Ceramic World Review India 2018 by Kairos Media Group (div. ceramics)

C eramic W orld R eview

ISSN 1121-0796

technology news markets

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Welcome to Indian Ceramics 2018!

IF YOU WANT TO GO FAST, GO ALONE. IF YOU WANT TO GO FAR, GO TOGETHER.

A Company of

THE WORLD LEADING TECHNOLOGY TO CREATE LARGE SIZE TILES NOW WITH THROUGH-PASSING VEIN

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VISIT US AT INDIAN CERAMICS 2018

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Energy Recovery Systems and Filtration

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We design plants based on the speciﬁc needs of our customers, our team is able to dimension a state-of-the-art recovery system for the optimization of energy consumption.

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Sleeve and Box Filters for Dust and Fumes Heat Exchangers Control and Supervision Instruments Water Puriﬁcation Systems Washing Towers and Scrubbers

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Year 28 Supplement to no. 125 January/February 2018 Bimonthly Review

contents

Cover picture by: Giancarlo Pradelli

Editorial

Welcome to Indian Ceramics 2018!

World News

22 Interview

Focus on

30 32 34 38

Paola Giacomini

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Paola Giacomini

The Indian market focuses on value

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large sizes & panels

LBXTRA and Freestile: technology for large sizes

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Emilio Benedetti Giuseppe Macchioni

Large-size ceramic panels and slabs: the evolution continues Andrea Bresciani

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Roberto Pelliconi

Aesthetics 4.0: a natural approach to industrial creativity

Davide Medici

Lamgea, technology for contemporary architecture

Andrea Gozzi

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Full Digital, barrier-free decoration

Rita Cagnoli

Twin-channel kiln for large size tiles

ICF & Welko

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Supera® and STS technology

The value of a complete technological finishing process

CMF XLT: Customised technologies for large size tiles

Digicol, the new generation of digital glues

Mirco Corbelli

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Giorgia Ferrari Vittorio Vandelli

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TECHNOLOGY

54 56 58 62

Marco Sichi

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Marco Ferrari

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Water-based glazes and engobes for full digital applications

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New air conditioning plants for the sanitaryware industry

Paolo Marcheluzzo

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Products

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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 Editor Paola Giacomini

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The Hindi version of the magazine has been published in collaboration with MR.DILIP KUMAR CHOUDHARY 1, TUGLAK LANE NEW DELHI -110011 (INDIA) Mob.: +91- 9718674379 Entire contents copyright Tile Edizioni. All rights reserved. Opinions expressed by writers are not necessarly those held by the publisher who is not held responsible. Editorial material, manuscripts, photographs, transparencies and artwork will not be returned.

Date of going to press: 20/02/2018 Promoted by

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OUR DIGITAL INNOVATION WILL TAKE YOU FURTHER

Our technology lies in real innovation, in the knowledge of fine arts and sciences and in a forward-looking approach. System Lamina is the first ever manufacturing process to have opened up new fields of applications in ceramic industry for a new concept of architecture. Lamgea, our moldless press, is at the core of this evolution. Multi-Format tiles, ceramic surfaces up to 1600x4800 mm, a wide range of thicknesses from 3 to 30 mm and a structured finish up to a depth of 2 mm. System Lamina offers you 4.0 industrial plants fully equipped, tailor-made services and cutting-edge technological solutions where you are the protagonist.

