Ceramic World Review India 2021

Wall and Counter: MAXIMUS PAlISSAndro Floor: MAXIMUS UnI

contents

Year 31 Supplement to no. 141 April/June 2021 Bimonthly Review

Cover picture by: Giancarlo Pradelli

7 Editorial

India strengthens its position as a global tile exporter

Paola Giacomini

8 Interview

RAK Ceramics returns to steady growth

Milena Bernardi

Focus on 12

16

20

22 28

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large sizes & panels

Gianluca Pederzini, Andrea Bresciani

Slabs and sub-sizes: high flexibility and a productivity of 21,500 sqm/day

LySCl vkSj lc&lkbt% mPp yphykiu vkSj 21500 oxZehVj çfrfnu dh mRikndrk System Ceramics

Uncompromising productivity, sustainability and connectivity

vVy mRikndrk] fujarjrk vkSj la;kstdrk ¼dusfDVfoVh½S Large slabs with a total black look

Colorobbia

iw.kZr% dkys Lo:i okys fo'kky LySCl Functionality and aesthetics with dry super-polishing

Focus on

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Marco Sichi

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Glazing & Decoration Digital glues: what they are, and where and how to use them!!

Inco R&D Dept.

34

DigitalGlass the eco-sustainable water-based glaze

Davide Zannoni

36

Full digital and hybrid technology for sustainable ceramic decoration Luca Berti

38

Covertech, new decorative digital effects

40

44

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Fritta

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Cutting-edge technology, outstanding aesthetics and care for the environment

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Torrecid

Products

54 Technology

Gas turbines: green energy for the future

56

Automation in sanitaryware production: anthropomorphic robot-assisted casting

60

Non-stop innovation in the field of ceramic finishing

64

Satellite system: the solution for lapping and polishing

68 Products

Solar Turbines

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Sacmi Sanitaryware Surfaces Group

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Piergiorgio Trevisan

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editorial

by Paola Giacomini, Editor - p.giacomini@tiledizioni.it

India strengthens its position as a global tile exporter Since it first made a mark on international markets less than 10 years ago, the Indian ceramic tile industry has continued its meteoric rise and by the end of 2020 had become the world’s second largest exporter behind China (which saw a 20% contraction to 622 million sqm) and ahead of Spain (422 million sqm).

Last year, India’s tile producers chalked up another astonishing success with total exports of 445 million sqm (up 24% on 2019), an achievement that has helped the industry recover more rapidly from the impact of the Covid-19 pandemic.

To talk of “double-digit” growth is a significant understatement. When in 2014 India’s exports passed the 100 million square metre mark for the first time, it was the result of an 85% upturn, followed by increases of 31% in 2015, 39% in 2016, 23% in 2017, 20% in 2018 and 31% in 2019.

India is also shipping tiles to a steadily growing number of countries, up from 150 in 2018 to 174 in 2020.

It is becoming increasingly clear that in many markets India is gradually supplanting China as the go-to supplier country.

Indian exports have grown in all global regions, including Asia (+14% to 270 million sqm), Africa (+27% to 60 million sqm), Europe (+60% to 50 million sqm), North America (+62% to 47 million sqm) and South America (+17% to 15 million sqm).

India saw growth in sales in no fewer than 23 of its top 30 target markets in 2020, compared to 4 for China, 16 for Spain and 12 for Italy.

Significantly, the Indian ceramic industry has also succeeded in cementing its position in GCC markets despite the anti-dumping duties which were imposed in November 2019 and renewed in June 2020 (for most Indian companies the tariff stands at 41%). In particular, Saudi Arabia not only confirmed its position as the largest export market for Indian ceramic tiles but saw further 25% growth to 91 million sqm. This compares to the 24% decline in sales by China, India’s main competitor which has likewise been hit by anti-dumping duties.

Exports also performed well in Kuwait (+29%), Oman (+11%) and the UAE (+8.5%).

The Indian ceramic tile industry’s other standout performance was in the USA, where exports tripled to 27 million sqm in 2020 and continued to grow by 88% in volume and 99% in value through the first quarter of 2021, making India the fifth largest exporter to the USA after Spain, Mexico, Italy and Turkey.

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jd fljsfeDl iqu% fujarj o`f) dh vksj RAK Ceramics returns to steady growth Milena Bernardi - m.bernardi@tiledizioni.it

RAK Ceramics, one of the largest ceramics brands in the world, announced its financial results for the quarter ended 31 March 2021, which confirm the return to a state of steady growth. The company surpassed pre-pandemic levels of operation, with record levels of revenue and profitability.

This is very good news for the Ras-al-Khaimah-based Group after a challenging 2020, when total revenues dropped by 8.7% to AED 2.35 billion (approx. 521 million euros) due to the COVID-19 lockdowns in the second quarter and despite the accelerated recovery in the third and fourth quarters.

“It would be an understatement to say that 2020 was a challenging environment,” said CEO Abdallah Massaad. “Despite the apparent challenges, I am pleased with our achievements in 2020 and the early parts of 2021, which resulted from our ability to act decisively during times of crisis and from our appetite, as an organisation, to adapt and innovate.

“We placed great emphasis on maintaining our customer relationships and product development schedule, with the launch of a range of innovative new products across all our business divisions. Moreover, we continued to invest in our production facilities with the installation of solar rooftops and co-generation technologies. Being a large energy consumer, these technologies help us be more sustainable and ultimately improve the bottom line”.

We asked Abdallah Massaad to tell us how business is going now.

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interview

Talking to...

Abdallah Massaad

Rak Ceramics Headquarter

CWR: What would you say about the results achieved in the first quarter of 2021?

ABDALLAH MASSAAD: Operations across global markets continued to improve, leading to the strongest start to the year recorded by RAK Ceramics since 2016. Total revenue is the highest it has been in 5 years, increasing by 21.9% year on year. Total gross profit margin reached an all-time high of 35.0% driven by an increase in revenue, an improvement in efficiencies and the optimisation of production lines. Reported net profit outperformed pre-pandemic levels of profit.

CWR: How do you view your performances and position in Saudi Arabia, one of your major export markets?

A. MASSAAD: Already in 2020, we were able to capitalise on the opportunity in Saudi Arabia and enhance our business.

Our revenue last year increased by 57.9% year on year, due to the introduction of differentiated tile sizes and a focus on retail and wholesale sales. These results were also backed by the imposition of anti-dumping duties on tiles from India and China in the Kingdom, which initially led to an increase in demand for RAK Ceramics’ products. We decided to invest on the market, opening new showrooms and developing significant brand equity. This strategy continued to yield results in Q1 2021 with revenue up by 78.5% and RAK Ceramics being now the go-to provider of premium ceramic products in the Kingdom.

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CWR: What about the other major markets?

A.MASSAAD: In Europe, our revenue increased by 2.7% last year, driven by growth in the sanitaryware and tiles market. In Q1 2021 we registered a growth of 22.7% on the same period in 2020, driven by improved economic activity, allowing us to surpass pre-pandemic levels of operation and to increase our customer base both in Central Europe and the UK by differentiating ourselves from competitors.

As for our domestic market, sales grew by 2.1% in Q1 2021, while exports to the rest of the Middle East (excluding Saudi Arabia) already increased by 12% in 2020.

CWR: Let’s talk about India, where you are present with one production plant for ceramic tiles and slabs and one for sanitaryware. What are your expectations considering the dramatic impact of the second wave of Covid-19?

A. MASSAAD: In India, we have taken short-term and longterm initiatives to streamline our business and boost efficiency, including team restructuring, strengthening sales strategy, production cost optimisation, sales and administrative rationalisation.

The year 2021 started with positive business sentiments in the real estate sector, which led to increased demand and steady revenue growth (+67% in Q1 2021). However, the recent surge in COVID-19 cases has led to a second wave of lockdowns in some states, resulting in restrictions in the logistics movement. We anticipate that revenue and profitability will be impacted from the second quarter of 2021 if the situation does not improve.

CWR: How is your production activity proceeding in Bangladesh?

A. MASSAAD: In Bangladesh, production is running at optimum capacity. We have developed and introduced differentiated products to specific market segments, such as supplying commodity products for the rural segment and value-added products for the urban and luxury construction segment. This has led to an increase in market share and our sales in Q1 2021 were up 18.9%.

To further stimulate growth, maintain our market share, and strengthen our customer relationships, we have offered high incentives to dealers, and to support these activities, a new showroom is also scheduled to open in Dhaka later this year.

CWR: Do you feel that relationships with the market have changed in some way since the start of the pandemic? How are you experiencing the “new normal” today?

