Ceramic World Review India 2022

C eramic W orld R eview

technology news markets

DISCOVER OUR

HIGH-TECH SOLUTIONS:

Dare to go beyond the avant-garde

redesigninnovation.esmalglass-itaca.com

www.esmalglass-itaca.com

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

®

Year 32 Supplement to no. 145 February/March 2022 Bimonthly Review

contents

Cover picture by: Giancarlo Pradelli

7

Editorial

Welcome to Indian Ceramics Asia 2022!

8

World News

News

14 Economics

18

20 Interview

24

Paola Giacomini

Hkkjrh; fljsfeDl ,f’k;k 2022 esa Lokxr gS!

World construction set to see strong growth through to 2025

MECS

World ceramic tile industry and market: forecasts to 2025

Ilaria Vesentini

2025 rd etcwr o`f) ns[kus ds fy, foÜo dh rS;kjh foÜo fljsfed Vkby m|ksx vkSj cktkj % 2025 ds fy, vuqeku RAK Ceramics looks to expand in Saudi Arabia

Milena Bernardi

Somany Ceramics set for further expansion

Milena Bernardi

jkd fljsfeDl dh lÅnh vjc esa foLrkj ij fuxkgsa lksekuh fljsfeDl vxys foLrkj ds fy, rS;kj

30 Technology

Excellence and sustainability as drivers of change in the industry Esmalglass-Itaca

32

The most versatile and compact line for top-selling sizes is launched

36

Superfast, a sustainable, energy-saving process

40

Alternating satellite and Fickert heads for higher quality and productivity in the lapping process

42

46 Sanitaryware

mR—"Vrk vkSj LFkkf;Ro m|ksx txr esa cnyko ds ekè;e

Sacmi

lcls T;knk fcØh okys vkdkj ds fy, vusd xq.kksa okyh vkSj Bksl iafä dk 'kqHkkjaHk Eustachio Tarasco

cgqr rst] fLFkj] ÅtkZ cpkus okyh çfØ;k

ySÇix çfØ;k esa vfèkd xq.koÙkk vkSj mRikndrk ds fy, oSdfYid mixzg vkSj fQdVZ 'kh"kZ

Premier

How the transition to smart gas turbines increases sustainability and reduces costs

LekVZ xSl Hkfë;ksa esa :ikarj.k fdl çdkj fLFkjrk dks c<+krk gS vkSj ykxr de djrk gS

Paolo Masiero Sacmi

LGVs, an efficient sanitaryware handling solution

,ythoh] ,d çHkkoh lSfuVSjhos;j gSM a Çyx lekèkku

50

New binders/plasticisers with low rheological impact for sanitaryware bodies

54 Products

mRikn

lSfuVsjhos;j bdkb;ksa ds fy, de fj;ksy‚ftdy çHkkoksa ds lkFk u, ckbaMlZ@IykfLVlkbtlZ R.Grassi, M.Antoniotti

CWR INDIA 2022

3

ADVERTISING Publisher Administration and Editorial Office

TILE EDIZIONI S.r.l.

Via Fossa Buracchione, 84 - 41126 Baggiovara (MO) - Italy Tel. +39 059 512103 - Fax +39 059 512157 - info@tiledizioni.it CEO Gian Paolo Crasta

g.crasta@tiledizioni.it Editor Paola Giacomini

p.giacomini@tiledizioni.it Editorial Board

Luca Baraldi, Milena Bernardi, Cristian Cassani, Omar Gubertini, Francesco Incerti, Paola Rolleri, Ilaria Vesentini Advertising

TILE EDIZIONI: Tel. +39 059 512103 Fax +39 059 512157 Paola Giacomini: Cell. +39 335 1864257 - E-mail: p.giacomini@tiledizioni.it Silvia Lepore: Cell. +39 345 7218245 - E-mail: s.lepore@tiledizioni.it Elisa Verzelloni: Cell. +39 338 5361966 - E-mail: e.verzelloni@tiledizioni.it Translation

JOHN FREEMAN (EN) DILIP KUMAR CHOUDHARY (Hindi) Subscriptions www.tiledizioni.it/subscription Each copy € 4 Annual subscription (5 issues): Italy: € 50; International: €70; Special tariffs for group subscriptions are available on request.

Graphic Layout

Sara Falsetti Photolits • Typesetting

Vaccari Zincografica Srl - Via Salgari, 61 - 41123 Modena - Italy

The Hindi version of the magazine has been published in collaboration with MR. DILIP KUMAR CHOUDHARY C-35, Sector-47, Noida, Uttar Pradesh-201303, (INDIA) Mob.: +91- 9718674379 Entire contents copyright Tile Edizioni.

All rights reserved. Opinions expressed by writers are not necessarly those held by the

Sense of perfection.

Raw materials for ceramics

publisher who is not held responsible. Editorial material, manuscripts, photographs, transparencies and artwork will not be returned.

KAOLIN – FELDSPAR – QUARTZ – CHAMOTTE

Date of going to press: 14/03/2022 Promoted by

Tile Edizioni also publishes:

Visit us at: • INDIAN CERAMICS ASIA 2022 The Exhibition Centre, Gandhinagar, India Hall 2 / B159 • CEVISAMA 2022 Feria Valencia, Spain Pav. N3-P3 / B70 • CERAMITEC 2022 Messe München, Munich, Germany Hall/Booth C2.201/302 Amberger Kaolinwerke, Eduard Kick GmbH & Co. KG E-Mail: ceramics@akw-kaolin.com, www.quarzwerke.com

Floor: LAPIDEUS

editorial

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

Welcome to Indian Ceramics Asia 2022!

From 6 to 8 April, the Indian ceramic industry will meet again in Gandhinagar for the 16th annual edition of Indian Ceramics Asia and its concurrent show IBaRT, the India Brick and Roof Tile Expo.

The industry’s leading international suppliers will all be present, including the Italian machinery manufacturers Appel, BMR, Cimes, Interser, LB, Metco, Poppi Clementino, Sacmi, Smac, System Ceramics and Tecnoferrari, most of which will be exhibiting in the Italian pavilion organised by ACIMAC in cooperation with the Italian Trade Agency.

The glaze, colour and ink sector will also be represented by the leading brands, including the Italian companies Colorobbia Group, Sicer/Inkera and Smaltochimica/Smaltochem India as well as the Spanish firms Esmalglass-Itaca, Torrecid and Vidres.

AKW and Alteo will be among the exhibitors in the field of ceramic raw materials, while the IBaRT show can count on the presence of several well-known European suppliers, including Beralmar, De Boer, Equipceramic and Metalcertima.

Following the cancellation of the show in 2021 due to the Covid-19 pandemic, its return in 2022 has been greeted with great enthusiasm by the industry. It provides a welcome opportunity to meet up with customers again in person, although relations had been assiduously maintained over the last couple of years through the use of digital technologies and the presence of local staff.

In the meantime, the Indian ceramic tile industry has further strengthened its position as a global tile player and as the world’s second largest manufacturer (above 1.3 billion sqm), consumer (almost 900 million sqm) and exporter behind China. In 2020, India’s tile producers chalked up another astonishing success with total exports of 437 million sqm (up 21% 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.

Exports also continued to grow in 2021. In the United States, for example, Indian tile exporters were able to increase their sales by 8.9% on 2020 to 20.2 million sqm, with a value (CIF) of US $164.6 million (+21.2% on the previous year).

The largest Indian ceramic companies are making substantial new investments aimed at increasing production capacity and productivity. In this issue, we look at those underway at Somany and Granicer as well as the projects announced by RAK Ceramics. X

www.CeramicWorldWeb.it

Follow us also on Social Networks. Daily updates!

Search “Ceramic World Web” and “Tile Edizioni” CWR INDIA 2022

7

TECNOCOATING 8

CWR INDIA 2022

world news

CWR INDIA 2022

9

world news

ADVERTISING

COMPLETE PLANTS FOR GLAZING AND HANDLING OF CERAMIC SLABS AND TILES

Discover more on: WWW.CIMES.IT/EN

ALWAYS ONE STEP AHEAD -FREE · C M

-FREE · C M

OM HR IU

TECNOFILIERE is strongly committed to eliminating the toxic hexavalent chromium from the industrial process of bricks production.