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

Welcome to Indian Ceramics 2018! India, the world’s second largest tile producer with volumes close to the 955 million square metre mark, has by now got us used to its impetuous growth rates. The immense volumes turned out by this key market have led industrial suppliers of technologies, raw materials and services worldwide to pay it special attention and develop a closer collaboration with its operators. So it’s no coincidence that, in a move to mark the 2018 edition of Indian Ceramics & Ceramics Asia in Gandhinagar – the biggest Indian exhibition for suppliers of ceramic tiles, sanitaryware and heavy clay industries – Ceramic World Review, the most important international magazine for the ceramic industry, is publishing again its special issue in the Hindi language. The idea is to be able to offer an even more effective communication channel to the Indian clients, in addition to the English version published internationally. Indian Ceramics 2018 is organised by MMI India (a branch of Messe München International) and Unifair, relies on support from the Indian Government and collaborates with the most important ceramics associations. It aims to exceed the figures registered for the 2017 edition, expecting more than 300 exhibitors and 7,500 visitors. Indian Ceramics 2018 will see the participation of the major international companies in the sector, who recognise the exhibition as an excellent opportunity to showcase the latest technological innovations. Italian producers abound, with esteemed companies like BMR, CMF Technology, ICF Welko, LB, Marcheluzzo Ceramics, Projecta Engineering-SITI B&T Group, System, Sacmi, Setec, Smac, Surfaces Technological Abrasives, Stylgraph, Tecnografica, Tecnoferrari, TekMak and Appel representing the ceramic machine industry sector; Tecnofiliere and Icra from the heavy clay and refractory plant production sector; Colorobbia, Smalticeram, Smaltochimica and Lamberti for glazes and additives. Most of the Italian companies will exhibit inside the traditional Italian national pavilion organised by ACIMAC (Association of Italian Manufacturers of Machinery and Equipment for Ceramics) and Italian Trade Agency. Other prestigious brands in the machinery sector include Alteo, Efi Cretaprint, Eirich, as well as the heavy clay machinery suppliers Verdes and Sabo, and the raw materials suppliers Esmalglass-Itaca, Ferro, Fritta, Imerys, Megacolor, Torrecid, Vidres, Sibelco and Esan. WE HOPE YOU ENJOY INDIAN CERAMICS!

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Upcoming 12 colour bars model

The Indian market focuses on value Paola Giacomini - p.giacomini@tiledizioni.it

Although growth rates remained below the previous year’s double-digit figures, Kajaria Ceramics closed the fiscal year to 31 March 2017 with a 6% upturn in total income to approximately 381 million euros (Rs. 28.5 billion) and a 9% rise in consolidated net profits to 33.4 million euros (Rs. 2.53 billion). “Given the backdrop of a significantly higher historic growth momentum, this uptick may seem marginal. But, when appraised, keeping in mind prevailing economic and sectoral headwinds during the period under review, this growth appears satisfying,” commented the company’s Chairman and Managing Director Ashok Kajaria. Kajaria Ceramics is the largest Indian tile manufacturer and one of the top ten producers worldwide. The ambitious expansion programme implemented over the last three years has raised total production capacity to 69 million sq.m/year (March 2017), while the expansion project at the facility in Gailpur, Rajasthan is expected to be completed by the end of September. The group aims to reach a capacity of 100 million square metres by 2020, a goal that may in part be achieved through acquisitions. For the current year Ashok Kajaria has announced a return to more sustained growth, driven by good prospects for market expansion and a further strengthening of the brand across the country. CWR: What strategies are you following to increase Kajaria’s share of the domestic market?

CWR INDIA 2018

interview

Talking to... Ashok Kajaria here with his sons Rishi and Chetan

ASHOK KAJARIA: From a market share viewpoint, Kajaria is doing three things: First, we are launching new products at frenetic speed that are aligned to customer aspirations. Secondly, we are spreading wider and deeper into the Indian landmass to strengthen our entrenched presence. And thirdly we are making significant investments in branding and advertisements (print and electronic) to cement brand recall in the minds of every aspiring Indian. These initiatives, we believe, will enable us to make inroads into the market share of regional and local players. CWR: What are the current market trends in terms of products and what new products have you launched yourselves? A. KAJARIA: Innovation has been the hallmark of Kajaria and the key reason for its success. Each year we develop new sizes and new designs for Indian customers â&#x20AC;&#x201C; some of which meet specific customer needs while others are in keeping with our commitment to bring global trends into India. In 2016-2017 alone we launched more than 500 new designs across existing product verticals. In addition, we launched new large-format tiles across product verticals (120x180 cm, 120x120 cm, 120x80 cm, 80x80 cm) to address discerning customer aspirations. We launched certain products for the first time in the Indian markets, such as 80x120 cm ceramic floor tile, 60x120 cm double charge polished vitrified tile and 120x180 cm glazed vitrified tile. What is satisfying is that these launches will expand the market size not just our market share. Going forward, we