RAK Ceramics Founded in 1989 in Ras-Al-Khaimah (UAE), RAK Ceramics is one of the world’s largest ceramic producers with a yearly production capacity of 118 million square metres of tiles, 5 million pieces of sanitaryware, 24 million pieces of porcelain tableware and 1 million pieces of faucets. Production takes place at its 21 state-of-the-art plants across the United Arab Emirates, India and Bangladesh. RAK Ceramics, which is a publicly listed company on the Abu Dhabi Securities Exchange, serves clients in more than 150 countries through its network of operational hubs in Europe, Middle East and North Africa, Asia, North and South America and Australia.

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interview

A. MASSAAD: Over the past 12 months, we have all had to adapt to the situation and embrace the new normal, and there is no doubt that technology has played a significant role in supporting this adjustment.

Last year, we launched a virtual reality showroom that allows our customers to virtually view and interact with our products.

The platform was well received and is actively used by many of our remote customers worldwide.

However, while technology provides an excellent platform for us to communicate, share ideas and exchange information, it does have limitations regarding product and brand experiences.

Experiencing our tile and sanitaryware products benefit from a physical interaction to stimulate the imagination and enhance the design process. Every aspect of our products are carefully designed, and our customers still prefer to experience the unique colours, textures and appreciating the qualities of our products in person rather than virtually.

CWR: In general, what legacy has the pandemic left behind?

A. MASSAAD: The pandemic has impacted all of us, and we have all learned how to adjust. Organisations must adapt quickly and act decisively in times of crisis, no matter their size, and business leaders must remain focused on longerterm fundamentals such as innovation, environmental impact, employee wellbeing and business profitability.

While 2020 was a challenging year for RAK Ceramics, the early implementation of measures to manage the impact of the pandemic has served us well and led to an accelerated recovery.

Today, we are in a strong growth position, surpassing pre-pandemic levels of operation, with gross profit margins reaching an all-time high. Our production levels are at the highest they have been since 2016, on the back of increased demand across our key markets.

Looking forward, we will capitalise on this demand by building our brand equity and positioning RAK Ceramics as a global provider of premium ceramic lifestyle solutions.

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LySCl vkSj lc&lkbt % mPp yphykiu vkSj 21500 oxZehVj çfrfnu dh mRikndrk Slabs and sub-sizes: high flexibility and a productivity of 21,500 sqm/day Gianluca Pederzini, Andrea Bresciani, Sacmi (Imola, Italy)

The revolutionary new PCR2180 is the latest addition to the Continua+ family, the global benchmark for the production of slabs and sub-sizes, and delivers the lowest levels of specific consumption in its category along with 160% higher productivity.

Like its sister version, the PCR2000, currently the most popular model on the market, this latest solution is designed to handle slabs and sub-sizes with variable lengths and thicknesses ranging from 3 to 20 mm (30 mm on the PCR3000).

The most important new feature on this model is the belt width, which allows it to produce fired slabs as wide as 1,800 mm while maintaining higher output rates. The result is a sharp increase in overall productivity, up to 21,500 sqm per day. ❱ How slabs have evolved Ceramic manufacturers have two closely-related needs in terms of finished products. The first is to be able to produce high-end slabs in increasingly large and innovative sizes, while the second is to maximise productivity and versatility in the production of sub-sizes and to allow for customised, justin-time production.

The PCR2180 offers a solution to both these requirements.

With regard to productivity, 1800 mm is equivalent to three 600x600 mm exits (and their corresponding modular sizes

PCR2180

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Focus on large sizes & slabs

Precomposition

600x1200 mm, 600x900 mm, 300x600 mm, etc.). For this reason, along with the higher speeds in terms of m/s, this Continua+ model can offer a system-wide response to the need to efficiently manage an increasingly diversified product mix that transcends the traditional distinction between slabs and conventional sizes. ❱ Waste-free versatility At least fifteen years have gone by since the pioneering days when ceramic slabs were considered a niche product. During this period, Sacmi has invested heavily in technology for maximising production efficiency, developing a system that allows scrap to be kept below 3% regardless of product size.

This latest version of Continua+ not only produces a very limited amount of scrap but is also capable of recycling it directly on the line, thereby entirely eliminating process waste.

Another advantage of the PCR2180 is its low consumption levels. Despite its higher productivity, it has the lowest levels of specific consumption in its category (0.06 kWh per square metre) against a modest increase in installed power. As for sustainability, this latest model is designed to operate with just 200 litres of hydraulic oil, 90% less than the quantity needed on a discontinuous press. ❱ Maximum flexibility in terms of raw materials and bodies Raw materials and bodies are a complex subject and vary enormously according to customers, geographical areas and markets. Nonetheless, the ceramic industry is showing growing interest in solutions ca-

On-the-fly cutting

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Focus on large sizes & slabs pable of using different types of bodies and raw materials, especially those available locally. The aim is not only to improve sustainability but also simply to ensure continuity of production, as witnessed in 2020 by the sharp contraction in supplies caused by international travel restrictions. This issue has also become central to Sacmi’s research efforts aimed at making the Continua+ family as versatile as possible in terms of different types of bodies and raw materials.

As for process quality, the key technological parameter to be taken into account is the density of the compacted material, which must be similar to that obtained with static pressing. In terms of figures, this means about 400 kg/cm².

The ceramic bodies used by manufacturers in different geographical regions may of course vary considerably in terms of cost, quality and product type. This is why Continua+ is designed to handle bodies for large slabs (which generally require high plasticity) as well as leaner bodies typically used for producing medium to small sizes by cutting the slabs immediately after compaction. In both cases, the products retain optimal mechanical strength. ❱ Automation and setup One of the new features of the Continua+ 2180 is the option of motorised size changeover, which marks yet another step towards just-in-time ceramic production as part of a make-toorder approach.

On both motorised and manual control versions, the operator can easily set the size without wasting time and resources.

Most importantly, the line does not lose efficiency in the case of size changeovers in terms of either speed or scrap rates, which never exceed 3% in any production scenario. ❱ Interconnected and digital In developing the new Continua+ model, Sacmi has reasserted its plant engineering expertise with a focus on digital process and flow control. Natively integrated with the HERE Sacmi plant supervisor, Continua+ is designed to be part of an Industry 4.0 ceramic plant, operating in synchronicity with the downstream glazing and digital decoration department and the upstream powder and raw material preparation plants.

This brings two main advantages. The first is the ability to constantly monitor quality, costs and performance, the second the capability to create on-surface and through-body decorations as early as the compaction stage through controlled deposition of spray-dried powders.

Thanks to the supervisor and the inline inspection systems, these tasks can be synchronised with all downstream glazing and digital decoration stages, giving manufacturers the opportunity to create products with unprecedented aesthetic qualities in terms of the depth and three-dimensionality of the decoration.

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vVy mRikndrk] fujarjrk vkSj la;kstdrk ¼dusfDVfoVh½ Uncompromising productivity, sustainability and connectivity System Ceramics (Fiorano Modenese, Italy)

Three factors have established Superfast as the new benchmark in the field of ceramic tile pressing: productivity, environmental sustainability and above all connectivity. As the world’s first and only mouldless press, it is capable of delivering advantages and levels of performance that simply cannot be matched by conventional systems.

Based on System Ceramics’ many years of experience working on innovative engineering solutions in the field of surface shaping, Superfast represents the latest technology in this segment as well as a vital step towards ever-higher standards of quality and efficiency.

With its single mouldless belt, the Superfast system achieves a level of flexibility unprecedented in the production of traditional tile sizes. The use of 60 cm, 80 cm and 90 cm modules and thicknesses from 3 mm to 30 mm ensures a quick and simple set-up.

The size and thickness changeover operation is also extremely straightforward and rapid as it is performed via software.

In this configuration, nothing is left to chance.

Superfast works with standard spray-dried powder formulations, allowing for a high degree of flexibility in the choice of incoming raw materials in terms of moisture, flowability and parti-

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Focus on large sizes & slabs

cle size. It is a process innovation that allows manufacturers to manage the entire manufacturing process with unprecedented flexibility and zero waste, resulting in 100% recycling of unfired materials in keeping with the principle of green technology.

Thanks to a shaping process based on the double filling technique, the material undergoes real-time grinding alongside the press and subsequent mixing ready for reuse. In the double filling operation, the recycled material is used to form the base of the ceramic tile and the pure spray-dried material is applied on top of this layer. This extremely efficient process is managed easily by software, resulting in zero waste and consequently lower consumption of raw materials.

The energy savings of up to 70% and the reuse of unfired materials mark an important step towards contemporary concepts of sustainable industry. The recovery and reintroduction of waste into the process also maintains the high level of quality of the ceramic product. Laboratory tests performed by accredited and independent research centres have shown that the aesthetic and technical quality of the finished tiles is identical to that of products made using solely pure spray-dried powder.

