forty years to 1970, when it was set up in Roteglia di Castellarano (Reggio Emilia), on the crest of the wave of enthusiasm generated by the significant rise in business of the Sassuolo ceramic district.

1970

India

Ev o l u t i o n in t im e

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.

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 power-on-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.

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).

Supervision system and remote support service SUPERA® is equipped with its own supervision system, which uses a 21” touchscreen monitor complete with a direct software-operator interface allowing for complete diagnostics of the state of the system. It provides historical data, analyses the overall performance of the system(s)

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Cera mic W o rld Review INDIA 2016

www.sitibt.com

(display and analysis of trends and alarm logs) and highlights any abnormalities to enable corrective action to be taken.

Moreover, the Unico supervision system is able to centralise 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.

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. As regards digital decoration, the EVO 8 printer 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 synchronisation between digital graphic design, texture and dry or wet applications of materials. The EVO 8 can now be used in conjunction with the new G5 printer, the first fully modular and customisable system with a printing width ranging from 700 to 1400 mm. In the field of finishing technologies for large panels, Ancora offers a series of innovative solutions, including the flexible, high-precision XXL Deepmotor Cut scoreand-snap line for cutting fired and unfired panels, the XXL Polishing machine, the XXL Wet Squaring machine, the high-speed DRY Squaring Speed machine which allows for considerable energy savings, and the Hi Coat protective treatment.

A complete line for large-size tiles and panels 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.

In addition to the raw materials preparation plants and the decoration and finishing technologies described above, 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 Titanium® heat recovery burner, it can fire tiles of various sizes up to 1600x3200 mm.

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

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Francesco Fontana - Sacmi (Imola, Italy)

Pressure casting: automation and productivity As part of its ongoing commitment to the development of innovative technology, in recent years Sacmi has concentrated on applications catering for the widely varying needs of the world’s sanitaryware producers. European manufacturers require plant and machinery that is automated and sufficiently flexible to cope with increasingly small batches of high-quality products. But in emerging economies where manufacturers have to turn out high volumes with a smaller mix of items, there is strong demand for reliable solutions with high outputs. In both cases, the manufacturers require automated solutions capable of reducing operator fatigue, improving working conditions, cutting production costs and timeframes, and improving the quality of the finished product. Productivity and automation combined with reliability and ease of maintenance are the key strengths of Sacmi machines for ceramic sanitaryware production.

On the one hand, Sacmi has developed single-mould casting cells that combine high automation with rapid mould changing; on the other, it has devoted efforts to standardising and speeding up casting cycles through the use of multimould machines featuring robotic demoulding and handling. For these latter applications in particular, it has designed and developed casting cells with the same layout

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Cera mic W o rld Review INDIA 2016

for the production of two-part items, such as washbasins, cisterns, lids, sinks and shower trays. This enables the production mix to be changed without having to modify the machine or the plant.

Robot programming and the relative position between the machine, robot and conveyor belts have been optimised so as to cut demoulding and handling times to a minimum. The robot mounted on a fixed base follows the shortest trajectories and therefore ensures maximum demoulding speed. On machines with rotating moulds, mould opening has also been greatly speeded up by inserting two carriages instead of just one. This results in demoulding times of under 45 seconds per mould, or less than 30 seconds in the case of vertical demoulding.

These changes have brought significant benefits and have enabled the ALS and ADS versions to achieve cycle times that are comparable to or shorter than those of simultaneous demoulding machines while maintaining the unique technical and technological advantages of sequential demoulding. These benefits include: • The option of performing vertical or horizontal demoulding depending on the model; thanks to its high degree of flexibility, a cell equipped with an anthropomorphic robot can readily adapt to the different articles needing to be demoulded and handled.

• A smaller footprint for the same number of installed moulds.

• The capability of casting deep items such as solid cast cisterns and some models of washbasin by using active containment with Isobox technology (Sacmi patent); this improves the quality of the article and eliminates problems during demoulding without needing to reduce the casting pressure (and consequently increase the casting time).

• The possibility of installing mobile resin inserts and elastic inserts in the moulds (Sacmi patent) so as to form the mounting and overflow holes directly on the machine, thus reducing the work needing to be done by the operator.