CWR INDIA 2018

interview

will continue working on developing new products that enhance customer delight and expand the opportunity matrix for sectoral peers. CWR: As for the growth prospects for domestic ceramic tile demand, is a recovery in the construction industry expected? A. KAJARIA: Regulatory roadblocks, sectoral issues and high interest rates adversely impacted the growth of the real estate sector for an elongated time period. But the priority accorded to the infrastructure sector in the Governmentâ&#x20AC;&#x2122;s recent Union Budget, declining interest rates and ambitious development programmes promises to unshackle the construction industry in general and the real estate sector in particular from the prevailing gloom. Moreover, the RERA (Real Estate Regulatory Authority) legislation which was implemented in May 2017 mandates stronger governance of real estate development and timely delivery of projects â&#x20AC;&#x201C; both factors which had plagued the Indian real estate sector for decades. This positive move is expected to drive real housing demand, leading to stronger tile offtake. CWR: How is the Indian market evolving in general? A. KAJARIA: In India, tiles have transformed from a functional necessity into an aesthetic imperative. So when India prepares to create the largest space increment in its existence (usable and liveable), this means that more tiles will be consumed than ever. And with growing affordability, consequent to economic resurgence, the average Indian aspires for large tiles, aesthetically-appealing tiles, fashionable tiles and specially treated tiles. Hence, the demand for tiles going forward will be volume-driven as much as it will be value-led. Todayâ&#x20AC;&#x2122;s Indian consumer is different from what he was a couple of decades ago. He is more aware. He is more aspiring, for he has knowledge at his fingertips. He understands product attributes, aesthetics and trends. His propensity to earn has grown multi-fold which has given wings to his aspirations. As a result, he is willing to pay that little more for superior value proposition. With price of tiles being relegated to just one of the factors influencing the tile purchase decision (from being a primary criterion in tile selection some years ago), the preference for organised players has increased significantly. As a result, growth in business volumes of organised players continues to outperform the industry average.

CWR INDIA 2018

When theory turns into practice. Marcheluzzo Ceramics is a byword for top quality and multi-year experience in the field of turnkey plants for ceramic materials. A technical staff with long standing experience makes Marcheluzzo Ceramics Division a reliable partner in the international market for the Ceramic Industry. Thanks to the acquired know-how, Marcheluzzo Ceramics Division is today capable to offer solutions in various industrial fields.