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Focus on large sizes & slabs This focus on the development of technologies for increasingly sustainable manufacturing is a crucial factor for System Ceramics, which is deeply committed to circular production and reducing costs and energy consumption. ❱ Interconnection and AR Smart Assistance This unique distillation of advanced technology has also become the testing ground for digitalisation. Through extensive R&D efforts in the field of IT Engineering and Digital Industrial Design and the adoption of cutting-edge manufacturing tools, System Ceramics has long been studying and deploying remote access and smart assistance solutions for the installation and maintenance of its plants and machines all over the world.

System Ceramics has completed major orders in recent months despite the slowdown of the international market, demonstrating that its plant engineering expertise is capable of reaching even the most distant geographical areas from the Italian headquarters thanks to a network of foreign branches and the wealth of knowledge it makes available to customers.

The travel restrictions have not prevented System from installing and starting up a new Superfast plant at the factory of a leading Chinese player. The operation was completed to the customer’s full satisfaction thanks to collaboration between the System Ceramics’ Italian headquarters and the System China subsidiary.

Thanks to the hard work carried out by engineers from the Italian headquarters, the Superfast press (Superfast 19000 with pressing area 1200x2700 mm) was successfully installed and started up on time and in complete safety. Once cameras had been installed in the customer’s factory, System China provided on-site assistance and managed the project remotely in close cooperation with the Italian headquarters. The engineers used latest generation technologies, such as augmented reality optical devices for AR Smart Assistance applications, which are particularly suitable for industrial environments thanks to their characteristics of reliability and safety.

This technology is able to interconnect operators with device and system data via a state-of-the-art Industrial Internet of Things infrastructure, integrating all the machines and plants involved. In the specific case of the new Superfast line started up in China, the client was able to make use of high-performance engineering and digital solutions in order to start up, manage and test the plant remotely.

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iw.kZr% dkys Lo:i okys fo'kky LySc Large slabs with a total black look Colorobbia (Sovigliana Vinci, Italy)

The range of ceramic pigments produced by Colorobbia cater for many different needs and can be customised according to companies’ production technologies and finished products.

Pigments for colouring porcelain stoneware bodies are currently attracting great interest due to their wide range of applications and the variety of solutions available. In particular, they can be used to produce an unlimited array of coloured bodies in a palette ranging from soft to more intense tones (black, orange, red, brown, blue, etc.).

Colorobbia produces three different series of pigments for colouring porcelain tile bodies: • the 6 series for wet dispersion colouring, • the 7 series for dry dispersion colouring, • the 7x7 series for dry dispersion colouring with high mechanical strength.

These pigments have recently seen a surge in demand for full-body colouring of large-size slabs, products that mainly serve as floor and wall coverings but are increasingly also being used as worktops, tables, walls, doors, ventilated façades, etc.

To meet the specific needs of this market segment, Colorobbia recently developed the 6 Series black pigment PG 64125, a product with high technical and colorimetric performance capable of producing coloured bodies in an extensive palette ranging from neutral grey tones through to intense blacks.

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Focus on large sizes & slabs

This is achieved without affecting the degassing process or the dimensional stability of the substrate and guarantees both a low pyroplastic deformation index during the firing phase (at a temperature of 1180-1220ºC) and constant levels of water absorption of the finished product, regardless of its thickness (from 6 to 30 mm).

The black pigment PG 64125 is able to create a coloured substrate suitable for direct printing of 100% digital (Full Digital) decorations, a crucial characteristic given the importance of the surface finish of large size slabs. ❱ 100 years serving the ceramic industry Gruppo Colorobbia, which celebrates its 100th anniversary this year, produces a wide range of pigments for ceramic tiles, sanitaryware, glass, sheet metal, plastics, etc., at its modern plants located all over the world and exploiting its own expertise in all production processes.

Colorobbia is a proactive partner and a key player in the testing and implementation of new industrial solutions thanks to its longstanding and close collaboration with leading plant manufacturers.

With production sites and branches located in the main ceramic clusters around the world, the group is able to maintain close contact with its customers and offer a complete service in terms of technical and graphic assistance, R&D and innovation for the development of individual projects. The group also guarantees the complete transfer of its technical know-how during industrial adoption of its high value-added products.

No less importantly, the company has a longstanding commitment to protecting the environment and safeguarding the health and safety of its employees and customers. It strives to continuously reduce emissions and waste, minimise the use of hazardous substances and comply with the latest laws and regulations on substance classification. 5

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'kq"d lqij&i‚fyÇ'kx ds lkFk dk;Z'khyrk vkSj lkSna ;Z Functionality and aesthetics with dry super-polishing Marco Sichi, BMR (Scandiano, Italy)

Driven by the need to improve the productivity and efficiency of new technologies, BMR has made further investments in R&D with the aim of developing a new finishing solution capable of guaranteeing an adequate, constant and high-performance workflow.

These needs are largely met by SuperShine, the hi-tech surface treatment machine that is transforming the ceramic surface and slab finishing process. SuperShine is effectively the first dry super-polisher. The process is based on a mechanical and physical interaction between the tool, the surface and the applied chemical product and is designed to enhance the digital graphics of the tile and give the surface a high level of gloss and protection.

Fig. 2: Untreated ceramic slab and slab treated with SuperShine

Fig. 3: Reduction in roughness of the treated surface The reduction in roughness makes the glaze extremely transparent with more reflected than refracted light

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Focus on large sizes & slabs Fig. 1: The lapping process

Lapping is the first processing step and involves removing a portion of the surface from glazed and/or porcelain products (photo 1). Its aim is to achieve the desired finish, giving the surface a high gloss level and an appearance of greater reflectivity and depth thanks to the considerable reduction in roughness (photos 2 and 3).

The lapping phase is followed by finishing and then treatment. In this stage, SuperShine alters the morphology of the surface by filling the pores that typically occur in the material, giving the finished product very specific technical characteristics such as high abrasion and acid resistance.

A lapped product generally arrives at the super-polishing stage with a Gloss value of 55/60 and roughness Ra 0.060 mm, whereas after treatment the Gloss level is 95/100 and average roughness Ra 0.020 mm. With this final roughness value the tile has a good level of resistance to soiling and staining.

Photo 4 shows an electron microscope image of a surface treated with supergloss applied by a BMR SuperShine lapping and treatment line.

For a correct understanding of the images, it is important to note that the colour scale is inversely proportional to the density. Higher density elements therefore appear whiter, while the voids (corresponding to an absence of density) appear blacker the deeper the pore.

In the photo showing a specimen of treated material, the light and uniform colour of the pores indicates a high degree of penetration of the treatment (the lighter the colour, the denser the treatment).

Conversely, we can see that the colour of the glaze around the pores has remained unchanged, indicating that it has not been coated with any material.

On enlarging the images (photos 5 and 6), we can see that not only the colour but also the appearance of the pores has changed. The green and blue boxes show the points where a qualitative analysis of the chemical elements present was carried out. The resultant spectra are shown below.

UNTREATED

TREATED

Fig. 4: Electron microscope analysis of treated and untreated surfaces

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Focus on large sizes & slabs ❱ Untreated material (fig. 7) The compositional analyses show that the elements present in the pore of the untreated material are the same as those found in the area surrounding the pore, namely: Si, O, Ca, Zn, Na and K. In box 3 relating to the empty pore, note the background noise represented by the values of between 0 and 2. This is because the surface is more difficult for electron beams to reach due to the cavity. ❱ Material treated with SuperShine (fig. 8) Comparing the values for the empty pore with the subsequent spectra (filled pores) for the treated material, it is evident that the elements inside the pore have changed whereas those in the area surrounding the pore have remained the same. This is due to saturation of the porosity following the treatment and underscores the fact that the surface portion of the glaze has not been coated.

Si, O, Ca, Zn, Na and K are again found in the area surrounding the pore, whereas almost solely Si and O are found inside. It can also be seen that the quantity of C (carbon) is very low and practically the same in all the samples, demonstrating the inorganic nature of the treatments. Conversely, the Au (gold) peak is attributable to metallisation, a technique necessary to prepare the samples for scanning. As can be seen from the above analysis, the post lapping process using SuperShine improves both protec-

Fig. 5: Untreated sample (empty pores are dark coloured)

Fig. 6: Treated sample (pores filled by the treatment are light coloured)

Fig. 7: Spectra of untreated material

Fig. 8: Spectra of treated material

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CWR INDIA 2021

SUSTAINABLE inkjet ceramic decoration We plant 17 trees with each hybrid printer installed, compensating 9 tons of CO2 emissions per year.