OM HR IU

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 - fax +39059677759 http://www.tecnofiliere.com - tecnofiliere@tecnofiliere.com

ADVERTORIAL

d a e h a s e g r o f I n t e r S e r n m a r ke t in the India

Marco Grani Inter Ser, a Vercelli-based company with a logistics centre in Sassuolo (MO), specialises in the supply of machinery and original spare parts for the ceramic industry. The company was founded in 1996 as a supplier of spare parts and rapidly built up a reputation for its excellent customer service and high-quality materials. Building on the credibility it had gained in the Sassuolo area, over the following years it branched out into an increasingly important second line of business that involved designing and developing machinery and accessories in collaboration with selected local mechanical engineering companies. Year after year Inter Ser has recorded remarkable growth in terms of both sales revenue (+40% in 2021) and customer portfolio, becoming a supplier of choice for 23 of the world’s top 25 tile manufacturers (*according to the ranking published by Ceramic World Review in 2021).

The company now operates in 60 countries worldwide and as of 2021 also has a presence in India. We discussed this latest expansion with CEO Gian Luca Zanoni.

How are you organised in the Indian market?

To address the unique challenges of this market, we work with two professionals with a solid and well-established background in the ceramic industry. The first is Marco Grani, a manager with proven international experience who has been with us since 2020, and the second Kiran Raut, an electrical engineer who will support Inter Ser as a local agent. Grani’s previous positions include production manager and technical service manager for Nassetti, TSC, Muliakeramik and Cahayputra and

customer service manager for System Ceramics’ Lamina Division. Kiran Raut has some 15 years’ experience working in production facilities, including that of RAK Ceramics. He is well known in India for having held the position of Technical Service Manager at Sacmi and Technical & After sales Manager for System India. His support for local customers will be crucial for strengthening existing partnerships and developing new business relationships. Moreover, the appointments will give Marco and Kiran the opportunity to resume the teamwork they initiated several years ago when they were both working for System Spa. What were the results of your first year of operations in India?

The overall results have been very positive.

We immediately received orders for spare parts from numerous local customers, then in late 2021 signed an important contract with Comet Granito, a leading manufacturer of vitrified tiles based in Morbi with sales outlets all over the country. We supplied the company with all the Sassuolo Lab research and quality control equipment, as well as the engobing machines, a field in which we are particularly competitive. On their production site we also installed our flagship I-NKFILLER® system for automatic ink tank filling on digital printers.

What are the factors behind the success of I-NKFILLER®?

I-NKFILLER®, entirely designed by I-Tech and sold by Inter Ser in many countries, including India, resolves the most serious ink management problems that have arisen with the advent of digitalisation alongside the unquestionable advantages of the new

processes. For example, it prevents product from settling in the container by using a diaphragm pump to continuously agitate the ink. This avoids ink wastage caused by settling, eliminates human error because the ink no longer has to be transferred by hand and improves the fluidity of the ink inside the digital printers, which in turn results in longer printhead, filter and pump service life and less machine downtime for maintenance. It also improves procurement management and avoids the need to store large quantities of stock.

Finally, it eliminates the need to dispose of spent ink tanks, ensures significant time savings and improves the quality of the finished product.

How many I-NKFILLER® systems have you installed to date?

A total of 92 systems are currently in operation at the facilities of leading manufacturers worldwide, including Florim, Marazzi, Daltile, Casalgrande Padana, Panaria, Laminam, Argenta, National Ceramic Industries South Africa, Coop Imola, Kerytaly, Polis, Fioranese, Florida Tile and many more.

The system has also been approved and certified by the leading manufacturers of ceramic technology (System Ceramics, Durst, Intesa, Projecta, Efi, Kerajet, Tecnoferrari, etc.) and by the glaze and colour producers, all of whom recognise its potential. The latest generation of digital machines are even produced on an I-NKFILLER® Ready basis for ease of installation.

Kiran Raut ADVERTORIAL

2025 rd etcwr o`f) ns[kus ds fy, foÜo dh rS;kjh World construction set to see strong growth through to 2025 MECS Research Centre - www.mecs.org

Following the darkest year of the Covid-19 crisis, the world construction market has been seeing a strong recovery in 2021, with growth reaching record levels (+6.4%, higher even than pre-pandemic figures). The growth trend is expected to continue strongly in 2022 (+3.5%) and then drop back to levels more in line with those of the last decade, fluctuating at around +3%.

These forecasts, presented by Cresme Ricerche during the ACIMAC members’ meeting on 10 September, reflect the general global economic recovery and the initial positive impact of the Italian government’s Superbonus tax incentive scheme on the national building industry.

“Despite the lingering repercussions of the Covid pandemic and the risk of a resurgence of infections coupled with ongoing political uncertainty and factors of financial instability, all the indicators are pointing to an expansion phase for the construction industry, the target market for ceramic and brick products and above all the main driver of the current and future economic recovery,” said Antonio Mura, technical director of Cresme Ricerche and head of Simco, the information platform that monitors the scenarios in 150 countries (99% of the world’s GDP) on a quarterly basis and cross-references 160 different statistical sources to make five-year projections.

According to the survey, the monetary and fiscal stimuli introduced by national and international institutions (including the unprecedented boost to infrastructure set to come with the NRRP) and the huge amounts of savings accumulated by households during the lockdown year (when incomes remained stable but consumption fell sharply) have already boosted the growth rates of construction investments, which are well above

FIG. 1 - THE GLOBAL CONSTRUCTION MARKET IN 2021

14

CWR INDIA 2022

economics

GDP trends in almost all world markets with the sole exceptions of Japan, Germany and the USA. ❱ Trends in different countries Taking a more detailed look at the figures for the construction industry, Cresme notes that in 2021 the global market amounts to a total value of €8,807 billion, with the residential sector accounting for €3,209 billion, 36.4% of the total, and is expected to grow by €200 billion by 2025. At a global level, non-residential construction accounts for 31% of the total (€2,651 billion) and public works the remaining €2,947 billion (33%), while the Italian market is strongly skewed towards residential construction which accounts for half of all investments.

In terms of macro-areas, Oceania is the region with the strongest projected recovery in construction output in 2021 (+7.6% compared to +6.4% worldwide), following a modest proportionate decline in 2020 (-3.6%). This is followed by Asia, where Cresme forecasts an increase in investment of +7.4% (after -3.2% in 2020, with China and India as the key drivers), North America (+6.3% in 2021), South America and Africa with +5.7%. In Latin America, however, the growth rate is insufficient to make up the ground lost in the previous year, when construction fell by 13.5%. Trailing in last place is Europe with +4.1%, compensating for the 4.8% losses of 2020.

Extending the analysis to individual countries, Mura notes that high investment in construction is no longer limited to wealthy developed countries such as Canada or Germany but is also observed in countries such as China, India and Indonesia, which

FIG. 2 - EVOLUTION OF GLOBAL GDP

CWR INDIA 2022

15

FIG. 3 - FORECASTS TO 2025 FOR GDP AND INVESTMENTS IN CONSTRUCTION (% var. at constant values)

are reaching the same levels of construction spending as western countries despite their much lower per capita GDP. In particular, the Chinese construction market is estimated at €2,730 billion in 2021 (30% of the global market) and is expected to grow at an annual rate of 3.1% through to 2025, while the US market (€1,241.1 billion; 14.1% of the total) will grow by less than half of that amount, 1.5% per year. Next come Japan and Germany, which account for 5.4% and 4.4% of total world construction respectively, with Japan expected to see a 2.1% annual decline through to 2025 (the only such case among the major markets) and Germany set to remain stable at an average annual growth rate of 0.2%.

The Cresme forecasts for Italy, which ranks tenth in terms of construction market size (€186.2 billion and 2.1% of the world total), are for an average annual growth of 3.6%. ❱ Medium-low risk areas with greater opportunities Finally, the study centre’s platform lists a series of countries where it predicts sustained growth of the medium- to low-risk construction market and therefore excellent competitive opportunities for industry players. Malaysia has been leading the ranking for years and has retained this position in 2021 (+8.3%),

FIG. 4 - THE TOP 15 WORLD MARKETS: COMPARISON BETWEEN CONSTRUCTION INVESTMENTS AND GDP GROWTH IN 2021 (% var. at constant values)

16

CWR INDIA 2022

economics while Thailand has climbed to second place FIG. 5 - RENEWAL AND RENOVATION MARKET SHARE IN THE BUILDING SECTOR (%, 2021) with +4%, confirming Southeast Asia as one of the most interesting areas for investors. As for Europe, the biggest growth is expected in France (+5.1%), Romania (+6.7%) and Spain (+3.3%), while promising scenarios are also opening up in the Pacific Alliance countries and Morocco.