interview CWR: Has the distribution system managed to keep up with this evolution? A. KAJARIA: The business of selling tiles in India has undergone a sea change. Today dingy shops have transformed into swanky showrooms closely resembling jewellery stores. Tiles are displayed with special emphasis on the probable customer segment in the catchment area. Dealers change display periodically to enhance footfalls. Moreover, technology solutions are leveraged to give customers an idea of their bathroom or living room with their preferred tiles. Today, tile sales is not just about mentioning prices and sizes but is a knowledge-sharing engagement between the salesperson/dealer and the customer in which the former wields significant power to influence the latterâ&#x20AC;&#x2122;s decision. So the bottom line is that the dealer has assumed centre stage in the art and science of selling tiles in India. His importance is two-fold: generating volumes and providing feedback on customer needs and desires. CWR: In such a dynamic market, what role do you see for tile imports? A. KAJARIA: India, I believe, is in line with global standards with regards to manufacturing technology, so we can replicate and even better tiles manufactured by our global peers. As a result, import of tiles has reduced significantly over the last few years. While this is a reality, some tile volumes will continue to be imported primarily due to cost factors. And then there are certain tiles which are developed for niche applications and will continue to be imported. CWR: What consequences do you expect from the introduction of the new Goods and Services Tax (GST)? A. KAJARIA: The Goods and Services Tax (GST) introduced on 1 July 2017 will bring a number of advantages. First, it will make India a truly unified common market by creating a single indirect tax that will take the place of all taxes previously in force across the 29 states and 7 union territories of India. GST also promises to create a level playing field between the informal sector and the organized/branded players because it promises to minimise the tax and duty differential paid by the informal sector and the organized/branded players. The reduction in taxes and duties for organized/branded players holds the potential to make branded tiles affordable. Moreover, with consumer affordability and consequently aspiration multiplying, I expect the tile demand to shift towards branded products. From the perspective of the market, GST will strengthen the sectorâ&#x20AC;&#x2122;s supply chain and will benefit end consumers, who will bear only the GST charged by the last dealer in the supply chain with set-off benefits at all the previous stages. CWR: A few years ago you decided to enter the sanitaryware and faucet sector. What are your main results to date? A. KAJARIA: Our entry into the sanitaryware and faucet space is largely in keeping with our efforts to delight Kajaria brand loyalists. For we have noticed a trend among most customers who walk into our stores. Having selected tiles, their next question they ask is to see sanitaryware and faucets. In a short span of years, we have created a basket of more than 200 SKUs in these product segments. In 2016-17, revenue from this vertical grew by more than 50% over the previous year (albeit on a smaller base), which demonstrates increasing acceptance of our product range. Going forward, we plan to strengthen our faucets offering by introducing premium ranges and launching sensor faucets for various applications. In the sanitaryware segment, we are increasing our manufacturing capacity by about 120,000 pcs per annum through a brownfield expansion to cater to growing demand and emerging opportunities. 5

CWR INDIA 2018

LBXTRA and Freestile: technology for large sizes

For almost half a century LB has been collaborating with the world’s leading ceramic tile manufacturers and investing in research and development of technical, technological, mechanical and plant solutions tailored specifically to the industry’s needs. These include products that are unique, exclusive and difficult to replicate, often in ever larger sizes and large thicknesses; higher productivity and flexibility; lower operating and maintenance costs, smaller production layouts and a lower environmental impact; technologies and services that are compatible with the principles of the Smart Factory (Industry 4.0). These efforts have led LB to install the latest technological solutions in the new LB Technology Centre, which has been completely upgraded with two production lines. The Centre can perform the following kinds of testing: • Migratech 4.0: the revolutionary microgranulation technology capable of producing granules suitable for the shaping of ceramic tiles or panels of any kind, bringing enormous savings in terms of operating and maintenance costs and a significant reduction in environmental footprint. • Divario: the latest press feeding solution for all kinds of porcelain products, both full-body and decorated in line. • Freestile and LBXTRA: the only technology in existence for colouring and decorating powders using an aesthetic effect kit, which is also suitable for large size tiles; the wide range of aesthetic solutions include the “through vein” effect for extra-thick full-body products. • AST4 PLUS and STAR: cockpit software for preventive and