• The option of performing horizontal demoulding using custom modelled supports to avoid deformation of cast articles, making use of the robot’s ability to guarantee perfect precision and repeatability of the demoulding se-

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quence; articles such as console washbasins can consequently be demoulded on their backs, leaving the upper section in view and avoiding the risk of damage to the visible side caused by adhesion to the demoulding support.

The technology also features a belt or carriage piece maturing system which enables the operator to perform finishing easily; when the pieces are removed they are already consolidated, allowing them to be separated from the demoulding supports. The maturing system may be complemented by a pre-dryer to speed up the consolidation process and ensure reliability and consistent product quality.

Last but not least, with robotic cells it is possible to implement automatic piece loading on the carriage to reduce operator fatigue and avoid potential damage to semi-finished products during handling. This is a particularly important feature in the case of heavy items such as shower trays, sinks and console washbasins and during night shifts and enables activities downstream of casting to be automated (movement of cars towards the dryer and offloading of pieces for glazing).

Special attention has been devoted to the development of automated solutions for battery production of WCs. The highly flexible new AVB casting bench has the same structure as the ALS and enables manufacturers to produce articles using 2, 3, 4 or 5-part moulds. The machine’s flexibility allows for the simultaneous production of various models using different casting cycles.

The machine can produce either wall-hung or freestanding WCs. In the event of a change to the production mix, the ALS can be converted into an AVB or vice versa. On the AVB cell equipped with an anthropomorphic robot, it is possible to install 8 moulds for freestanding WCs, 7 moulds for wall-hung WCs or a mixture of the two.

The AVM is capable of producing low-cost WCs as an alternative to traditional casting. It reduces both occupied space and labour requirements for the finishing operations and improves the quality of the finished product by using porous resin moulds.

Depending on requirements, Sacmi can supply a complete modelling package with mould, machine and piece maturď œ ing system.

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Products

I.C.F. & WELKO From large-size firing technology (mm 1600x4800 Lamina panels) comes the new I.C.F. & Welko’s WFRE roller kiln for firing large-size traditional ceramic products. The first one was installed in the Italian Emilceramica facility for firing ceramic tiles with size 600x600mm and 800x800mm, with excellent results in terms of output, product quality, energy consumption and management flexibility: up to 390 kcal/kg and 0.015 kWh/kg are the values of the energy consumption for firing 800x800mm tiles at a temperature of over 1200°C. The kiln features the new combustion system with high-efficiency burners, which optimize the air-gas mixture and develop the complete combustion inside the cone, achieving the perfect flame temperature for the best heat rate before the introduction into the channel.

The very high outlet speed of the combustion products (up to 100 m/second) ensures uniform distribution of calories in the section, considerably increasing the fume/ product exchange coefficient.

In the cooling area, besides the indirect cooling fan, two

54

other fans are installed to extract hot air, so as to be able to separate the air with higher energy content which is used for combustion and maintain the remaining hot air for any dryers or ambient heating.

All the burners are suitably insulated to upgrade heat efficiency and avoid dispersion in the work environment.

The system envisages the possibility for the operator to optimize consumption by deciding, through the system control computer, the volumes of air to be conveyed to the burners, the air temperature, the pressure values in the channel and all the parameters able to affect thermal efficiency.

All the parameters can be automatically associated with the types of products.

Cera mic W o rld Review India 2016

Besides the cutting-edge control system, featuring touchscreen type double interface, traditional regulators are also provided in accordance with operator requirements.

Process control is realised by means of the well-tested temperature and pressure curve control system, both during firing and cooling.

The motor inverters optimize not only the electricity bill but also the gas bill, since they are part of an integrated system.

Saving and production go hand in hand; a simple and flexible system for saving, without making life complicated for operators, safeguarding ease of management and end product quality.

The kiln features the following integrated control systems: • A PC for running, supervising and managing data with simple and immediate operator interface to have real time control of all characteristic kiln parameters.

• A PLC for controlling kiln movement, able to acquire the speed of the individual drives and warn the operator in case of a fault.

• A PLC to dialogue with the automatic regulators and manage their data, with possibility of setting the required set point directly from the monitoring PC. • A PLC dedicated to the safety of operators, which controls the condition of the emergency cables along the drive line and all possible alarms, monitoring indicator lights and sirens.