Visit: sustainable.eficretaprint.com

Hybrid Ceramic Ecosystem

EFI Cretaprint | Tel. +34 964 340 264 · www.efi.com/cretaprint · creataprintsales@efi.com

Focus on large sizes & slabs TAB 1. ROUGHNESS ANALYSIS Untreated

Treated with SuperShine

Measurement

Ra

Rz

Rq

Ra

Rz

Rq

1

0.053

1.613

0.156

0.046

0.443

0.066

2

0.046

1.513

0.112

0.045

0.861

0.089

3

1.171

4.797

0.527

0.052

1.585

0.137

4

0.196

4.858

0.578

0.048

0.971

0.089

5

0.086

3.031

0.249

0.037

0.567

0.063

6

0.144

3.797

0.395

0.081

1.241

0.169

7

0.063

1.191

0.124

0.132

1.190

0.210

8

0.100

3.460

0.328

0.079

1.091

0.144

9

0.199

5.589

0.595

0.098

1.198

0.208

10

0.108

3.773

0.333

0.094

1.955

0.247

AVERAGE

0.053

3.364

0.340

0.071

1.110

0.142

tion and the surface finish. Following the lapping process, the average roughness value Ra was further reduced by approximately 40% (Table 1). ❱ Conclusions The tests carried out show that the SuperShine process has a dual function: aesthetic polishing performed by the mechanical action of the tools, and a protective treatment that involves closing the surface porosity. These results are demonstrated both by the increase in gloss level (from 73/76 at the entrance to 89/92 at the exit from SuperShine) and by the lower degree of roughness, which is reduced by a further 40% after lapping. The compositional analyses also show that no material from the treatment is found on the glaze and that the treatment inside the pores is inorganic. Furthermore, the polishing process carried out with SuperShine allows the line to be upgraded in terms of finish. The process has a proven track record of improving aesthetic quality due to its ability to remove finishing defects such as stains, movement marks and tiny scratches. This increases the productivity of the line by reducing fixed production costs and significantly improves the quality of the slab.

5

Fig. 9: Acid resistance

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Fig. 10: Foot traffic resistance

Inco R&D Dept. (Pavullo, Italy)

Digital ceramic glues for inkjet application are the latest version of a technology that has frequently been used in the past for ceramic tile decoration.

Essentially, digital ceramic glues or adhesive inks are inkjet inks for drop on demand technology that enable glass grits or powders to adhere to the tile surface according to a digital design.

Due to their special polymer content, they have a bonding or gluing capacity when applied to the tile surface. But to ensure excellent technical results, these polymers must guarantee perfectly stable bonding of the applied grits through to the firing/melting stage.

At the same time they must not give rise to film-forming effects as this would risk damaging the printhead.

Clearly, this solution offers exceptional decorative potential.

As the glues are applied according to a digital design, they can be synchronised with both the coloured graphics and the material effects.

This overcomes the problem of anonymous, flat-looking digital printing and allows ceramic products to acquire low-relief effects and unique contrasts of light and colour.

These products can be loaded on the last bar of traditional decorating machines, if available, followed immediately after the exit by a grit application machine.

For greater flexibility of the system, as an alternative it is recommended to use new generation stand-alone machines with limited cost (a single machine consisting of a printing bar fol-

1

28

SOLVENT BASED

WATER BASED

ORGANIC INORGANIC

ORGANIC INORGANIC

CWR INDIA 2021

FOCUS ON: Glazing & Decoration

lowed by a grit applicator, in some cases incorporated).

Due to its small size, this machine can be positioned at the point on the production line considered most appropriate.

Digital ceramic glues can be used on all types of ceramic materials, including porcelain, white body, red body, large slabs, etc., either for full-field applications (over the entire surface of the tiles) or solely for decorative graphic effects.

Depending on the intended use, consumption can vary from a few grams per square metre up to 50-80 g/m2 for full-field grit applications. ❱ Solvent and water based digital glues Although digital glues have evolved significantly over time in step with advances in technology, both the older and more recent versions are relevant today and each offer different characteristics and advantages.

Digital glues are divided into the two large categories of solvent-based and water-based products, which in turn are divided into organic and inorganic (photo 1).

Solvent-based means products that use solvents, such as oils, which are not miscible with water and have a high lubricating power.

Water-based means products with a high water content as well as water-compatible and water-miscible solvents.

A glue is defined as organic when it consists entirely of intermixable organic solvents/additives and presents as a clear,

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29

FOCUS ON: Glazing & Decoration

transparent liquid.

It is inorganic if it contains a fraction of suitably milled and stabilised inorganic matter, with sub-micron particle size distributions (as is the case with all ceramic inkjet inks).

So what are the main characteristics of the various glues currently on the market?

In chronological order, the first type to be developed were organic solvent-based glues, which consist entirely of completely intermixable organic chemical materials that are incompatible with water, generally oils and polymers.

Thanks to the high degree of lubrication and complete homogeneity typical of their constituent organic substances, they eliminate the problems that typically arise with conventional ceramic inks such as sedimentation, open time and filterability. They allow the printheads to be kept in excellent condition without the need for any special care or maintenance.

As they do not contain inorganic material, the colour intensity of the underlying designs is unaffected.

These types of products are recommended for users looking for a solution that is suitable for any kind of printhead and which combines excellent in-machine performance with good bonding power, as well as the high flexibility necessary to achieve material effects without sacrificing definition.

Inorganic solvent based glues are true ceramic inkjet inks containing an inorganic material milled to a particle size distribution of less than a micron.

Inorganic inks with different percentages of inorganic matter can naturally be chosen according to requirements in terms of application and colour intensity.

But what are the benefits of using inorganic material in a glue?

There are three main advantages.

• It increases drainage times during application, which in turn improves gluing times from ink application through to the subsequent grit/powder application.

• It acts as a flux during firing, allowing for homogeneous, compact and defect-free application even with low grit application weights. In other words, it avoids the distinctive tree bark effect that occurs during firing when grits tend to

30

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INNOVATION & DIVERSIFICATION EXIT FROM PRODUCT FLATTENING THROUGH TECHNOLOGICAL INNOVATION.

TESTPRINT DIFFERENT DIGITAL STRUCTURES ON SAME TILE WITH FLAT MOLD.

Matching structure printing with revolutionary Gamma DG digital glaze synchronized with Gamma XD.

DURST — THE INNOVATION LEADER IN CERAMICS durst-group.com/ceramics

FOCUS ON: Glazing & Decoration

accumulate in some areas rather than others due to surface tension differences with respect to the substrate.

• For the same quantity of applied glue, it guarantees lower emissions of VOCs and odours from the flue compared to an organic solvent-based glue.

This type of product is recommended for users who need a solution that is suitable for any type of printhead and combines outstanding machine performance with optimum bonding power and excellent grit application. ❱ The development of water-based glues Over the years, problems relating to emissions of harmful substances in flue gases along with odours generated by the combustion of these solvents have driven research into new solvent phases capable of solving these two issues while maintaining the products’ excellent technical characteristics.

This led to the development of eco-friendly formulations designed to reduce the environmental impact of digital glues, especially for high weight applications.

This initially involved using new types of solvents capable of reducing the quantities of harmful and foul-smelling organic substances generated during combustion.

Then at a later stage, the development of innovative printing technologies allowed water-based inks to be used.

The new printing technologies available on the market today ensure excellent jetting and in-machine performance.

This was initially achieved thanks to the new water-compatible printheads, then as a result of printer developments in terms of the ink heating/cooling system, the automatic cleaning system, and the ink circulation/de-airing system.

As mentioned above, the water-based adhesive ink may be organic or may contain a fraction of inorganic material, as in the case of solvent-based glues.

The big difference compared to the respective solvent-based versions is that water-based inks ensure a significant reduction in atmospheric emissions of organic substances and odours, even compared to versions developed with eco-friendly solvents.

One very important advantage of water-based adhesive inks compared to analogous solvent-based products is the fact that they have a greater affinity with other ceramic applications and for this reason allow for unmatched printing definition.

Inco offers a wide range of solvent-based adhesive inks (DigiGlue S) and water-based adhesive inks (DigiGlue W) containing different percentages of inorganic material.

This enables them to meet any production requirement in terms of environment/emissions, technical/application aspects and colour intensity.

With such a comprehensive range and the technical expertise of its staff, Inco is able to recommend the most suitable solution for any ceramic company. ✕

COLOUR INNOVATION INDUSTRY

32

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EXPERIENCE AND INNOVATION

Ink Refill

Technology

Refill your colours

Equipment and systems for suppling inks to digital ceramic printers

Cisterna di rifornimento Refilling tank

Gruppo valvole a servizio della stampante Valve unit for servicing the printer Dispenser Dispenser

VIBROTECH S.R.L. CERTECH GROUP Sede Legale: Via Racchetta, 2 int. 20 - C.P. 41049 Sassuolo (MO) Italy Sede Operativa: Via Don Pasquino Borghi, 4 - C.P. 42013 S. ANTONINO DI CASALGRANDE (RE) Italy Tel. +39 0536 823776 - Fax +39 0536 812009 - www.vibrotech.biz - info@vibrotech.biz

®

DIGITALGLASS THE ECO-SUSTAINABLE WATER-BASED GLAZE Davide Zannoni, Esmalglass-Itaca (Villareal, Spain)

In keeping with its commitment to sustainability and the environment, the Esmalglass-Itaca Group has developed and implemented a new family of water-based digital glazes aimed at accompanying ceramic producers on their journey towards greater sustainability. Called DigitalGlass, the new digital solution reduces water consumption by a factor of ten compared to traditional glazes. Fresh water is an increasingly scarce commodity on the planet, so every drop of water is important for building a more sustainable future.