“The figures must be interpreted on the basis of the underlying socio-political factors,” explains Antonio Mura. “In particular, the expected upturn must be seen in the light of the (permanent?) movement away from the model of economic austerity that has dominated the Western market for decades.”

This will allow Member States to make long-term investments in the real economy and place infrastructure development at the heart of a new Marshall Plan, effectively ensuring that the construction market is no longer pro-cyclical (i.e. strongly linked to the state of the economy, as in the case of the 2008 financial crisis and the subsequent collapse of the property market) but anti-cyclical and consequently more resistant to periods of downturn. ❱ Price increases expected The return of inflation will also play a key role: after a prolonged period of price stagnation and in some cases even deflation, a combination of several events - such as the sudden rise in commodity prices, disruptions in logistics chains, the introduction of new tariffs and the increase in demand in the construction sector (partly stimulated by speculative buying) - will trigger a rise in construction prices. The growth in private savings that occurred in 2020 should also not be underestimated. It appears very likely that these additional resources will feed into the private construction sector, further boosting demand and creating a virtuous cycle. ❱ Sustainability and building renovation In this context, we are seeing the emergence of another macro-trend that is closely linked to the real estate sector, namely sustainability, which in turn will drive demand for new, renewable, durable and insulating materials and above all will push western markets towards renovation of existing properties and away from investments in new buildings. Italy stands out for its record level of investments in renovation projects (driven by government incentives, especially the 110% Superbonus scheme), which are expected to account for 77% of all building investments this year compared to an average of around 50% in Europe as a whole and less than 9% in China.

With their characteristics of healthfulness, durability and recyclability, ceramic and clay products play a key role in increasing energy efficiency and improving environmental sustainability.

5

CWR INDIA 2022

17

foÜo fljsfed Vkby m|ksx vkSj cktkj % 2025 ds fy, vuqeku World ceramic tile industry and market: forecasts to 2025 Ilaria Vesentini - MECS (i.vesentini@mecs.org)

Over the five-year period from 2021 to 2025, the world ceramic tile market is projected to grow at an average annual rate of 5% in terms of production (an additional 4.5 billion square metres by 2025) and 5.1% in terms of consumption, resulting in a very slight increase in inventory.China will remain the undisputed leader accounting for half of global ceramic tile production and consumption, followed at a considerable distance by India with a projected output of more than 2 billion square metres in 2025 (almost half of which will be exported, making it the world’s largest exporter in terms of volume).

These are a few of the trends revealed in the recently published MECS Study Centre report entitled Ceramic Tile Market Forecast Analysis, TREND 2021-2025.

The report begins with a qualitative analysis of all the key factors used to predict trends over the next few years, including population and wealth, geopolitical tensions, energy price fluctuations and the effects of the ecological transition, the upswings and downturns of the construction sector and the impact of logistics. It then provides detailed analysis of macroregions and individual countries (91 of which are analysed in detail) based on absolute figures and five-year growth rates in ceramic tile production and consumption, as well as macroeconomic indicators that help gain an understanding of market trends. The newly published report aims to provide industry entrepreneurs and managers with a useful tool for understanding the sector at a time of unprecedented uncertainty following two years of pandemic that have overturned economic models and expectations.

The MECS research centre draws on thirty years of experience in the ceramic tile sector and in particular on the wealth of information acquired over the last decade, which includes in-depth analyses and reports on the international market along with accurate and up-to-date figures on production, consumption, trade and the economic and financial performance of manufacturers worldwide. With its consolidated expertise, continuous direct contact MECS Machinery Economic Studies is the new brand name of the research centre set up by Confindustria Acimac and Ucima to conduct systematic and comprehensive market analyses, economic forecasts and statistical surveys on the capital goods sectors and the relevant upstream and downstream industrial supply chains. MECS offers its services to Italian companies, providing customised information and reports aimed at improving their knowledge and international competitiveness. www.mecs.org

18

CWR INDIA 2022

economics

with Italy’s world-leading ceramic and ceramic technology manufacturing districts and collaboration with the Cresme research centre, MECS offers unique insights into market trends. Despite the unpredictable nature of short-term trends in the event of unexpected fluctuations in commodity and energy prices, as in the current situation, and the difficulty of assessing the effects of new government policies for fighting the pandemic, the analytical methodology and algorithms underpinning the forecasts make the medium- and long-term projections in the new MECS report robust and consistent.

Figures contained in the new Ceramic Tile Market Forecast Analysis, TREND 2021-2025 also show that, unlike during the global financial crisis of 2008-09, the Covid-19 pandemic has aided the recovery of advanced economies while penalising developing and emerging market economies. The pre-Covid growth surge observed in a number of Asian and African countries is expected to subside over the coming years due to difficulties in reacting to the production challenges and social disruption caused by the pandemic.

China will retain its leadership position in the global ceramic tile market with a production of 10 billion sqm, while Asia in general will increase its dominance in terms of production but not consumption. Africa remains the most dynamic macroregion (starting out from lower levels in absolute terms and with a considerable gap to make up), but the most surprising trend – already observed in the last edition of World Production and Consumption of Ceramic Tiles – is the sheer pace at which non-EU European countries are gaining ground among their competitors.

5

CWR INDIA 2022

19

jkd fljsfeDl dh lÅnh vjc esa foLrkj ij fuxkgsa RAK Ceramics looks to expand in Saudi Arabia Milena Bernardi - m.bernardi@tiledizioni.it

The 2021 results announced by RAK Ceramics on 7 February demonstrate that the Ras-al-Khaimah-based ceramics group has fully capitalised on the gradual return to normality. After four consecutive quarters of revenue growth, the Emirati multinational’s annual revenue reached AED 2.86 billion (€687.5 million at the 31/12/2021 exchange rate), up 21.8% on 2020. Total gross profit margin for 2021 reached an all-time high of 36.2%, total EBITDA increased by 32.7% to AED 501.3 million (more than €120 million) and net profit grew by 102.5% to AED 298.1 million (€72 million), an increase of 102.5% on 2020 and 45.3% on 2019.

All three divisions contributed to the group’s growth: tiles revenue rose by 21.3% year-on-year to AED 1.95 billion (€468.7 million); sanitaryware revenue grew by 17.5% year-on-year driven by all markets except Saudi Arabia; tableware revenue improved by 73% year-on-year after being badly hit by the pandemic in 2020 due to its strong presence in the food service and air transport segments.

All geographical markets recorded double-digit sales growth, the only exception being the UAE domestic market where the slowdown in the project segment led to a decline in tile sales and a 3.1% fall in overall revenues.

In India and Bangladesh, where RAK Ceramics has its own facilities, the group reported revenue growth of 60.9% and 30% respectively. In Europe, a larger customer base enabled the group to increase its revenue by 17% year-on-year despite a

Glamour collection by Elie Saab

20

CWR INDIA 2022

interview

Talking to...

Abdallah Massaad

RAK Ceramics Headquarters

decline in the final quarter of the year due to higher shipping freight rates caused by the global shortage in shipping containers. Revenue increased by 48% in the Middle East, with the exception of UAE and Saudi Arabia. And it is in Saudi Arabia – where sales continued to rise, closing the year at +26.7% – that RAK Ceramics is focusing its attention with a view to a forthcoming expansion project abroad.

The launch of the greenfield project for a new tile factory in Saudi Arabia was announced by CEO Abdallah Massaad, who gave us further details about this and other development programmes.

CWR: What are your aims for the new site in Saudi Arabia?

ABDALLAH MASSAAD: Saudi Arabia continues to be a significant growth market for RAK Ceramics, and by establishing a facility in the Kingdom, we can capitalise on the opportunity to further strengthen our premium brand positioning and offer differentiated products compared to local manufacturers.

We are excited by the project, but it is still in a very preliminary stage. We have a team of experts who are currently evaluating all options and preparing a roadmap for development.

CWR: Which segments of the Saudi construction industry are the most dynamic and are fuelling the surge in ceramic tile consumption?

CWR INDIA 2022

21

Travertinum collection by Elie Saab

Preziosi collection

A. MASSAAD: The construction industry in Saudi Arabia is booming as a result of significant government investment in housing and infrastructure development projects. As a result, we have seen a substantial increase in demand for products suited to residential and commercial construction projects in the transport, infrastructure, hospitality and retail sectors.

CWR: RAK Ceramics’ revenues have increased significantly in all your key markets, with peaks of 30% in Bangladesh and 61% in India. What factors have driven the growth in these countries?