• The PLCs are connected by means of dedicated line to the drive and fan inverters to make all adjustments automatically, thus optimizing kiln operation.

• An Ethernet port permits connection with the customer’s LAN network, thus making it possible to save the data and product recipes directly in a protected server.

This way, the operator does not have to bother about making a safety backup.

• Furthermore, with an Internet connection at disposal, remote maintenance can be installed to quickly solve any problems that might occur.

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products TECNOFILIERE Tecnofiliere used its consolidated experience to develop a dedicated extrusion unit consisting of an extruder die designed and built for operation at very high extrusion pressures. A special lubrication system introduces lubricant liquid into the die to minimise friction during extrusion, thereby avoiding deterioration of the materials, loss of efficiency and wastage of energy. In view of the high abrasiveness of the material being extruded, the new TFI Special type die was built with a liner made of Tecnocarbide, a material with a wear resistance of 2000 HV. The extrusion pressure head features an external braking system to regulate the flow of clay.

The lubricating unit consists of a plate served by a hydraulic power unit with scope for fine adjustment (1%) of the introduced liquid and with intake pressures of up to 75 bar. The specially designed power unit is equipped with an independent tank of 100 litre capacity to en-

sure the maximum efficiency and reliability of the shaping system.

Thanks to this special extruder die it is possible to obtain products with high level of hardness and durability, used as a paving material in many different applications (pedestrian areas, cycle paths, urban streets with vehicular traffic, harsh environments, etc.) specially in environments where pollution, acid rain and other aggressive agents would cause standard materials to deteriorate rapidly.

BEDESCHI The VHTBED type electronic cutter is designed and manufactured by Bedeschi for cutting bricks, blocks, hollow bricks, hollow flat blocks, flue liners and chamfered bricks. The machine can perform horizontal, vertical and oblique cuts. In the singlewire configuration, the cutting length can be set directly from the control panel without the need for additional machine adjustments.

The column speed checking system specially developed for this machine adapts to the cutting

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frequency and allows the bricks to the chamfered. It is also extremely precise as it is installed in the stage prior to cutting.

The machine is equipped with a wire cleaning system and electronic wire breakage control. The cut pieces are spaced immediately after the cutting stage by a system of belts driven by a brushless motor. All the brushless movement elements are integrated into an electronic control system.

The cutter was recently installed and tested in the Czech Republic by KM Beta Cihelna Hodonin.

Cera mic W o rld Review India 2016

20 years of global success

Cer15-Logoblock-f-Tragetasche-E-neg.indd 1

Thanks to our customers worldwide

DIES AND RELATED PRODUCTS FOR THE HEAVY CLAY AND CERAMIC INDUSTRIES

TECNOFILIERE S.r.l. - 41016 Novi di Modena (MO) ITALY - Via Provinciale Modena, 57/A Tel. +39059677797 (r.a.) - fax +39059677759 http://www.tecnofiliere.com - tecnofiliere@tecnofiliere.com

products SMALTOCHIMICA In the last year, Smaltochimica has become the first company to perform industrial-level production of adhesives for micro grains for inkjet application. These innovative and complementary additives are used in the digital decoration of ceramic tiles to extend the range of decorations that can be performed. This has been made possible by two factors: the creation of a new digital department equipped with everything necessary to perform tests and specific measurements; and the longstanding partnership with some of the leading producers and suppliers of chemical products for the industry. The products were developed through collaboration with inkjet machine manufacturers, most notably Projecta Engineering. The new adhesives for grains and powders, which can be applied using conventional digital printheads, are liquid products with the following technical specifications: • A solvent-based chemical nature that makes them compatible with the materials used on conventional printheads and printers;

• Suitable chemical and physical parameters for application with digital printheads (low, constant and Newtonian viscosity, adequate surface tension and absence of particulate guaranteed by a filtration procedure to 5 µm); • Long drying times and high bonding capacity to ensure perfect adhesion of the dry deposited grains and powder particles; • High jetting capacity, which allows the printhead to deposit the maximum permitted volume of product. This increases the deposited quantity and consequently extends the drying times and increases bonding strength.