CWR INDIA 2018

Focus on large sizes & panels

proactive maintenance of machines and plants which exploits all the potential of virtual and augmented reality. In the last 2-3 years around 40 new lines have been installed worldwide for the production of ceramic panels and slabs in sizes of up to 160x320 cm and thicknesses of up to 3 cm. The fact that it has supplied more than 80% of plants feeding these lines all over the world (Argentina, Brazil, Egypt, India, Italy, Poland, Russia, Spain, Turkey, Ukraine and the USA) underscores LB’s role as the manufacturers’ key partner. In particular, its Colorboost, Freestile and LBXTRA technologies guarantee finished products with unique and highly innovative aesthetics. ❱❱ Migratech 4.0 Production of large ceramic panels and slabs requires special treatment of the granule prior to forming in terms of flowability and particle size. The innovative Migratech 4.0 technology is the ideal solution for guaranteeing perfect compaction or pressing of the granule and ensures very high savings in production line management and operation, as well as cutting atmospheric CO2 emissions by around 60%. The process, plant and method are all patented and are currently undergoing final technological and plant engineering testing in the LB laboratories and on the industrial production lines of world-leading ceramic tile manufacturers. The innovative nature of Migratech 4.0 technology is demonstrated by the funding received by LB Group from the Emilia- Romagna regional government and the Italian Ministry for Economic Development. ❱❱ Freestile and LBXTRA The Freestile and LBXTRA technologies have been developed to meet the needs of the most innovative ceramic tile producers. They can be used for the production of tiles of various thicknesses and any size, including large panels and slabs, and are capable of creating unique, exclusive and non-replicable products. Advantages include greater production flexibility, optimisation of the plant layout and lower environmental impact. The use of these technologies allows for real-time colour digitisation to supply the various kits required for creating aesthetic effects on large-size panels. Adopting these solutions concurrently allows for the production of full-body double loading and single loading products with a “through-vein” effect or double and single loading products to be used as a base for subsequent supplementary inline applications/finishes. 5 CWR INDIA 2018

Large-size ceramic panels and slabs: the evolution continues

The production of large porcelain panels and slabs is now reality, testifying to the power of Italian innovation and the enormous development potential of traditional ceramic tiles. The growing success of this new product type in its various versions owes much to recent advances in plant engineering and the development of innovative, high-performance solutions. The Continua+ line from Sacmi aims to offer manufacturers a hi-tech, full digital technology that is at the same time versatile and simple to use, capable of producing glazed and full-bodied porcelain in all sizes and thicknesses required by the market. The system has the flexibility needed to easily vary the powder loading width up to a final fired and rectified size of 1600 mm and thicknesses from 3 mm to 20 mm, allowing for the production of panels and slabs in all commercial sizes (1600x3200 mm, 1500x3000 mm, 1200x2400 mm, etc.) and the corresponding modular submultiples (80 cm, 75 cm, 60 cm, 50 cm, etc.) while avoiding the production of waste and maximising productivity. The availability of various devices for loading the powders on the steel conveyor belt makes it possible to apply any type of semi-finished products (spraydried, dry coloured or micronized powders, granules, flakes, dry glazes, etc.) by means of automated digital dosing systems. The upper continuous forming belt can be chosen in a smooth steel version, producing a ceramic surface that is ideal for subsequent digital decorations, or it can be clad with a regenerable structure with a graphic design extending over a length of 7.5 metres. Continua+ is effectively a Full Digital line: it combines dry digital decorations, a digital graphic texture, inkjet glazing and decoration and digital decoration with granules, providing manufacturers with cutting-edge tools for the production of ceramic materials with extremely high technical and aesthetic added value. However, to produce large panels and slabs the entire plant must be special-