Reducing water consumption tenfold through the use of new water-based digital glazes brings environmental benefits as well as improving the industry’s production activities.

As the culmination of more than a decade of hard work and dedication, DigitalGlass is a truly revolutionary solution for the ceramic industry.

A number of companies have already chosen this new technology and are reporting significant benefits after more than a year of use. Specifically, DigitalGlass has been used since October 2019 as part of a Full Digital process (with digital primer application at the beginning of the process and digital coating at the end) on a line producing 3 and 6 mm thick 1200x3600 mm large surfaces. During these 17 months, the company has not reported a single line stoppage, it has resolved all delamination and clogging issues, and it has not had to replace a single printhead.

DigitalGlass digital glazes can be used in production in two different ways. One is the fully digital process described above, in which both the initial primer and the final coat-

34

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FOCUS ON: Glazing & Decoration

ing are replaced with DigitalGlass. But it is also possible to proceed in stages, i.e. replacing only the initial primer and opting for a hybrid digital process. In both cases, these new water-based digital glazes offer significant advantages.

The innovative DigitalGlass solution offers four main advantages for ceramic companies as well as significant environmental benefits. The first is a reduction in emissions and environmental impact. As well as drastically reducing water consumption by a factor of up to ten compared to traditional glazes, the adoption of the new water-based digital glazes also eliminates excess material, waste, odours, materials requiring filtering, etc. A second major advantage is the simplification of production by reducing operational and logistics costs. DigitalGlass is a ready-to-use material whose main benefit lies in the more rapid, digital adjustment compared to the high level of control necessary with conventional glazes (corrections of alumina, crystalline, etc.). Furthermore, only the required quantity of glaze is applied, so no waste is generated and storage and personnel costs are also optimised as only a single material supply process needs to be managed. If surplus material is generated during production it can be reused, thereby avoiding waste.

DigitalGlass also offers a number of technical advantages, most notably improved product quality and aesthetics.

By synchronising the application of the water-based digital glazes with the other digital applications, it is possible to achieve entirely natural finishes, for example by using the initial primer to create reliefs. Another area in which there is a significant improvement in quality is in the production of low-thickness surfaces (less than 6 mm) due to the smaller quantity of applied water compared to traditional glazing.

Last but not least, this innovation helps to reduce the time-to-market. The smaller number of materials makes it quicker to perform modelling and to change the graphics of existing products so as to respond more quickly to market demand; the production of small batches is also accelerated.

DigitalGlass digital glazes are fully approved and certified by most printhead and machinery manufacturers. In addition to the various glazes used to obtain different finishes, this family of products also includes the first certified water-based digital glue, further confirming the valuable work being done by Esmalglass-Itaca in this sector. ✕

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35

FULL DIGITAL AND HYBRID TECHNOLOGY FOR SUSTAINABLE CERAMIC DECORATION Luca Berti, Efi Cretaprint (Castellon, Spain)

The environmental impact analysis of a technology is not limited to the specific production phase in which it is used but involves the entire production process. In this respect, full digital ceramic decoration is a highly sustainable technology that contributes to a more sustainable overall process by consuming fewer resources and producing lower emissions and waste.

The use of water-based inks and glazes brings technical benefits as well as significant savings in terms of production costs.

Above all, digital glazing applies exactly the right quantity of glaze and does so in a controlled manner. It uses ten times less glaze than traditional glazing methods. This means less consumption of raw materials, energy and water, but also less wasted glaze, less water used for cleaning and lower emissions to the atmosphere. The technical advantages are mainly linked to uniform glaze application, which is essential for certain products such as large-size tiles. Furthermore, digital glazing followed by inkjet decoration with water-based inks reduces the phenomenon of water repellency, which often causes defects and consequently poor quality costs.

But the full digital process provides significant savings not just in terms of improved production quality: less glaze application also means lower logistics and transport costs. In addition, it reduces direct application costs for certain types of tiles, such as large slabs and rustic matt finishes.

Thanks to selective glaze application, water-based digital decoration and glazing also paves the way for the development of new ceramic products.

Last but not least, it is a digital process that helps companies implement complete factory digitalisation in keeping with Industry 4.0 principles. ❱ EFI Cretaprint’s Hybrid Ecosystem EFI Cretaprint Hybrid is an ecosystem consisting of 5th generation digital glazing and decoration printers, eco-solvent and water-based inks and glazes, and hybrid inkjet printers that can be used with both types of inks. This gives manufacturers the flexibility to choose whether and when to adopt water-based technology according to their needs.

The Cretaprint Hybrid printers boast upgraded electronics, ink delivery systems specifically designed to operate in an aqueous environment and an innovative cleaning protocol that maintains constant levels of humidity and prevents sedimentation.

EFI has also introduced Shield printers to its hybrid printer family, a series of stand-alone auxiliary printers used for digital application of inks, glazes, materials, glues and ef-

36

CWR INDIA 2021

FOCUS ON: Glazing & Decoration

fects and equipped with hybrid printheads arranged on two high-discharge bars. Also available for large sizes, they are versatile machines that complement existing equipment. They are used for performing digital glazing with uniform and controlled glaze application, for applying effects when an inkjet printer upgrade is not possible, or for applying eco-solvent or water-based glues. Shield printers can be synchronised with the other machines in the line using the CretaSync system.

This ecosystem also includes EFI’s Cretacolor ceramic inks, which are available in a wide range of eco-solvent and water-based inks. Eco-solvent inks are formulated with hydrocarbon- and ester-free solvents of plant origin. Their high performance and stability make them ideal for tile manufacturers who prefer to continue to use current technology. For producers who are more interested in adopting water-based technology, EFI aqueous inks and hybrid printers are receiving an excellent response from the market. Their formulation minimises the quantity of solvent in the composition, which means they integrate more effectively with the rest of the manufacturing process. They reduce carbon emissions by an average of 73% and volatile organic compounds (VOCs) by more than 90%, as well as reducing the consumption of chemical solvents used for cleaning. Compared to solvent-based inks, Cretacolor water-based inks also offer technical advantages that enhance the value of the ceramic products. These include shorter drying times, better integration with other stages of the production process, elimination of water repellency and higher print quality due to improved image definition.

EFI Cretaprint’s commitment to protecting the environment is not limited to developing ground-breaking low-impact technologies, but also takes the form of concrete initiatives... one tree at a time! The company is excited to take part in the Bosques Sostenibles project to reforest areas devastated by climate change, specifically the Valle de Iruelas nature reserve in Spain. For every EFI Cretaprint printer sold, the company pledges to plant 17 trees, thereby offsetting the equivalent of 3 tons of CO2. ✕

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37

COVERTECH, NEW DECORATIVE DIGITAL EFFECTS Fritta (Onda, Spain)

Covertech is the new digital effect developed by Fritta capable of creating a specific decorative result or improving the technical properties of glossy or matt glazed floor tiles, depending on the type of application.

The fact that the new ink can be used on different types of glaze means that it is highly versatile, contributing to the digitalisation of a stage in the ceramic decoration process that could previously be carried out using only analogue methods (spraying, rollers, screen printing, etc.).

Different types of products can be manufactured using the same production line and the same printer while exploiting the well-known advantages of digital technology, i.e. the ability to decorate reliefs, create ever-changing designs, produce smaller batches and reduce product changeover times, not to mention the environmental benefits and reduced quantities of waste and scrap.

Furthermore, the use of inkjet printers with printing widths of up to 2 metres to apply Covertech to large-size surfaces ensures more uniform application over the entire surface of the tile and resolves the dimensional limitations typical of bell applicators or spray booths.

Simply by adapting the application weight according to the base glaze, the firing cycle and the graphic design, Covertech can alter the technical properties of the ceramic tile and improve its abrasion, slip and chemical resistance, as

TECHNICAL PROPERTIES OF COVERTECH ANTISLIP APPLIED ON MATT GLAZES Light design

Dark design

Laydown Covertech (g/sqm)

0

13

0

10

Glossy (G.U.)

15

3

16

3

Slip resistance (RD)

11

50

18

50

Abrasion resistance (Class)

3 1500

4 2100

3 750

3 750

Stain resistance

✔

✔

✔

✔

Chemical resistance HCL

✔

✔

✖

✔

KOH

✖

✔

✖

✔

HCit

✔

✔

✔

✔

HLac

✔

✔

✔

✔

38

CWR INDIA 2021

FOCUS ON: Glazing & Decoration

well as its surface gloss or matt level.