A. MASSAAD: We have seen a strong performance and positive business sentiment in India and Bangladesh as lockdowns and logistical restrictions have eased. This has boosted the economy and driven demand in the ceramic tile sector, bringing better than expected results. Our business in Bangladesh demonstrated resilience and reported strong growth supported by the introduction of differentiated products for rural and premium segments. In India, we have witnessed a strong turnaround, with performance surpassing pre-pandemic levels. This performance was underpinned by improved profitability, despite significantly higher fuel costs.

CWR: How have you mitigated this increase in costs?

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.

22

CWR INDIA 2022

interview A. MASSAAD: In India, we have fixed-price contracts for our Samalkot plant, but price increases have affected our plants in Morbi, Gujarat. However, we have mitigated this impact through production optimisation. In Bangladesh, gas is very cost-effective.

In the United Arab Emirates, we source our natural gas directly from RAK Gas, and we have a fixed price for specific volume consumptions.

CWR: Given your robust growth in India and Bangladesh, are you planning new investments?

A. MASSAAD: We are upgrading our facilities in India and Bangladesh, which will enable us to produce more oversized and higher-value tiles. In the United Arab Emirates, we are expanding our tile and sanitaryware production capacity, and we are also extending our tableware offering by introducing Bone China products. Innovation, technology, and sustainability are key pillars in the RAK Ceramics’ manufacturing philosophy, and we are always looking for ways to improve our capabilities.

CWR: What are your expectations for 2022?

A. MASSAAD: Following our strong performance in 2021, we are cautiously optimistic about positive growth in 2022. The easing of COVID-19 lockdowns and restrictions across all key markets have enabled economies to open up and rebound. Despite the latest challenges, our priority in 2022 is to protect our market share and further strengthen brand perception in our core markets with a sustained investment. We are excited to strengthen our online and offline presence with the launch of our eCommerce platform and new outlet stores and showrooms across India, Bangladesh, Europe and Saudi Arabia. We look forward to introducing various new products and collections and strengthening our collaborations with international brands, such as ELIE SAAB, a well-known fashion and design brand with whom we have signed a long-term partnership agreement. We presented the first collection of surfaces and bathroom furniture developed through this partnership during the Dubai Design Week in November 2021. Despite rising input costs and supply chain disruptions, we aim to sustain our current operating costs. We will continue to improve our productivity and efficiency and upgrade plants to enhance sustainability and profitability. We will also increase selling prices to offset the increased freight costs in Europe.

5

Royal collection by Elie Saab

Soft lux collection by Elie Saab

CWR INDIA 2022

23

lksekuh fljsfeDl vxys foLrkj ds fy, rS;kj Somany Ceramics set for further expansion Milena Bernardi - m.bernardi@tiledizioni.it

Started production in 1971, Somany Ceramics is India’s second largest ceramic tile manufacturer and one of the top 15 global players. The company has its corporate office in Noida (Uttar Pradesh) and has access to a production capacity of 63 million sqm/year in FY 2022 at the two manufacturing units in Kadi (Gujarat) and Kassar (Haryana) as well as a further seven subsidiary and associate plants and arrangements with other manufacturers.

In more than 50 years of business, the group has focused on innovation and technology with the aim of developing a complete range of home décor products, including ceramic tiles, polished and glazed vitrified tiles, tile laying solutions and bathroom fittings. In this latter segment it produces both sanitaryware (the factory in Morbi has an annual production capacity of 1.15 million pieces) and chrome plated fittings at the plant in Chandigarh.

Over the years, the brand has established itself not only in the Indian market but also overseas with a presence in more than 70 countries, particularly the EU, Africa, the Middle East, the UK and Russia. This has led to the need for a major capacity expansion, a plan that was announced in February 2021 and has

24

CWR INDIA 2022

interview

Talking to, from left...

Abhishek Somany and Amit Bhatnagar

gained further momentum following the strong performance in the first half of the current year. We spoke to Managing Director Abhishek Somany and Assistant Vice President, International Business & Strategy Amit Bhatnagar.

CWR: Somany Ceramics posted strong results in 2020. How did business go in the first half of the current year?

ABHISHEK SOMANY: That’s true, the financial year ending March 2021 was very positive despite the outage of 1.5 month of covid 19. While revenues saw only marginal growth amid the challenges of the pandemic (+2.7% on 2020), EBITDA jumped by 45% to 11.6% of turnover, debt fell to zero and our cash surplus was the highest ever recorded. The first half of the current financial year also brought very good results. Tile sales to 30 September 2021 were up 50% on the first half of 2021 at 26.2 million sqm, consolidated turnover rose by 50% and EBITDA climbed 141% to 10.3% of revenues. The resilience of Indian economy together with the improvement in business sentiment and consumer confidence was reflected in our results despite the unprecedented increases in gas prices, freight rates and other production costs which are continuing to put pressure on our margins.

CWR: Could you tell us about your expansion plans in the tile sector?

A. SOMANY: It is the largest expansion capacity in our recent history and will bring a net 20% increase in saleable capacity to around 76 million sqm/year compared to the current level of 63 million sqm/year. These expanded capacities are expected to be onstream and effective by the last quarter of the financial year 2021-2022, so foreseeably by March 2022. There are some good reasons why the capacity expansion was essential. Firstly, the structural shift in consumer preference from unorganised to organised brands makes it imperative to commission additional capacity rapidly or risk losing market share to competitors who expand faster than us. Additionally, the capacity expansion will be concentrated in large format glazed vitrified tiles & technical porcelain range, allowing us to insource a portion of production that is currently outsourced to third party manufacturers. All of this will have a very positive impact on our margins, so we expect to be able to pay back the investment within a very short timeframe.

CWR: The most difficult period of the pandemic is now behind us. How have you coped?

A. SOMANY: It has been a huge challenge involving the en-

CWR INDIA 2022

25

interview tire company organisation, from safety of human capital to communication, optimal usage of budget and business relationships. As for business channels, we made extensive use of digital technologies, forayed into e-commerce and started social media campaigns. To give people a similar experience to what they would have when coming to the showroom, we converted all our catalogues to a digital format and created a tile visualizer on our website to give customers a real feel for the products from the comfort of their homes.

We also sent cut samples to all customers who wanted a close-up view of the product before they made their purchase decisions.

It is an experience that has taught us a lot and that we will be developing further in the future, again as pioneers. We will shortly be introducing an app and a new online visualiser for our entire range of tiles and bathware based on AR and VR technology to give consumers a completely different “touch and feel” experience compared to traditional visualisers.

CWR: Somany is one of the most recognised brands in India.

How have you achieved this position?

A. SOMANY: The credit goes to our vision of delivering ex­ cellence in every product and ethos of nurturing long and steadfast relationship with all our stakeholders. Today we are proud big Somany family, who share same vision, language and ethics with an aim of achieving the most respectable company. Our employees, trade partners and vendors are our biggest assets, who stood by us through thick and thin and there long association with us are live testament of our success story, with more than 2,500 dealers and the approximately 10,000 points of sale that have been working relentlessly over the years to make Somany Ceramic a successful brand. Today our relationship has grown ahead from mere professional relationship to more compassionate belonging.

CWR: Are the factors that differentiate you from your competitors in the unorganised sector in the Indian market the same as those that are driving your success abroad?

26

CWR INDIA 2022

VITAL Rainforest: The ecosystem richest in biodiversity

Complete ecosystem of solutions for ceramic inkjet decoration.

EFI Cretaprint is VITAL

A reliable, essential technology.

Digital printing that brings life to your tiles.

Hybrid Ceramic Ecosystem

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

ADVERTISING

interview AMIT BHATNAGAR: Definitely. Product quality is an essential factor alongside a reliable pre- and after-sales service.

Our products are made using state of the art technology and selected raw materials, glazes and colours imported from Italy and Spain, all of which meet or exceed the highest international standards. In the domestic market and above all abroad, we aim to offer the most innovative products and technologies at competitive prices. In recent years, our constant commitment to R&D has allowed us to patent numerous technologies, such as the VC Shield tiles. These tiles have received the Corporate Technical Achievement Award from the American Ceramic Society (AcerS) for their very high abrasion resistance, which makes them ideal for high-traffic areas such as shopping malls, airports, hospitals, offices, etc.

One of the latest patented innovations is Germ Shield, an anti-bacterial surface technology that prevents the proliferation of germs even in extreme weather conditions. Another patented solution called Cool Tile is one of the most interesting products in the field of sustainable building as it reduces the temperature of ceramic surfaces. This brings significant savings in electricity for cooling homes and fights against the urban heat island effect. A patent has also been applied for Slip Shield non-slip surfaces.

CWR: So are you also planning to expand in foreign markets?