As a result of digital application of adhesives for grains, tiles can be decorated with powdered vitreous materials according to clearly defined patterns that can be synchronised with the coloured decors, likewise applied by digital printing. This new family of adhesives, sold under the Digicol brand name, consists of various products, some of which are shown in the table.

Drying time

Viscosity

Adhesive power

Certifying plant manufacturer

Printhead

Digicol 2124

Long

Low

+++++

Projecta Engineering

Xaar 1002 GS12

Digicol 2891

Long

Medium-low

+++++

Projecta Engineering

Xaar 1002 GS40

Digicol 3970

Long

Medium-high

+++++

Tecnoferrari

Xaar 1002 GS40

Digicol 3976

Long

Medium-high

+++++

Tecnoferrari

Xaar 1002 GS40

All adhesives in the series are coloured with special organic tracers and filtered to 5 µm. Custom products can also be ordered.

The drying time and bonding strength are directly proportional to the quantity deposited. To increase this quantity, it is advisable to use high discharge printheads (such as the Xaar 1002 GS40) and if necessary to double the number of adhesive application bars in the ceramic inkjet printer. Digicol 2891 was the first digital application adhesive to be used at an industrial level by an Italian ceramic company.

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products POPPI CLEMENTINO Poppi Clementino operates in the field of energy saving and protection of the environment and has gained experience all over the world. In particular, it offers an energy check-up service capable of analysing a company’s current situation and offering solutions tailored to its specific needs.

Optimising energy usage and reintroducing waste energy into the production system can considerably reduce consumption without altering the production cycle. The most energy-intensive machines in the ceramic industry are spray dryers and dryers. The first source of recovered energy originates from the kiln cooling air, which unlike kiln flue gases can be introduced directly into the energy-intensive machines without the need to be treated. Flue gases on the other hand have to pass through a system to reduce pollutants which might damage the machines.

A distinction can be drawn between two kinds of systems depending on whether the waste energy is recovered directly or indirectly, although in reality the two systems can be integrated. In the figure below, we can see that the energy recovered from 5 kilns is

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used to feed 2 spray dryers and 8 dryers, of which 5 are vertical and 3 are horizontal. Poppi Clementino technology is able to create a kind of “energy bank� that can channel the available hot air volumes giving precedence either to the spray dryers or to the dryers according to production requirements. In this specific case, the hot air originating from the kiln cooling system is channelled to the user devices by means of a duct. This is connected to another pipe coming from a heat exchanger which generates hot air using the heat contained in the kiln flue gases.

After the two branches have merged, the duct has a larger diameter so as to be able to transport the larger available air volumes, which are then channelled towards the individual user devices. Various pressure switches and thermocouples are installed along the route and serve to measure the available flowrates in real time to determine the potential reduction in use of the burners installed on the spray dryers and dryers.

Looking in greater detail, the installed heat exchanger is a selfcleaning plate type to avoid the various problems that may occur when using classic shell and tube

C era mic W o rld Review India 2016

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type exchangers. This machine is able to generate an airflow of around 25,000 Nm3/h at 180°C, which added to the 50,000 Nm3/h at 165°C from kiln cooling results in an “energy bank” of 75,000 Nm3/h at 170°C. The available flow can be completely used by the energy-intensive machines without in any way altering their operation, resulting for example in a 20% reduction in the energy consumption of the spray dryers and a 2530% reduction in that of the dryers.

To convert the effective flowrate in m3/h of hot air into m3/h of CH4, it is necessary to determine the quantity of kcal/h available and divide this figure by a coefficient of 8,250, which is the heating value of natural gas. In this specific case we obtain an hourly saving of 395 Stm3/h of CH4.

Considering an average cost of 0.30 euro/Stm3 of CH4, this plant guarantees an hourly saving of 118.50 euro, which multiplied by a production time of 7,000 hours/ year corresponds to a total saving of 829,500.00 euro. From this we need to subtract the plant management costs, which in this case are limited to the higher electrical consumption of the inverterized installed fans. Along with the benefit of around 829,500.00 euro/ year obtained from direct fuel savings, another major contribution comes from white certificates issued according to the number of TOE (tons of oil equivalent) saved. At present these incentives are only available in Italy through companies called ESCO and have a duration of 5 years. An installation of this kind may save 2,600 TOE/year, convertible to 234,000.00 euro/year obtained through this contribution. All plants are supplied with legally valid instruments to measure the values subsequently used by the ESCO. The guaranteed performance of the system is determined on the basis of the data measured by these instruments. The savings allow for a very rapid return on the investment (10-16 months), which is achieved without affecting production setup due to the fully automatic operation of the energy recovery system.