CWR INDIA 2018

Focus on large sizes & panels

ly designed, sized and implemented in all stages of the process, from the transport and handling systems to the thermal machines (dryer and kiln) and the auxiliary end-of-line operations. The ideal solution for drying is without question the multi-tier horizontal dryer, typically with 5 or 7 tiers, which is able to reduce space while maintaining perfect control over the thermal cycle, including temperature uniformity across the entire width of the dryer, final stabilisation and rapid extraction of the panels to be sent on to glazing/decoration. The kiln for panels and slabs must be designed in such a way as to avoid the stresses that typically arise in large-size tiles, especially in the cooling phase, which means it must have a suitable length. It is also necessary to minimise potential deformation of the panels or slabs in the firing zone caused either by incorrect roller pitch or by bending of the rollers under high loads, especially in the event of medium or large thicknesses, in which case kilns with a narrow entrance width (2170 mm) are preferable. A complete plant for large-size panels and slabs must also include finishing lines that are suitably redesigned to cope with the large dimensions. These include: • squaring and rectification lines • honing/polishing lines • fibreglass backing application lines for low-thickness panels • submultiple cutting lines • sorting and palletisation lines • picking and packaging lines. These finishing operations must be combined in order to handle the many semi-finished products that need to undergo further processing to create the packaged finished product. This, together with the ever smaller batch sizes and the greater product diversity resulting from the ease of varying the sizes and decorations of the panels, makes it necessary to adopt new production models designed for more efficient warehouse management of both semi-finished and finished products. The reorganisation of production and scheduling of operations in the various production islands requires the adoption of new control and logistics functions integrated with the company ERP, as in the case of the HERE supervision system proposed by Sacmi. Thanks to Continua+ technology, which already boasts more than 40 installations in the factories of top industrial groups, mainly in Italy, the production of porcelain panels and slabs can now be considered an outstanding example of the application of Industry 4.0 criteria. 5

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Focus on large sizes & panels

Aesthetics 4.0: a natural approach to industrial creativity

Over the last ten years, glazing and decoration have seen far greater development in terms of application techniques than any other stage of the production process. Integration with new shaping methods has taken the concept of “glazing line” to a higher level. The creation of product aesthetics is no longer limited to glazing but also includes the powder loading and shaping stages, as well as the operations of cutting, squaring and surface finishing. This makes it essential to operate in a digitally controlled environment capable of interacting with and supervising the various stages, leaving designers the creative freedom to combine materials, textures and colours with perfect synchronicity. Pre-compaction dry glazing and dry digital decoration: On the new Continua+ lines, the process of aesthetic enrichment begins even before the shaping stage with the application of a fine layer of dry glaze which contributes to digital decoration subsequent to compaction. Moreover, with the DDD (dry digital decoration) systems, it is possible to decorate the still unpressed bed of powder, which will subsequently be compacted to create a smooth or textured surface coordinated with the overall graphic design. DHD - Wet digital glazing and decoration: The perfect compactness of the surfaces of Continua+ panels makes it possible to apply smaller quantities of digital glaze while creating perfect ceramic surfaces. The precise order in which the drops released by the digital printheads are deposited ensures the best possible coverage of the surface with any gloss or matt finish. More efficient material application together with the technical characteristics of Continua+ surfaces makes it possible to operate almost exclusively using digital techniques. DHD, the range of digital printers produced by Sacmi-Intesa, is designed to make the most of these innovative opportunities. The total efficiency of the ink feeding systems, the sophisticated electronic printhead management and the stability of the entire system demonstrate that this cutting-edge technology is particularly suited for use on large and very large sizes. Intesa has also developed a sophisticated proprietary screening algorithm called FLS, which enormously increases image quality and the compactness and uniformity of full-field surfaces, a characteristic that is essential for digital glazing and for meeting the market’s current graphic design requirements. DHD is naturally able to use the printing device most suited to the user’s needs. High-definition images, ceramic effects, glazes and final coverings can all be applied using the most suitable printheads, whether designed for fine resolu-