Fritta proposes three different Covertech applications: Antislip, Savegloss and Matt dot.

When applied as a top coat on matt glazes, Covertech not only improves chemical, stain and abrasion resistance (with a change of the class), but also gives the tile anti-slip properties by raising the RD level to >45: Class 3 (UNE-EN 12633:2003 standard).

This brings two advantages: firstly, different finishes (satin, matt or hard matt) can be obtained with a single digital ink; secondly, a satin porcelain tile (more suitable for indoor use) can be functionalised so that it is suitable for use outdoors and in high-traffic public areas.

The second application of Covertech is Savegloss for use on glossy floor tile glazes. In this case, the most significant result is the reduction of surface defects such as pinholes.

This can be achieved by applying a very low weight of ink, which due to its high transparency does not affect the gloss values of the glaze or the colour rendering of the coloured inks. Here, too, greater abrasion resistance on dark designs is achieved (from Class 1 to Class 2).

A further application of Covertech on glossy glazes is Matt dot, which is very similar to Savegloss but uses medium to high ink weights for both a decorative and a protective function. ✕

COVERTECH APPLICATIONS Covertech Antislip

Covertech Savegloss

Covertech Matt dot

Glaze Type

Matt

Glossy

Glossy

Technology

porcelain

porcelain

porcelain

Ink

Covertech

Covertech

Covertech

Graphic effect

100% coverage

“Texture”

“Texture”

Colour design

Light

Dark

Light

Dark

Light

Dark

Laydown (g/sqm)

10-15

7-12

10-15

6-11

25-30

20-25

Printing mode

BIN-5

BIN-5

BIN-3

BIN-3

BIN-5

BIN-5

CWR INDIA 2021

39

CUTTING-EDGE TECHNOLOGY, OUTSTANDING AESTHETICS AND CARE FOR THE ENVIRONMENT Torrecid (Castellon - Spain)

Innovation is part of the DNA of Torrecid Group, leading it to develop new solutions capable of revolutionising processes and products and driving future trends. In other words, the group’s longstanding aim is to cause change through global leadership in innovation to generate new solutions and future trends capable of providing the best competitive advantages and the greatest added value to its customers. Far from being an ephemeral trend, this quest for ever more advanced, cutting-edge materials has guided all the group’s actions and decisions over the years and has led to the development of ground-breaking solutions that have transformed the ceramic industry, from monoporosa tiles to the digital revolution and today’s fully digital decorative processes capable of offering a wide variety of reliefs, effects and finishes. The following are some of the latest and most innovative materials developed by Torrecid: • 3DCID, an application capable of creating a three-dimensional effect and a sense of volume, depth and realism; • MateryCID and ShapeCID, pioneering solutions capable of creating more natural, material-effect digital reliefs; • RainbowCID, a family of high colour rendering inks free from hazardous substances; • MicroCID, a highly versatile finishing solution that can be combined with other effects and innovations; • Flakes available in a wide range of colours and sizes for different applications, reproducing the natural look of stone, granite and terrazzo;

40

CWR INDIA 127/2018 2021

FOCUS ON: Glazing & Decoration

• BacteryCID, an antibacterial solution suitable for all ceramic surfaces; • 2mattCID, a new collection of ultra-matt and smooth-textured glazes.

All these products reflect the continuous quantitative and qualitative progress of the STYLE-CID® range, designed to combine cutting-edge technology with the highest aesthetic standards and create unique atmospheres. Thanks to the contribution of STYLE-CID®, ceramic tiles have continued to evolve from small sizes limited to use in kitchens and bathrooms to increasingly large surfaces with exclusive aesthetics, ever-changing designs and a broader range of applications in the fields of furnishings, exterior façade coverings, ceilings, etc. This transformation has attracted the attention of architects and interior designers, who are increasingly keen to use ceramic surfaces in their projects.

No other architectural material has seen such dramatic technological and aesthetic development as ceramics, which are now among the most popular of all surface covering products. ❱ Environmental awareness At Torrecid, the search for technological and aesthetic innovation of materials goes hand in hand with an equally strong commitment to the development of eco-sustainable solutions. Environmental awareness is a cornerstone of the Spanish group’s activity and has led to the development of ECOINK-CID®, the first water-based fully digital system launched on the market, which drastically reduces atmospheric emissions of organic compounds and simplifies equipment cleaning and waste management. Another example is the low-emission 2lowINKCID inks, which can be used with conventional printers and printheads. This research activity is accompanied by a commitment to reducing the environmental impact of the production processes carried out in all Torrecid’s plants. ❱ Building market loyalty For a group that has always preferred to invest in the development of solid long-term relationships, technological innovation plays a key role in building customer loyalty through an ongoing commitment to R&D, in the knowledge that the ability to innovate processes and products is the most powerful tool for ensuring the future success of the industry. This is true not only in periods of rapid development, but also in more challenging

CWR 127/2018 CWR INDIA 2021

41

FOCUS ON: Glazing & Decoration

times when it is essential to offer greater attention and support to individual customers. This is what Torrecid tried to do during 2020. A year ago the Covid-19 pandemic brought the world to a standstill, interrupting business, travel and events. Staying true to its philosophy, Torrecid continued to work and innovate by reinventing its approach to the market. Exploiting the latest advances in communication technologies, it created a programme of personalised remote presentations and virtual trade fairs to enable customers to explore the company’s innovative solutions using custom-designed tools and media and equipment provided by the group. When the conditions permitted it, Torrecid reopened its showrooms to host in-person events and presentations in full compliance with safety measures. ❱ A global group As we were saying, innovation is a part of Torrecid’s DNA. It is a philosophy pursued by the company since it was founded back in 1963, when a group of eight people were producing 800 tons of ceramic frits per year in a small 392 square metre factory in L’Alcora (Castellón). Within just a few years, this small company had grown into a leading globalized ceramic group with companies in over 28 countries and customers in more than 130. This growth was achieved through a continuous process of international expansion that involved setting up subsidiaries as well as entering different market segments through an intense programme of acquisitions, including those of Glazura, Surcotech, Wandegar, Chilches Materials, Colores Cerámicos Tortosa, Reimbold & Strick and Mefrit.

✕

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DURST

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LATEST TECHNOLOGIES ON: Glazing & Decoration

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xSl VckZbu % Hkfo"; ds fy, gfjr ÅtkZZ Gas turbines: green energy for the future Solar Turbines (Riazzino, Switzerland)

Cogeneration with gas turbines is widely recognized as the best way to improve efficiency in the ceramic market. How does cogeneration work in the ceramic production?

The exhausts from the turbine go directly into the spray drier and the electricity produced by the generator is used in the factory. Gas turbines bring high quality heat into the drying process, increasing the overall process efficiency.

Cogeneration with gas turbines brings several advantages in the ceramic market: • Cost savings by reducing the overall gas consumption and electricity cost (up to 30%) • Reliable on-site power generation • Enhanced productivity (speed and quality) using a very stable and clean source of heat • Great environmental benefit (up to 50% CO2 reduction) • Increased efficiency (from 30% up to 90%) • Increased reliability and availability. ❱ From coal to gas Chinese factories are transitioning from coal to gas for a more sustainable and efficient production. Switching from coal to gas generates about 30% reduction of the CO2 emissions with great benefits for the environment.

Cogeneration with gas turbines can further improve the environmental benefits reducing the CO2 emissions to about 50% compared to coal, while bringing up to 30% savings in the operating costs compared to gas.

Environmental compliance and sustainability are strong drivers of Solar’s product design and development programs. Solar’s gas turbines produce low exhaust emissions that meet or exceed emission standards around the world.

Solar Turbines is committed to operating a sustainable business and contributing to a better world through: • Reducing emissions for its products • Giving new life to existing products • Developing new technologies and processes • Transforming its safety performance • Operating sustainable facilities through reduction of greenhouse gases and hazardous waste.

Moreover, Solar Turbines latest-generation of turbines, ideal for application in the ceramic applications, can burn green fuels: biogas and syngas, both up to 100%, and hydrogen blends of up to 70% and more, with additional benefits in terms of emissions and cost savings.

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technology

❱ Cogeneration experience in ceramic applications In the ceramic industry, Solar has successfully installed more than 100 units worldwide, helping its customers to reduce energy costs with the installation of a cogeneration plant with gas turbine.

With Solar’s technology, customers have an additional energy source for their facilities, which allows the elimination of production interruptions caused by an electrical blackout.

Medium scale industrial gas turbines, which have few rotating parts, are well appraised for their robustness, fuel flexibility and the ability to absorb or reject sudden load demands.

Such a design generates multiple benefits in terms of maintainability and operability, including no lubricating oil consumption, lower downtime (therefore increased availability) and the potential to easily replace the complete engine when an overhaul is required or at the end of the turbine’s life.