A. BHATNAGAR: Despite the post-pandemic changes in business dynamics, we are growing steadily abroad and have now expanded our brand presence to 80 countries and we further want to expand our business in other continents.

Along with a strategic product mix and competitive pricing, our corporate values and ethos system allow us to build strong and lasting relationships with customers all over the world. In the near future we expect growth to vary across regions with some countries offering huge growth potential in the coming years.

✕

mR—"Vrk vkSj LFkkf;Ro m|ksx txr esa cnyko ds ekè;e Excellence and sustainability as drivers of change in the industry Esmalglass-Itaca

The key to Esmalglass-Itaca’s success lies in its innovation and ability to offer advanced solutions that meet specific market needs. The group aims to act as a technological partner for its customers, bringing excellence and added value to its production processes while caring for the environment.

One example of its commitment to sustainability is the development of DigitalGlass, a new family of water-based digital glazes that reduce water consumption by a factor of up to ten compared to traditional glazes, while offering a range of other environmental and industrial benefits. The first advantage of these glazes is their lower levels of emissions and environmental impact, because they not only reduce water consumption but also eliminate excess materials, waste and foul odours. The second benefit is the reduction in operational and logistical costs. Because DigitalGlass glazes only use the quantity of material actually needed for application, they generate zero waste and also achieve savings in terms of storage and personnel.

Another benefit is the improvement in product quality and aesthetics, as the most natural finishes are achieved by synchronising the application of water-based digital glazes with the rest of the digital applications. Last but not least, these glazes ensure a shorter time-to-market. The fact that the process is fully digital means that new products can be made more rapidly in response to market demand.

One of the new products launched by Esmaglass-Itaca in 2021 is Shape-ink, an application that creates fully digital reliefs synchronised with the design without the need to use a press, rollers or belts. Shape-ink saves on consumables while reducing relief changeover and product development times. All reliefs, such as those of wood and stone, are generated digitally,

30

CWR INDIA 2022

technology

allowing for different results in each production run. As well as synchronising the reliefs with the designs, Shape-ink is also able to create designs tailored specifically to the needs of each customer or distributor, as well as determining the depth of the relief according to the deposited ink quantity, resulting in very natural finishes.

Shape-ink is also joined by Shape-glass, a new family of high-performance glazes that achieve outstanding results in terms of definition and depth. This option is ideal for companies searching for efficient use of materials.

In the field of non-slip finishes, Esmalglass-Itaca has developed Diamond-glass, a complete range of products that guarantee the highest levels of safety and comply with all international regulations and standards. Diamond-glass glass-ceramic materials are available in natural, non-slip and lapped finishes for both floors and walls and are able to create extremely natural surfaces, improving aesthetics and anti-slip properties while maintaining a remarkably silky feel.

The range is fully compatible and complementary with digital applications. The technical characteristics of this solution make it the perfect choice for long-lasting results, including high abrasion, stain and chemical resistance, a non-reflective matt finish, efficiency on highly transparent surfaces and an anti-slip finish with a silky surface.

5

CWR INDIA 2022

31

lcls T;knk fcØh okys vkdkj ds fy, vusd xq.kksa okyh vkSj Bksl iafä dk 'kqHkkjaHk The most versatile and compact line for top-selling sizes is launched Sacmi (Imola, Italy)

The 60x60 cm size is currently the world’s most popular ceramic tile. It’s a large tile but not quite a slab, a term that by convention is used for products measuring 120x120 cm or more. And it’s in this mid-size range – above all in the 60x60 size and its submultiples – that the world’s suppliers of ceramic forming technology face some of their greatest challenges.

These are the reasons why Sacmi has decided to further expand its Continua+ range, which already counts more than 100 lines sold worldwide since its launch. Just a few months after presenting the PCR 2180, the machine with the highest productivity on the market with an output of over 21,000 m2/ day of slabs and submultiples, Sacmi is now launching the brand new PCR 2120, the smallest, most compact and versatile machine in its category. As Sacmi’s Forming Product Unit director Gianluca Pederzini put it, this solution is capable of “breaking down the last barrier separating slabs and standard size tiles”. ❱ The highest levels of productivity The PCR 2120 can produce slabs with thicknesses of up to 20 mm, a potentially infinite length and a maximum width of 120 cm after firing (the equivalent of two 60x60 cm cavities).

Considering a 1 cm thickness and sizes of 60x60 cm, 120x120 cm and submultiples, productivity stands at 16,000 m2/day, the highest in this category.

The PCR 2120 also delivers outstanding compactness and lower operating expenses, and depending on the product to be made it can incorporate from 1 to 5 powder feeders.

Downstream from the compactor, each version features a TPV cutting machine that enables manufacturers to create all the required sub-sizes in a coordinated, automated manner.

“While bringing together all the characteristics of the other machines in the Continua+ family such as flexible size changeovers, low scrap levels and the lowest consumption on the market, the new PCR 2120 responds to manufacturers’ needs to keep productivity high even when dealing with smaller average batch sizes, frequent size changeovers and the need to develop products with greater added value such as dry decoration,” observes Alberto Tassoni, Sacmi’s Forming Product Manager (Tiles Business Unit).

According to Pederzini, this is because it combines all the productivity, cost and space-saving advantages of a traditional pressing solution with the versatility of Continua+ in terms of size changeover management.

32

CWR INDIA 2022

technology

❱ Unrivalled performance The new PCR 2120 stands out for four key characteristics: • excellent performance on different sizes (80x80 cm and 90x90 cm, with productivities ranging from 10,600 m2 to 12,000 m2); • potentially infinite slab length; • rapid changeovers (always under 30 minutes); • superior quality without any falloff in productivity, especially in the case of decorated products, thanks to the continuous process with controlled de-airing. ❱ Consumption and sustainability The machine offers two advantages in terms of sustainability.

Continua+ 2120 keeps production scrap levels below 3% at all times. Moreover, this waste is fully recyclable, regardless of the product size, so it is much lower than on alternative solutions. Importantly, about 2% consists of powders that can be fed directly into the production cycle without any reprocessing costs. The remainder can be sent back to the mills, ensuring zero waste along the entire production line.

Specific consumption is also the lowest in the category at just 0.06 kWh per m2 for an installed power of 80 kW. Like previous solutions, the Continua+ 2120 uses just 120 litres of hydraulic oil, more than 95% less than on a discontinuous press, and brings more than proportional savings in terms of the energy needed to control the cooling circuit.

CWR INDIA 2022

33

technology

❱ Kajaria adopts Sacmi Continua+ technology and enters the large slab segment Kajaria Ceramics, India’s top tile manufacturer and the seventh largest producer in the world, is about to complete another major investment. The new PCR2120, the latest addition to the Sacmi Continua+ line-up, is due to come on stream this spring at the Tirupati plant, one of the Group’s ten production sites in India, and will enable the well-known ceramic brand to enter the premium ceramic slabs and surfaces segment. Kajaria has invested constantly in innovation and service throughout its more than 33 years of history and is now the leading brand in the Indian market and a major exporter to Europe and the USA. “Technology, research, quality and design have been part of Kajaria’s DNA ever since it was founded,” says Chairman Ashok Kajaria, who now runs the company together with his sons Chetan and Rishi. “We have always adopted the latest available technologies with a view to improving the quality and appeal of our products and the efficiency of our factories.”

The PCR2120 is designed specifically to produce the most popular sizes on the market, from 60x120 cm to 120x240 cm together with the corresponding sub-sizes, and is extremely compact and versatile, largely due to the integrated TPV on-the-fly cutting system supplied by BMR. As a result, it is a valid alternative to even the highest performance traditional presses. Equipped with upstream APB0 and DMS feeders, when fully operational the machine will be capable of producing 3.5 million square metres per year in the various sizes and thicknesses. It will have a specific consumption of just 0.06 kWh per square metre (compared to an installed power of 80 kW) and scrap levels below 3%, regardless of the product size.

Kajaria also commissioned Sacmi to supply the thermal machines for its new Tirupati plant: a 5-tier dryer with a useful width of 2850 mm and length of 47.6 metres, the 25.3-metre pre-kiln and the new 210-metre HTE295 kiln, a latest-generation machine fully equipped with systems for recovering hot air from the kiln and sending it to the burner preheating area and dryer.