SAVE MONEY WITH OUR

ENERGY SAVING SYSTEMS Poppi Clementino S.p.A. Via Saragat 5 - 42124 Reggio Emilia - ITALY Tel. +39 0522 921337 / 921851 Fax. +39 0522 924044 poppi@poppi.it www.poppi.it

products SMALTICERAM Digital printing has seen rapid expansion in recent years and appears certain to become the main decoration technology used in the ceramic industry in the near future. Due to its sheer scale, this innovation has had a significant impact on the technical and aesthetic trends in the ceramic industry at a global level. The high printing precision of an inkjet printer ensures excellent optical results.

For this reason, manufacturers and suppliers of materials are developing products aimed specifically at exploiting the full potential of inkjet printing.

The first-generation colour printheads have now reached almost optimal levels. The same applies to dyes, where the colorimetric range that can be achieved with 5 printing bars has reached a very high standard. With this in mind, the Smaltink ecosolutions range from Smalticeram currently consists of 12 base colours capable of generating all the tones required for modern ceramic fourcolour printing. In recent years, printhead manufacturers have shifted towards the development

of high ink discharge printing units.

This has opened up new and previously unimaginable potential for applying materials other than a simple coloured ink onto ceramic tiles. The new SD Special Digital line, part of the Smaltink ecosolutions range, consists of reagent compounds, microlustres, devitrifying mineral bases and opacified micro pigments developed

by Smalticeram specifically for this new technology. SD Special Digital materials include special digital materials capable of enhancing ceramic surfaces by creating extremely natural three-dimensional effects. As a result of the combined digital application of colour and material, the Smaltink ecosolutions range offers ceramic tile producers a complete and effective tool for meeting the needs of an increasingly discerning and competitive market.

EBI - CERAMICURE® CeramiCure® Light-Cure Acrylic (LCA™) is the complete sanitary ceramic and porcelain repair solution for making invisible repairs of minor defects, such as pits, iron spots, small chips, or pinholes, in visible, glazed areas. CeramiCure® Self-Cure Acrylic (SCA™) is a complete repair solution for restoring previously unusable “cracked” or “scrapped” pieces, allowing for the repair of larger cracks, even those below the water line. The CeramiCure® Carbon Credit Project is one of the latest initiatives promoted by the US company and demonstrates EBI’s commitment to the environment. CeramiCure® Carbon Credit Project is an invitation to test the environmental benefits of the proposed solutions in terms of CO2 emissions from sanitaryware production facilities. CeramiCure® LCA™ and SCA™ are able to reduce scrap due to defective

62

pieces and the need for refire, resulting in lower costs and greenhouse gas emissions. They also allow sanitaryware manufacturers to increase the number of carbon credits available for trade or sale on the carbon markets. CeramiCure® is looking to partner with its sanitaryware clients worldwide to establish a recognized and accredited formula that can be used to determine the reduction rate, or amount of CO2 reduced, by a plant utilizing the CeramiCure® LCA™ and SCA™ repair products. Companies interested in taking part in the CeramiCure® Carbon Credit project should write to info@ceramicure.com.

Cera mic W o rld Review India 2016

Discover the new

ecosystem A complete solution for the

ceramic world

New Digital Inkjet Printer C4 Maximum performance under all printing conditions.

Color Management EFI™ Fiery® proServer The first complete color management system for ceramic tile printing.

EFI Ceramic Inks A new and full range of ceramic inks.

Intense colors for a very large color gamut and special effects for high performance and premium quality.

Tel: + 34 964 340 264 · cretaprintsales@efi.com · www.efi.com/cretaprint · Carretera Nacional 340a, Km 970 · 12550 Almazora · Castellón, Spain

products LB Migratech is the innovative dry milling system with microgranulation designed by LB. The technology for dry preparation of ceramic bodies has been optimised by developing plant solutions for various types of production, while at the same time ensuring an extremely high quality finished product and a drastic reduction in energy costs and allowing for production based on criteria of sustainable development.