In places where grid power is not available or is unstable, gas turbine generator sets are ideal to support the continuous operation of an industrial plant. Solar Turbines packages can accept or reject loads up to 80% of nominal, which makes them ideal for starting-up and supporting industrial operation.

Solar Turbines Incorporated manufactures the world’s most widely used family of mid-sized industrial gas turbines, ranging from 1 to 23 megawatts. More than 16,000 Solar units are operating in more than 100 countries with more than 3 billion operating hours. Solar is a leading provider of energy solutions, featuring an extensive line of gas turbine-powered compressor sets, mechanical drive packages, and generator sets. With years of experience and fleets installed worldwide, its turbines have achieved high reliability. Additionally, Solar offers an advanced monitoring system, and local support we are capable of optimising operations of the turbine by eliminating unscheduled stoppages and minimising maintenance time. Solar active communication with customers, end-users and market operators is enabling the possibility to offer the best products and services on the ✕ market.

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lsfuVSjhos;j mRiknu esa Lopkyu % ekuo:ih jkscksV dh lgk;rk ls <ykà Automation in sanitaryware production: anthropomorphic robot-assisted casting Sacmi Sanitaryware (Imola, Italy)

Quality, repeatability and operator efficiency are the three main advantages of total automation, a solution that Sacmi has continued to develop ever since it installed the first anthropomorphic robots in casting cells. Over the course of its history, Sacmi has built and put into operation more than 6,000 moulds and 570 casting machines for the ceramic sanitaryware industry. A pioneer in the use of anthropomorphic robots in casting cells since the 1990s, the company has driven the development of the sector and now supplies more than 90% of its plants equipped with robots or ready for future implementation.

One of these advanced systems is the AVI cell for high-pressure casting of complex WC bowls with stick-on rims.

First launched onto the market five years ago, more than 30 of these machines have been installed in various countries around the world. As in the case of all latest-generation Sacmi machines, the distinctive feature of the AVI is the complete elimination of hydraulics due to the use of pneumatic mould clamping with special air cushions. Proportional mould clamping control during all phases of the casting cycle improves process sustainability and ensures perfect product quality. The AVI cell is highly innovative in terms of automation and offers the perfect combination of quality, process repeatability and workplace health and safety. In this solution every single stage is performed by a robot, from sticking through to demoulding and car loading.

AVI stick-on rim WC

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AVI engine-shell WC

While maintaining the same configuration, the AVI can manage the most varied types of pieces. In addition to WC bowls with stick-on rims, it can also produce the modern rimless WCs and even the highly complex one-piece and shell-engine models, a technology whereby the internal functional part of the WC (engine) and the external section (shell) and the rim are made in separate moulds. At the same time, Sacmi guarantees compatibility with existing moulds already used by customers on machines such as the single-mould AVM and the multi-mould AVE. Quality and functionality in the production of articles requiring up to 12 mould parts are assured by the perfectly repeatable robotic movements and the single gluing line on the external surface of the WC bowl, which guarantees an optimal aesthetic result.

As is now standard practice, a pre-dryer is installed in the cell to drastically reduce the time required for the piece to harden sufficiently for loading onto the dryer cars, which are moved manually or - increasingly - by means of laser-guided vehicles (LGVs).

Thanks to the use of automatic casting machines combined with anthropomorphic robots, a pre-dryer and automatic car loading, the entire process can be fully controlled and the production operations systematically reproduced, minimising the external variables capable of causing errors and generating rejects.

The level of automation achieved in these cells means that the robots can also be assigned many of the finishing operations (including sponging of the outside, siphon and under

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ALV cell

rim area), which also minimises the need for manual operations during these stages. The AVI is equipped with the rapid mould change-over system (it takes well under an hour to complete compared to the several hours required with traditional systems), making it the ideal solution for handling complex production mixes and small batches while fully eliminating the more heavy-duty and low-value operator tasks.

The Sacmi ALV solution for the production of washbasins, especially countertop washbasins, differs in terms of aesthetics and functionality but was developed in accordance with the same concepts of automation and total quality. Designed to handle up to 6 casting modules with a single robot (which can also be tasked with the automatic finishing operations and car loading), the ALV cell is uniquely versatile thanks to the possibility of rotating the mould from 0 to 90° during each stage of the cycle. Independent control of the work cycle for each single module means that different products can be made at the same time, even with different bodies. After casting, the robot handles the part of the mould holding the piece and performs demoulding onto a support ready for the finishing operations. For certain types of articles, this completely eliminates the need for supports and for operator intervention in manual finishing operations, thereby simplifying factory logistics and reducing the footprint. Advanced tracking functions, such as adding a barcode to the piece, make it possible to implement advanced MES (order scheduling) functions, monitoring and preventative maintenance with a small number of operators and optimised flow control.

These operations can be controlled by customers completely independently, although a Sacmi technician is always available to provide remote assistance and help customers resolve any production stoppages.

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SACMI: experience and complete solutions for your product

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T H E C O M P L E T E S A C M I S O L U T I O N F O R Y O U R S M A R T S A N I TA R Y W A R E FA C T O R Y

SACMI manufacturing technology: the advanced sanitaryware production solution, from single machines to complete lines. www.sacmi.com

ENDLESS INNOVATION SINCE 1919

fljsfed fQfuf'kax ds {ks= esa fujarj [kkst Non-stop innovation in the field of ceramic finishing Surfaces Group (Italy)

Surfaces Group, a globally recognised brand renowned for its surface processing technologies and protective treatments, continues to strengthen its position by developing new solutions for leading ceramic manufacturers.

In the field of new technologies for processing technical and glazed porcelain stoneware, the group recently launched the Flat Reflex Finishing System based on operational synergies between its various member companies. It has also made further advances in the field of chemical finishing treatments under the Nocoat brand, including the development of the new Antibacterial Formula for polished and lapped slabs.

Both launches required major investments in research and development, an area that is one of the group’s greatest strengths along with the testing activities conducted in the Surfaces LABs and a 24/7 remote service available anywhere in the world. ❱ The multifunctional Flat Reflex Polishing System combines tradition and innovation The innovative system is capable of processing extra-large wall tiles as well as high-thickness countertops, allowing for the production of both traditional tiles and innovative slabs simply by adopting the most suitable tools for the processing plant. Depending on the tools used, it is also possible to extend the range of finishes from matt to satin and supergloss.

For technical porcelain stoneware of any thickness, the process is divided into 4 phases: the use of Polishing Tiger (full fickert) from Luna Abrasivi for the most consistent removal phase; Turbo Tools (metal grinding wheels) from ADI for the calibration phase; full polishing (full fickert) from Surfaces Technological Abrasives for the preparation phase prior to finishing; and Superlux (full fickert) also from Luna Abrasivi for the final finishing and polishing operations.

Given the need to remove smaller quantities of material, in the case of glazed porcelain the process consists solely of the 2 final steps using Full Polishing (full fickert) and Superlux (full fickert) tools. With the Flat Reflex Polishing System, the various processing stages from roughing to actual finishing are carried out seamlessly.

Whereas in the past the calibration and polishing operations had to be performed using different machines (which meant stopping, reconfiguring and then restarting the operation with a different machine, resulting in the risk of production defects), it is now possible to perform the entire surface finishing cycle using the same equipment. For the roughing

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and finishing operations, a simple tool change is all that is required to complete the machining cycle without stopping production. The new technology allows the operation to be tailored to the specific surfaces and production requirements, thereby optimising performance and yields simply by adapting the tools to the line and reducing machining times and waste. This exceptional flexibility is the result of coordinated action between the various brands, which ensures consistent machining on different sizes, greater surface removal in less time and longer tool life thanks to a high level of customisation according to the specific plant. Moreover, in the event of diversified production processes, it is no longer necessary to have two different lines (one for traditional machining and the other for new application processes) as the interchangeable tools mean that the plant is universal.

“We have transformed a revolutionary concept for the ceramic world into reality,” said Simone Sorrentino, Export and Marketing Director at Surfaces T.A. Depending on the configurations, this process technology is able to handle various types of product. And of course it’s quicker and cheaper to replace tools than to have to modify or expand the production plant. Our technology provides ceramic companies with a dual-function plant that allows for innovation as well as production with traditional systems.”

All the stress tests carried out during the industrial implementation phase fully met expectations, demonstrating that the new application solution has been developed correctly. ❱ Antibacterial Formula for healthy and safe surfaces As regards product innovation, the Surfaces Group’s Nocoat brand specialising in surface treatment and protection products has developed several lines with specific antibacterial properties.

The new Antibacterial Formula for polished and lapped slabs represents a step up from the traditional range as it maintains all the treatment properties but offers the added benefit of antibacterial protection.

This innovation applies to the Gloss range, for products used in room temperature treatment, to Supergloss for products used on Supershine surfaces, and to Zero Gloss, for surfaces with a satin finish.