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Focus on

large sizes & panels tions or for high or very high discharges. DDG - inline dry digital decoration: The range of materials available for decorating ceramic products is constantly being expanded. Dry phase material adds volume and helps create a sophisticated natural look to offset an otherwise excessive focus on graphic design. Like DDD, DDG also aims to extend digital decoration to the application of powders and grits in combination with the three-dimensional texture of the tile and the graphic design. DDG is used on the glazing line, where it coordinates with the wet glue application bars to create very high definition images. DGD - pre-press dry digital decoration: Sacmi has developed the DGD system to extend the dry glazing or decoration concept to the world of traditional pressing and provide the same opportunities to lines or plants that use standard technology. DGD is suitable both for applying a layer of dry glaze and for depositing powders according to a specific design in order to enhance the productâ&#x20AC;&#x2122;s aesthetics. These powders can be combined with all post-pressing digital applications. CAM 1200-1800 airless glazing with synchronised mobile arms: To meet any kind of production requirement, Sacmi-Intesa has developed an efficient wet glaze application system based on a mobile nozzle booth specially designed for handling large and very large sizes. Perfect synchronisation of the axes allows for optimal glaze application in the absence of tracking. DSP 1608 - post-firing decoration: The DSP 1608 multi-pass digital printer is the result of years of research in which technical developments has been adapted to technological advances in the field of fluids and applications. The new digital materials for third firing (inks or precious metals) require a different application technique to the one used in traditional ceramics. The development of a dedicated hydraulic supply system and a technique for fixing drops onto non-absorbent surfaces means that the components can be refined and completely integrated. Multi-pass printing requires the development of sophisticated screening algorithms that can be tailored according to the desired end product. The solutions developed by Sacmi-Intesaâ&#x20AC;&#x2122;s imaging engineers resolve various technological issues and bring significant competitive advantages. As a result, decoration with DSP ensures unparalleled printing quality on any type of substrate and with any kind of ink, glaze or effect. 5

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Lamgea, technology for contemporary architecture

System Lamina technology has utterly transformed the use of ceramics in architecture, opening up new markets in sectors that would previously have been unimaginable: from the world of furniture, which now has a real alternative to traditional materials such as natural stone, to public and commercial building, where these highly original and customised interior and exterior surface coverings are now much in demand. This revolutionary technology stems from an original idea by Franco Stefani, Chairman of System Group, an intuition that marked the beginning of a new chapter in the history of the world ceramic industry. Starting out from the concept of single tiles, System went on to develop 1600x4800 mm surfaces in thicknesses ranging from 3 to 30 mm using Lamgea, the worldâ&#x20AC;&#x2122;s most powerful mouldless press. Lamgea uses a specially designed hydraulic circuit with a dedicated work cycle and maximum pressing force of 44,000

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Focus on large sizes & panels

tonnes to produce large-size panels (up to 1600x4800 mm) in a wide range of thicknesses (from 3 to 30 mm) while completely eliminating internal stresses. The raw materials are processed using an innovative system of customised belts to create either smooth surfaces or – using a laser engraving system applied to the belts – textured finishes with relief depths of up to 2 mm. First unveiled in 2000, System Lamina technology has evolved over the years and now offers the international market cutting-edge solutions with higher production capacity and greater flexibility in terms of sizes and thicknesses. The unique strengths of Lamgea technology make it the market leader in the production of large low-thickness ceramic surfaces. These include: • total absence of residual stresses after pressing; • easy-to-learn press functions; • a process that is stable and simple to manage; • the possibility of using standard bodies without the need for special mixes; • a green-oriented pressing system with low energy consumption; • complete recovery of waste; • unlimited aesthetic potential for the production of textured surfaces. The Lamgea mouldless press is renowned for its versatility in terms of the range of thicknesses it can produce. It is especially popular for the production of thin (6 mm) and ultra-thin (3 mm) panels, which offer a range of advantages including higher production capacity, reduced consumption of raw materials and energy, and lower weight per square metre. System Lamina technology has taken porcelain into previously unimaginable areas of application thanks to a pressing system (Lamgea) and a digital printing technology (Creadigit) that see architecture and interior design as an expression of human talent. The process is able to create unique surfaces that reproduce the patina of oxidised metal, the tactile appeal of wood grain, and the rarest and most prestigious kinds of marble or natural stone, to mention just a few. But compared to the original materials, they are much more durable and maintain their outstanding technical and aesthetic characteristics over time. 5 CWR INDIA 2018