This investment reflects the efforts made by the Indian ceramic industry to respond to the problem of soaring energy prices by adopting advanced energy efficiency solutions capable of improving the energy balance of its factories. ✕

34

CWR INDIA 2022

cgqr rst] fLFkj] ÅtkZ cpkus okyh çfØ;k Superfast, a sustainable, energy-saving process Eustachio Tarasco, System Ceramics (Fiorano Modenese, Italy)

Today industry has a clear duty to pursue the goal of environmental sustainability. But rather than making vague ecological statements and promoting generic green awareness, companies must adopt concrete, effective actions that produce measurable results. For years System Ceramics has been using part of its R&D investments to make an effective contribution to these issues. Lower CO2 emissions, monitoring of energy consumption and the reuse of waste are all tangible and verifiable results of these efforts. One example is Superfast, the latest System Ceramics technology for ceramic pressing designed to guarantee high levels of performance while caring for the environment and bringing considerable benefits in terms of energy savings.

As the world’s first mouldless press, Superfast brings numerous advantages and a high degree of operational versatility, but to appreciate the true significance of the innovation it is important to understand the underlying premises of the technology. As industry professionals are well aware, the characteristics of a ceramic tile can be thought of as a series of layers.

These are: an aesthetic level, consisting of a surface with visual and tactile characteristics; a resistance thickness that determines the mechanical strength of the tile and its ability to withstand loads according to the intended use and legal regulations; a technical thickness determined by the constraints of the production technology; and finally a perceptual thickness, which corresponds to commonly accepted stereotypes of what a tile should look like. Not all of these “layers” are necessary or serve to add value to the ceramic product.

While the “aesthetic” layer and the “resistance thickness” are both essential aspects of a tile that respectively determine its beauty and its ability to withstand stresses during use, the same certainly cannot be said for the technical and the perceptive thickness, both of which can and must be reduced in order to lower consumption levels.

Superfast is capable of producing medium, large and very large tiles in thicknesses ranging from 3 to 30 mm using a robust, efficient and flexible production process.

Superfast removes everything that is superfluous from the finished product and eliminates waste during the production process by means of three steps: • uniform compaction; • pre-fire cutting; • the recovery system.

36

CWR INDIA 2022

technology

Uniform compaction equates with reduced thickness and calibre tolerances, resulting in lower costs and fewer rejects. The cutting machine makes it possible to produce an unfired tile with the most appropriate size, helping to optimise the subsequent production processes: the pressed spray-dried material is cut after shaping and the excess raw material produced during the cutting process is fully recovered.

Superfast adopts a zero waste process in which the recovered scrap is dry ground alongside the press, then mixed and introduced directly into the spray-dried material batching units.

Superfast technology goes to the very heart of the production process and increases the sustainability of raw materials management by focusing on a number of different aspects: the moisture content of the clay, the thickness produced in the press, 100% waste recovery, energy savings during firing and a

CWR INDIA 2022

37

technology

dimensional precision that ensures limited production of scrap.

While Superfast overcomes all technical constraints, the final aspect concerns the stereotypes that determine the choice of tile thicknesses on the part of consumers. A radical new approach is needed to transform the way tiles are conceived as finished products and to convey the message that although greater thicknesses equate with stronger and more resistant tiles, they are in fact entirely unnecessary and simply result in greater consumption and waste. As in all sectors, in the ceramic industry supply inevitably adapts to demand. The more the market continues to ask for large thicknesses, the more the industry will continue to supply them but without providing any real benefits.

In terms of sustainability, it is essential to promote an approach focused on using only what is necessary. This way, a given surface area of tiling will equate with a smaller quantity of consumed materials, bringing benefits for all steps in the supply chain, from processing the spray-dried product to firing, transport to the point of sale and so on. A philosophy based on the “essentials” achieves concrete energy savings in all its many different aspects. At System Ceramics we are confident that this can be achieved, as clearly demonstrated by the growing interest in technologies such as Superfast and the large number of machines that have been sold in recent years. ✕

38

CWR INDIA 2022

ySÇix çfØ;k esa vfèkd xq.koÙkk vkSj mRikndrk ds fy, oSdfYid mixzg vkSj fQdVZ 'kh"kZ Alternating satellite and Fickert heads for higher quality and productivity in the lapping process Premier (Villaverla, Italy)

Premier has long been experimenting with the use of satellite heads for polishing, lapping and calibrating porcelain tiles and slabs to determine their potential advantages in terms of costs and productivity.

Following a series of tests conducted in the company’s laboratory, Premier’s engineers concluded that the alternating use of satellite and Fickert heads is the configuration that ensures maximum tool yield and highest finished product quality.

This is because the marks left by the Fickert head during machining consist of concentric circles (photo A), whereas the satellite head leaves curved marks arranged radially with respect to the centre of rotation of the head (photo B).

After completing the laboratory tests, Premier installed a lapping line with alternating Fickert and satellite heads for a longstanding Argentinian customer, Cerámicas Lourdes, with excellent results.

At the entrance to the line there are 2 multi-diameter satellite heads with tools angled in such a way as to facilitate tile infeed, eliminating edge breakages at the entrance and overcoming height differences of up to 10 mm and spacing of more than 30 cm without any problems. This was followed by alternating Fickert and satellite heads to achieve maximum tool yield and line productivity. Fickert finishing heads were installed at the end of the line as they were found to be the most effective solution for this stage of processing.

Photo. A: Mark left by a Fickert head

40

CWR INDIA 2022

Photo. B: Mark left by a Satellite head

Fig. C: The trajectories followed by Fickert tools (green) and satellite heads (orange)

technology

This solution combines the advantages and specific qualities of the satellite heads (versatility and productivity) and the Fickert heads (machining quality) and results in a lapping/polishing line that significantly increases machining speed and productivity and tool yield.

Figure C shows the trajectories followed by the Fickert and satellite tools and clearly reveals their perpendicular intersections, an arrangement that allows any grooves created during one machining operation to be smoothed out by the passage of the tools on the subsequent head.

This alternating configuration also improves the performance of both tools, helping to keep them constantly sharp and with a clean, open cut.

This is particularly beneficial for the Fickert tools, which operate at low speed and have a tendency to dull. Alternating them with satellite tools on the lapping line significantly extends their service life, with the added benefit of reducing swing so that the Fickert heads do not extend beyond the edge of the tile, which in turn brings an improvement in terms of several centimetres of processed material.

The increased tool life brings two clear advantages: lower production costs and a smaller quantity of non-recyclable waste produced by the line, thereby reducing its environmental impact. Aldo De Stefani, Premier’s technical sales manager for South America, confirms that “since Cerámicas Lourdes started up the new line, we have been machining large dark coloured slabs with excellent results in terms of both quality and productivity. The problem of feed marks typical of lapping has been eliminated and the quantity of non-recyclable waste has been

✕ reduced.”

CWR INDIA 2022

41

LekVZ xSl Hkfë;ksa esa :ikarj.k fdl çdkj fLFkjrk dks c<+krk gS vkSj ykxr de djrk gS? How the transition to smart gas turbines increases sustainability and reduces costs Paolo Masiero, Solar Turbines

CO2 emissions have grown exponentially over the last 120 years in step with demand for electricity and mobility and it is now imperative to take action to reverse this trend. For this purpose, the European Union has introduced an ambitious mandatory emissions reduction plan to be achieved by 2030: 55% reduction in greenhouse gas emissions, 32% lower energy consumption and 32% use of renewable energy. The pandemic has also revealed the strengths and weaknesses of the current energy system and shown that it is essential to speed up the development of digital infrastructures and data management in order to allow all our activities to continue. Ecological transition and digital transformation are at the heart of the Next Generation EU plan, which has allocated €750 billion to the 27 EU member countries. Italy is one of the countries expected to benefit the most.

Of the €222 billion allocated in the NRRP (National Recovery and Resilience Plan), 31% is earmarked for the green transition (including €3.6 billion for hydrogen) and 22% for digitalisation.

These are also the two core areas of activity of Solar Turbines, the world’s largest manufacturer of 3.5 to 24 MW industrial gas turbines since the ‘80s. It has installed more than 1,200 power

Smart grid integration - InSight Platform: the enabling technology • Data acquisition • Analytics and monitoring • Optimization process

Cloud-based Service:

Energy Market Prices

Cloud-based Service:

• Electrical & thermal tracking • Maximizes operative revenue • CO2 emission

InSight Platform (Solar Turbines)

• Primary Energy Savings monitoring

LocalWeather Forecast

• Efficiency certificates calculation Local SCADA CHP “Power Island“

Plant/Facility

Plant Data System CHP Steam (to Plant)

Renewables

Caterpillar: Confidential Green

42

CWR INDIA 2022

CHP Electricity (to Plant)

Utility Services

technology

generation and cogeneration systems, allowing corporate customers to save more than 30% on their electricity bills and reduce their CO2 emissions by 40%. In the ceramic industry there are already more than 90 spray dryers connected to Solar turbines.