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technology This need first emerged during the pandemic and prompted the company to develop specific formulas that would allow for the production of safe and healthy surfaces in terms of bacterial load. After months of research and testing conducted in collaboration with several Italian universities, Nocoat has unveiled a pore-filling, stain-resistant treatment with bactericidal properties based on the combined action of silver ions and special additives designed to block the proliferation of pathogens (bacteria, microbes, mould and fungi) that come into contact with the surface and eliminate those that are already present.

Silver (Ag) nano-particles and nano-compounds are the most widely used antimicrobial nanomaterials and have a biocidal action against a wide range of Gram-positive and Gram-negative microorganisms, fungi, moulds and viruses.

Silver has a broader spectrum of antimicrobial action than many antibiotics, and its bactericidal action is effective at low doses and prevents bacteria from developing resistance. The Nocoat antibacterial technology allows tread-resistant and antibacterial properties to be achieved with a single treatment, as the filled pores also hold the particles that combat the formation of pathogens.

Tests carried out in compliance with the international standard ISO 22196:2011 have shown that the treatment is effective under any lighting conditions (sun, LED or other artificial lighting), and even in the dark, and certify that the bacterial load falls significantly within one hour of contact with the treated surfaces and continues to fall over the subsequent hours, eventually reaching an efficacy value of 99.99%.

Following the excellent results obtained in the university laboratory tests, Nocoat also began the important phase of testing the product on customers’ production lines.

The treatment is performed in two ways according to needs: • The ambient temperature system which involves applying the treatment with Fill-it and subsequent brushing, • The Supergloss system devoted to Supershine machines.

In both cases, the treatments proved to be perfectly compatible with plants that were already using classic Nocoat products. Customers experienced no application difficulties or variations from the usual formulas, a very important result because it demonstrates that the new treatments are perfectly compatible with the plants already in use.

“The most important aspect for us was to avoid production line difficulties while providing added protection and maintaining all the qualities of our products,” says Giuseppe Soli, General Manager of Nocoat. “Our aim was to enable the ceramic industry to create antibacterial surfaces through lapping and polishing processes and consequently enhance the functionality of ceramics. We are convinced that these standards are a vital resource. Today it is no longer sufficient to improve the cleanability of surfaces, it is essential to functionalise them so that they not only achieve high levels of gloss and slip and water resistance but also have antibacterial properties. This is an increasingly pressing need, especially for certain locations and applications where ceramic surfaces act as functional elements, for example kitchens, bars and public places such as healthcare facilities.” ✕

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Energy Recovery Systems and Filtration

ECONOMIZE

with our ecological solutions Thermal Energy Recovery System “Intelligente” Sleeve and Box Filters for Dust and Fumes Heat Exchangers Control and Supervision Instruments Water Purification Systems Washing Towers and Scrubbers Raw Materials Plant Division Plant Division Glass Sector

www.poppi.it

lSVsykbV flLVe % ySfiax vkSj i‚fyf'kax dk lek/kku Satellite system: the solution for lapping and polishing Piergiorgio Trevisan, Premier (Villaverla, Italy)

The latest innovation from Premier was launched onto the market a year ago and is receiving very positive feedback both in Italy and abroad, especially in Spain, the USA and Latin America.

The Satellite System for lapping and polishing was presented in February during the Tecna Next webinar devoted to ceramic finishing, where it attracted great interest amongst participants.

With regard to the lapping process, the operation of the Satellite System is based on the concept that in order to obtain maximum performance from diamond tools, they must work at the highest possible speed.

Unlike the squaring process where the tools operate at speeds of over 40 m/s, the lapping process involves machining very hard materials and needs to remove a much larger quantity of material, resulting in speeds no greater than 10 m/s when using the Fickert system.

So there is clearly a need for a system that allows lapping to be performed at higher speeds.

After numerous tests conducted at the Premier Lab, which is equipped with a 20-spindle line for tile sizes of up to 1200 mm, a new satellite head capable of operating at double the lapping speed of Fickert tools was developed. The resultant system is safe and simple but also much cheaper and more efficient. ❱ Characteristics The satellite system consists of a rotating head on which a series of rotating tools are mounted at a slight angle to the feed plane. The combination of the two concordant rotary movements of the head and the tool greatly improves uniformity and stock removal capacity. Moreover, the movement of each tool follows a unique contact line that differs from that of all the oth-

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er tools on the same head.

The Satellite (i.e. the tool mounted on these new heads) consists of a flexible disk with two concentric circular rows of blocks in which grains of abrasive and diamond are incorporated into the resin.

The disk is glued to a layer of elastic material (the damper), and the disk-damper assembly is connected to a rigid base that makes up the body and also serves as the attachment to the head tool holder. The tool can be rigid, semi-rigid or elastic depending on the type of elastomer the damper is made of. ❱ Strengths This new solution offers numerous advantages.

One standout feature regarding the top finish is the fact that the tool contact line has a width of about 25 mm, at least 4 times smaller than that of the Fickert tool (about 100 mm), which means that the tools can penetrate any surface depression.

In addition, the movement of each tool traces out a unique contact line that is different from the others, thus avoiding the overlapping of lines and the unsightly effect typical of Fickert tools known as “feed marks”.

The Satellite System is also an optimal solution for dark colours, as tools with a finer grain can be used while maintaining the same removal rate, resulting in scratch-free tiles with a higher gloss level.

The new system also offers clear benefits in terms of increased efficiency. This is primarily because the combination of the rotary motion of the head and that of the tool allows the system to achieve a much higher cutting speed, bringing a significant increase in productivity compared to the Fickert tool.

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Machining costs per square metre and maintenance costs are also reduced significantly: in the first case, because the more effective use of abrasive increases the tool life; in the second, because the pressures applied to the heads are much lower resulting in less wear to mechanical parts. The system is manoeuvrable and easy to use: the retracted attachment points and the fact that the satellite is slightly angled relative to the feed plane facilitates feeding and allows the system to cope with height differences of several millimetres without damaging the material or the tool.

It is also highly versatile, as the modularity of the resin and diamond tool together with the fact that it can be used with or without a damper, allows the configuration to can be changed according to the desired degree of flatness.

Last but not least, the Premier Satellite System is also an environmentally friendly solution as the satellite’s much longer lifetime compared to the Fickert tool (3 times longer for coarsegrained tools and twice as long for fine-grained tools) means that the quantity of waste produced annually by end-of-line machines is reduced by more than 40%. ❱ The future Exploiting the slight inclination of the tools with respect to the feed plane, which makes it easier to overcome any height differences between two consecutive tiles, Premier’s engineers have successfully trialled the parallel-row lapping process, which allows the productivity of a line to be multiplied at will.

This solution would have been impossible to achieve using Fickert tools, which sweep to the right and left and could easily catch on the side of the tile, lifting it and damaging the entire set of tools, the head, the tiles and even the conveyor belt.

A further development of the Satellite System regards the possibility of performing both lapping and polishing on the same line. Premier has successfully explored the feasibility of using metal satellites on an existing lapping-only line and transforming it into a line capable of polishing technical porcelain tiles and lapping glazed tiles simply by replacing the tools. The application of satellite heads to a lapping line has created the first “polishing/lapping” machine capable of performing calibrating/polishing and lapping without the need for bulky calibrating machines.

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Poppi Clementino

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Latest technologies

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Tecnofiliere

Certech

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CWR INDIA 2021 2018

Latest technologies

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Latest technologies Syneco

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GMM Group

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Bologna from 27 September to 01 October 2021

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International Exhibition of Ceramic Tile and Bathroom Furnishings.

New ideas and products for the evolving world of architectural design.

from 20 Sept. to 08 Oct.

THE ITALIAN WORLDWIDE BENCHMARK TO KEEP AHEAD OF FUTURE STANDARDS IN CERAMIC

FINISHING

Italian technology innovation know-how research experience worldwide presence custom solutions

Surfaces Group is Italian leader worldwide in the production of integrated solutions for finishing ceramic surfaces, keeping ahead of future trends and offering complete solutions, thanks to the synergy of brands of excellence representing the best of Italian output.

With the new technologies of the Surfaces Group integrated solutions, you can achieve the best appearances and higher productivity, all due to the complete synergy of the group’s various member Brands.

Perfect, polished slabs without unevenness, more resistant to scratches, stains, heat and erosion, with an immaculate gloss or lappato matt finish and a silky feel.

To provide customers with the service they need and expect, SURFACES has developed a LAB able to reproduce the real conditions on processing lines. Engineers, operators and senior technical specialists can develop and test new integrated solutions to guarantee product properties and process conformity.

more brands one group

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IN COLLABORATION WITH

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Ministry of Foreign Affairs and International Cooperation

ENDLESS INNOVATION SINCE 1919