LB has chosen to use the MRV vertical roller mill for the grinding process, as this type of mill is capable of grinding the material to a fineness comparable to that obtained with wet mills. MRV is a finishing mill with built-in dryer and dynamic separator which performs optimal mixing of body components with different levels of hardness. The GRC microgranulation process differs from traditional processes in that the finely ground powder undergoes a small degree of humidification before entering the EVF fluid bed dryer so as to restore the body moisture content to optimal values for pressing. The Migratech bodies display all the positive characteristics of microgranulates while at the same time reducing compaction problems during pressing and guaranteeing a good level of reactivity in the drying and firing stages. Migratech

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also drastically reduces defects caused by the organic impurities usually found in the raw materials, and improves the mechanical and aesthetic characteristics of the finished product. Based on experience with different types of ceramic products, considerable savings of gas, water and electricity can be achieved, resulting in a reduction in CO2 emissions into the environment. Furthermore, the cost of using deflocculants is eliminated and the plant maintenance costs are lowered, as indicated by the average percentage savings shown in the tables.

The body obtained using Migratech technology has a comparable high quality to that of the wet milling processes with spray drying, but involves less bulky production layouts and lower plant operating and maintenance costs. The innovation introduced

by LB with the introduction of the microgranulation process allows for the production of large-format porcelain.

Further innovative characteristics of Migratech include: good flowability of the body during press mould feeding; ease of deairing during pressing; greater uniformity of the unfired pressed body; and reduction in the powder thickness inside the press mould. The average investment payback time is 12-18 months.

Cera mic W o rld Review India 2016

New monolayer tunnel kiln for self-standing roof tiles

SINCE 1908‌ TAKING THE BEST FROM THE PAST TO BUILD THE FUTURE www.bedeschi.com

products SURFACES TECHNOGICAL ABRASIVES Surfaces Technological Abrasives has developed an innovative system for Matt or Silky Matt honing which was unveiled at Cersaie 2015. Polishing and honing have always involved polishing unglazed (full-body) and glazed porcelain surfaces. With the new Matt honing process it is possible to obtain non-glossy, satin surfaces that are extremely smooth to the touch as well as innovative anti-glare surfaces with a gloss level below 10.

This opens up new opportunities in the field of honed products, which can maintain their natural beauty with smooth but not necessarily polished or highly glossy surfaces.

The result can be obtained on conventional glazed ceramic or porcelain surfaces. The new process is also able to solve the surface porosity issues often associated with satin finishing. A major contribution comes from the newgeneration Flexit tools, provided they are used in the ideal sequence. Developed after more ADVERTISING

than a year of tests and studies performed at SurfacesLab, Flexit tools are based on a selection of new and higher performance raw materials and industrial implementation of the technological process tested on machines at the Surfaces polishing pilot plant.

Even the smallest details have been designed to adapt to different ceramic surfaces. The high removal capacity typical of Surfaces products has been combined with a sophisticated machining operation that produces the innovative silk touch effect.

These machines also have a high degree of flexibility that enables them to reach any rough areas on the surfaces.

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

The future of ceramics

26 -30 SEPTEMBER 2016 RIMINI - ITALY th

Organized by

In cooperation with

With the support of

tecnargilla.it

th

ULTRA-HIGH QUALITY OF THE SLAB SURFACE

UNLIMITED EXPANSION OF DESIGN POSSIBILITIES

BELT CLEANING WITHOUT MACHINE DOWNTIMES

DIGITAL DRY DECORATION FOR AN INFINITE RANGE OF EFFECTS

The continua+ compaction belt is always moving with respect to the ceramic powder. So unlike the steel plunger in a traditional press, it never gets dirty and always ensures the pressed slab has a perfectly flat and glossy surface.

Thanks to Sacmi’s ddd (digital dry decoration) technology, continua+ lets manufacturers maximise digital design potential, providing innovative aesthetic effects that would be unattainable with any other type of system.

continua+ can be used to manufacture porcelain ceramic slabs and tiles in a wide range of thicknesses and sizes, customised both on the surface and in-body.

The aesthetic effects range is practically unlimited. www.sacmi.com