Solar Turbines is developing new products and services to keep pace with the changes in the way we produce and consume energy. These include new digital solutions designed to ensure more sustainable cogeneration and to allow economic and environmental targets to be met more rapidly.

So let’s take a look at how data management and smart integration of Solar gas turbines into the production process can generate additional value for companies, what technologies and elements facilitate this virtuous circle and, finally, how the current environment is favouring the development of these opportunities. ❱ SMART turbines, integrated and automated One interesting case study is that of a client company operating in the pharmaceutical sector which adopts a gas turbine of similar size to those typically used in ceramic factories and with comparable daily and weekly operating breaks. The company, which has a cogeneration plant operating at an efficiency of over 82%, has already reduced its CO2 footprint by around 16% compared to the national emissions average, resulting in savings of more than €330/hour.

For this purpose, the cogeneration plant was upgraded with the new InSight enabling technology developed by Solar Turbines. The platform is based on data acquisition, monitoring and management through to the formalisation process, where the system suggests the best operational points to follow over the subsequent few minutes to achieve the set targets. Solar takes care of the connection (SCADA, DCS, PLC) and the signals necessary for system operation, as well as the user interface. The platform allows for development and further integration with other systems and functions (e.g. renewables, energy storage, multiple gas turbines and other power generation systems) and meets the highest cybersecurity standards. ❱ Economic and environmental benefits Shifting focus from the concept of maximum efficiency towards that of the most profitable and sustainable solution, we can see at a glance how the use of the new SMART turbines

CWR INDIA 2022

43

technology

can optimise financial performance and increase environmental sustainability. · Reduction in operating costs. The thermal power plant can be monitored remotely and can operate for up to 72 hours unattended, allowing operators to focus on other tasks and saving the company around €60,000 per year. · Increase in available hours. By interfacing the customer’s ERP data with the turbine’s health status in advance, it proved possible to avoid between 5 and 10 days per year of plant downtime for scheduled maintenance, bringing an economic benefit of around €32,000/year. Predictive maintenance and advanced data management also reduced unplanned downtime, increasing turbine availability from 95% to 97.5% and resulting in additional cost savings of €73,000/ year. · Monitoring plant efficiency and participation in the spot energy market. The balanced scorecard developed by Solar enables plant managers to perform real-time monitoring not just of the main operational parameters (thermal power plant efficiency, specific CO2 emissions per kWh of electricity produced, cost of electricity production, etc.), but also of economic and environmental performance. All parameters are constantly benchmarked against local regulations, legal limits or company targets.

For example, the system may suggest maximising electricity production at weekends and propose the optimal set-up according to external factors (electricity prices and costs, CO2 and gas costs). In this case study, the extra energy produced in this way and exported to the spot market amounted to approximately 3500 MWh, with an additional 4-6% margin on operational savings (€53,000).

The system is also capable of recommending turbine shutdown during the weekend in the event of unfavourable conditions that fail to offset the CO2 cost effect. · The flexibility mechanisms of energy markets. The Smart cogeneration plant can also participate in the Power Flexibility Markets. This is an economic opportunity that is regulated by the Flexibility Market’s specific auctions and can be as high as €30,000 per MW per year (or €400 per MW per call, usually 2 hours of feeding energy into the grid at 15 minutes notice). · Increased environmental THE MAIN MACRO TRENDS: OPPORTUNITIES AND THREATS and financial performance.

Target sector Adding together the results Probable increase of According to Paris Agreement obtained with the optimisafossil fuels cost and European Sustainable Development Goals tions described above, the Carbon cost client company was able to Increasing of CO2 cost Up to 60 ‐ 90 €/tCO2 by 2030 reduce its annual CO2 emisUp to 100 ‐140 €/tCO2 by 2040 sions (already below the naPower technologies Decreasing of electricity tional average) by a furRenewables and no‐carbon technologies production cost ther 564 tonnes, equivamore and more competitive lent to a carbon tax saving Europe H2 production objectives 1 mtpa H2 in 2024, 10 Mtpa in 2030 of around €28,000, while the Increasing of H2 and bio-gas 2019 demand of 173 Mtpa H2 equivalent additional economic benefit of a SMART gas turbine Resiliency and sustainability Increasing of Digitalization Renewables enabler – SMART grid reached 11%, equivalent to Energy efficency €259,000/year. ✕

Macro Trends – Opportunities & Threat

Caterpillar: Confidential Green

44

CWR INDIA 2022

Reduction

Sustainability at your fingertips

+100

SPRAY DRYERS APPLICATIONS

+40%

CO2 AVERAGE EMISSIONS REDUCTION IN CHP APPLICATIONS

Contact us. for more information and to locate the office nearest you: visit solarturbines.com; Call +41 91 851 1511 (Europe) or +1 619 544 5352 (US) email infocorp@solarturbines.com

+100

GAS TURBINES IN CERAMIC

>30%

COST SAVINGS ON UTILITIES BILL

,ythoh] ,d çHkkoh lSfuVSjhos;j gSMa Çyx lekèkku LGVs, an efficient sanitaryware handling solution Sacmi (Imola, Italy)

As part of its commitment to delivering increasingly automated and reliable product traceability systems, Sacmi offers solutions for automating the cars used to transfer pieces along the entire sanitaryware production line.

Due to the mechanical properties of the unfired product, effective piece handling is a particularly crucial factor between the end of the casting stage and arrival of the product at the kiln.

After being demoulded, ceramic sanitaryware underENDLESS goes a process of consolidation and hardening in the atmosphere. During this stage, the ceramic pieces lose some of their moisture content and gain mechanical strength prior to the final drying process.

Automated handling with AGVs (Automatic Guided Vehicles) is an extremely advantageous alternative to the use of manual cars as it ensures controlled product handling throughout the entire production process. This optimises the length of time the sanitaryware spends in the intermediate stages (such as consolidation and ageing in the atmosphere prior to drying) and in the storage areas associated with the various production lines, thereby reducing and optimising the occupied spaces.

46

CWR INDIA 2022

INNOVATION SINCE 1919

sanitaryware

Further benefits of automated handling include less physical labour and improved working conditions for the operator, as well as a reduction in waste caused by manual handling errors.

In the solution proposed by Sacmi for highly automated factories, AGVs are used in all stages from the casting department through to the end-of-line stage downstream of the kiln, at the entrance to the automatic sorting lines and for transferring the product to the final packaging and storage stage.

Unlike other handling systems such as conveyors, AGVs do not require fixed floor structures and do not permanently occupy factory space, which has the advantage of reducing space requirements.

The AGVs proposed by Sacmi for the automated transport of semi-finished and finished products are of the unmanned LGV (Laser Guided Vehicle) type. They meet a wide range of needs by adapting to the specific type of car, the size and number of racks on the handling car and the available factory space.

The laser guidance technology uses wall-mounted reflectors along vehicle pathways. These enable the system to make routing calculations and verify the positions of the LGVs, each of which is equipped with a rotating optical laser sensor. The position of each LGV is monitored constantly thanks to continuous detection by means of reflectors located in the surrounding area and direct communication with the machine’s computer, which in turn ensures precise mission precision and zero risk of error.

Needless to say, all vehicles are equipped with on-board safety systems that constantly survey the surrounding areas and prevent collisions, thus guaranteeing complete operator safety.

CWR INDIA 2022

47

sanitaryware

Another important advantage is that LGV handling systems are extremely flexible due to the possibility of changing the production flow and layout. Routes can be modified or added in the case of increased production capacity simply by making adjustments via the software. It is also possible to disable pick and place stations as required from the computer.

The floor-mounted computer acts as a “traffic manager”, allowing users to control and optimise routes. A vehicle control computer manages missions on a priority basis and coordinates traffic with production flows. This allows the status of production to be monitored precisely at all times, including the exact position of each moving vehicle and the distribution of products over the various stages of the production process.

The control computer, potentially integrated with factory supervision systems, is therefore able to monitor the intermediate semi-finished and finished product warehouses along the entire production line.

A centralised control system synoptic panel displays the vehicle parking status and position in real time, as well as alarms and machine status. For each parked vehicle, users can view data on the product it contains and the date it was last moved.

As part of Sacmi’s fully integrated approach to automation, this LGV solution is fully integrated both mechanically and in terms of software with Sacmi’s robotized casting units. The LGV control system is compatible and can be integrated with factory supervision or ERP systems.

5

48

CWR INDIA 2022

international exhibition of technologies and supplies for the surfaces industry

ORGANIZED BY

IN COLLABORATION WITH

WITH THE SUPPORT OF

Ministry of Foreign Affairs and International Cooperation

lSfuVsjhos;j bdkb;ksa ds fy, de fj;ksy‚ftdy çHkkoksa ds lkFk u, ckbaMlZ@IykfLVlkbtlZ New binders/plasticisers with low rheological impact for sanitaryware bodies Riccardo Grassi, S.R.C. Engineering (Dormelletto, Italy) Marco Antoniotti, Lamberti (Albizzate, Italy)

In ceramic sanitaryware production, the potential for improving the mechanical characteristics of cast pieces simply by adding a chemical auxiliary to the slip is often limited by the significant rheological alterations caused by the additives currently available on the market. These alterations have to be corrected through adjustments to the production process, an operation that producers often consider too laborious or costly.

As part of its Tenagreen series, Lamberti has recently developed several new products that significantly improve the mechanical characteristics of the cast pieces while having a minimal impact on slip rheology, allowing for rapid and problem-free adoption on existing production lines. Following an initial screening operation carried out in its own laboratories, Lamberti asked S.R.C. Engineering (a well-known technology consultancy firm that has been operating in the international ceramic sanitaryware sector for decades) to carry out its own laboratory assessment of three new-generation Tenagreen products with different chemical properties. The purpose of the evaluation was to confirm the suitability of the products for use in sanitaryware production, to verify their expected low impact on the slip rheology and to compare their performance in terms of improved mechanical characteristics in order to determine which of them would be the most suitable to launch onto the market. ❱ The tests A standard vitreous china body slip prepared industrially by a leading Italian manufacturer was used for the tests. The slip was brought to a standard casting density of between 1800 and 1810 g/l. The products to be tested were subsequently added to the mixture and homogenised using a mechanical stirrer.

Laboratory tests were performed to evaluate the following parameters: • Viscosity and thixotropy • Thickness formation in 30/60/90 minutes • Dry, fired and total shrinkage • Pyroplastic deformation • Water absorption • Dry bending strength (M.O.R.).

50

CWR INDIA 2022

sanitaryware

❱ Tested products and results Along with the reference body, the following products and dosages were tested: • Tenagreen CS 555, at dosages of 0.5% and 1% of dry content • Tenagreen WW 01010, at dosages of 0.55% and 1.1% of dry content • Tenagreen WW 01038, at dosages of 0.7% and 1.4% of dry content The results are shown in Table 1. ❱ Evaluation of results The tests gave the following results: • Viscosity: minimal variations in the viscosity value for all evaluated products.

• Thixotropy: a limited decrease in thixotropy is observed for CS 555 and an even smaller decrease for WW 01038, while WW 0100 showed a certain increase at low dosage and a limited re-

TABLE 1: CHARACTERISTICS OBSERVED FOR THE NEW TENAGREEN BINDERS Reference body Dosage

Tenagreen CS 555

Tenagreen WW 01010

Tenagreen WW 01038

0.50

1.00

0.55

1.10

0.70

1.40

22

22

23

23

23

22

22

Density

1804

1800

1799

1800

1801

1809

1795

Viscosity

340

342

345

340

345

342

343

Viscosity

318

332

330

310

332

330

325

Thixotropy

22

10

15

30

17

12

18

Thickness

5-7.1-8.1

5.3-7-8.6

4.8-7.3-8.7

5-7.1-8.5

4.5-6.5-8

5.2-7.4-8.5

4.4-6.8-7.9

Dry shrinkage

3.97

2.98

3.08

3.17

3.08

3.67

3.47

Firing shrinkage

8.23

8.23

8.23

8.23

8.13

8.13

8.23

Total shrinkage

12.2

11.21

11.31

11.4

11.21

11.8

11.7

55

56.5

56

55

55

55

56

Water absorption

0.36

0.24

0.26

0.37

0.39

0.21

0.48

L.O.I.

6.13

6.24

6.44

6.22

6.55

6.21

6.33

M.O.R. dry

55.5

83.3

115.07

67.91

93.26

88.44

95.47

50

107

22.3

68.6

59.3

72

T °C

Pyroplastic Deformation

M.O.R. increase

CWR INDIA 2022

51

sanitaryware

duction at the highest dosage.

• Thickness formation: at low dosages, the values are equivalent to or better than the standard for all products. At high dosages, the values for WW 01010 and WW 01038 are lower than the reference values but tend to reach them after 90 minutes.

• Total shrinkage: no significant variations.

• Pyroplastic deformation: no significant variations.

• Water absorption after firing: no significant variations.

• Dry M.O.R. values: the increases are highly significant and proportional to the dosage for all products tested, ranging from +22% to +107% compared to the reference. ❱ Opportunities All three new products in the Tenagreen series brought about a significant improvement in the mechanical properties of the body for minimal variations in the rheological parameters.

In some cases, improvements in thickness formation were also observed, along with a mild deflocculant effect which could be exploited to slightly reduce the quantity of deflocculant used in body slip preparation. At the dosages used in the tests (from 0.5% to 1.4% of dry content), the improvements in the observed mechanical characteristics (up to +107%) are generally higher than the levels normally sufficient to improve production yields by reducing cracking and breakages prior to firing. This means it may be possible, for industrial production, to use lower dosages than in the tests, further reducing the already low impact on the slip rheology. All the tested products can therefore easily be introduced into existing production lines and are capable of improving the mechanical properties of the body before firing.

The best product for each individual user must be chosen on the basis of the test results obtained with the different body formulations and/or economic considerations linked to the optimal dosage and current cost of the products. In the current situation of extreme instability in raw material costs and consequently in the prices of additives, manufacturers may find it very useful to be able to choose between several products that can all be easily introduced into the process in order to achieve the best possible benefit-cost ratio. ❱ Conclusions To conclude, the new Tenagreen products offer the following advantages: • ease of introducing the additive into the production process; • reduction of rejects due to cracks during shrinkage and breakages during pre-fire handling; • the possibility of reducing the quantity of deflocculant in body slip preparation; • the possibility of improving the economic and environmental sustainability of the process by at least partially using less plastic and less expensive alternative raw materials and/or raw materials sourced from areas closer to the production facility.

These conclusions are based on laboratory observations and have already been confirmed in several plants following the introduction of one of the presented products into the normal production process. The product was adopted for standard use within a few weeks of the first on-site tests.

5

52

CWR INDIA 2022

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

Smalticeram

54

CWR INDIA 2022

Latest technologies

Cimes

CWR INDIA 2022

55

Latest technologies Unilin Technologies

56

CWR INDIA 2022 2018

Latest technologies Certech Group

58

CWR INDIA 2022 2018

Latest technologies Efi Cretaprint

60

CWR INDIA 2022 2018

Latest technologies Syneco

62

CWR INDIA 2022 2018

Poppi Clementino

Inco

COLOUR INNOVATION INDUSTRY

64

CWR INDIA 2022 2018

Latest technologies

ADVERTISING

A scientific approach to face complexity

Tiles

Whiteware

The place where expertise create solutions

Plasticizers for body

Fluidizers for body and glaze

Binders anti anti-settling agents for microgrits

CMC series. Traditional binders and rheology modifiers for glaze

Multifunctional additive for grinding and application of glazes

Special binders and rheology modifiers for glaze

Tailored solutions for a dynamic industry

Innovative and functional solutions for Sanitaryware, Tableware and Technical Ceramics

Reolam Special surfactants for glazes

Casting rate improvers

Surfaces Group

66

CWR INDIA 2022 2018

Latest technologies

CWR INDIA 2022

67

Latest technologies BBM Industrial Maintenance

68

CWR INDIA 2022 2018

PATENT N.1388913

Latest technologies Officine Smac

advertisers list AKW Certech

5 2-4-69

Lamberti

65

Surfaces Group

Off. Smac

71

Syneco

III cop 28

Cimes

10

Poppi Clementino

53

System Ceramics

Efi Cretaprint

27

Premier

59

Tecna 2022

49

6

Tecnofiliere

11

Torrecid

57

Esmalglass-Itaca Group

1

Rak Ceramics

Fritta

63

Sacmi

Inco

61

Smalticeram

39

Solar Turbines

45

Inter Ser

70

CWR INDIA 2022 2018

12-13-29-35

IV cop - 72

II cop

ENDLESS INNOVATION SINCE 1919

more brands one group

ENDLESS INNOVATION SINCE 1919