Full Digital, barrier-free decoration

In recent years digital decoration has established an important position in the ceramic industry, a sector that delivers innovative, cutting-edge products suitable for all architectural applications. The glazing lines present in production facilities are now almost all equipped with digital printers for depositing the colours that will serve to decorate the tile, as if the ceramic body were a blank sheet ready to be transformed into a decorated surface without placing any limit on creativity. Creadigit digital printing from System is an invaluable and highly innovative decoration tool capable of adding unprecedented aesthetic, emotional and functional value to the ceramic surface. It was developed through intense research efforts that have made drop-on-demand digital inkjet printing unique anywhere in the world. If we look at the process of digitisation in the ceramic sector, we see that it is opening up potential for new functions, including the possibility of performing glazing and final protective treatment with a single-pass inkjet system. Back in 2014 System was the first company to launch this concept with Diversa, a 25 metre long integrated ceramic line in which all the steps in tile decoration were designed to be performed digitally. Diversa became the design vision for the ceramics of the future. Over the following years, full digital has become reality and the product segment in which it has seen the greatest expansion is that of large-size ceramic tiles. The reason lies in the advantages offered by the digital process, first and fore-

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Focus on large sizes & panels

most the fact that in the production of large-size tiles only first-choice products are accepted. The full digital process allows for perfect application of material, ensuring precise, waste-free consumption and allowing for the production of small batches with great graphic variety. System has achieved total digitisation of the ceramic production line thanks to the high performance of Creadigit as well as the development of a series of technological innovations. These include: 1. interchangeability of printheads in the Creadigit bars; these printheads can be either of the small drop type for high definition designs or high discharge models for glazing and depositing large quantities of materials; 2. the development of Creavision, the vision system used for aligning the graphic design of the incoming tile; 3. introduction of a sequencer for synchronising two or more machines on the line. Thanks to its highly specialised technical departments, System is continuing to create real innovation and open up new applications, confirming its mission as a â&#x20AC;&#x153;process innovatorâ&#x20AC;? with globally unique solutions. The full digital process initially used solvent-based inks and materials, although these proved not to be so efficient because the fully-digital line requires shorter drying times and a greater focus on the environment. In these processes the quantity of material deposited on the tile using inkjet technology is much greater than that of a hybrid line, where digital decoration only involves the application of colours. Due to their chemical nature, the combustion of solvent-based products in the kiln is not entirely efficient, resulting in the release of small odorous molecules into the atmosphere. In keeping with its focus on environmental sustainability of its products and processes as a key factor driving innovation, System has begun to analyse multiple factors, including continuous improvement and monitoring of the production plant and the development of new inks and materials. The glaze and colour producers are in turn proposing new solutions that System is adopting on the Creadigit system, namely the use of high-density, high particle-size solvent-based inks and inks with a high percentage of water. All solutions are designed to improve the process and eliminate the odorous component. For several years System has been in the front line in developing and promoting water-based inks and materials, the area where it sees the greatest development potential for the future. 5 CWR INDIA 2018

Twin-channel kiln for large size tiles: high output and flexibility in small spaces

The growing production of large size tiles in the ceramic sector has given rise to a new problem: the elimination of residual post-firing stresses to allow for subsequent operations of cutting, drilling, etc. For this purpose, large size tiles need to be fired for much longer times than medium-sized tiles, regardless of the stresses generated in the previous steps. Given that the use of large kilns affects the quality of finished products and limits the range of thicknesses and surface finishes, the solution is to use very long kilns, although this is sometimes not compatible with the spaces available. To solve this problem, Welko has developed a twin-channel kiln with two independent channels positioned one above the other. This solution offers numerous advantages: • The kiln length is halved, • Occupied space is halved, • The two channels can be operated as two independent kilns, • Two different kinds of products can be produced at the same time, • Two different cycles can be used in the two channels, • The same product can be produced at the same time in the two channels, • Consumptions are reduced thanks to the lower heat losses. Let’s look at the kiln’s main technical characteristics. The two channels are separate and independent. The two channels’ service fans and combustion plants are completely independent, while the thermal insulation allows very different operating temperatures to be maintained in the two channels without affecting each other.

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Focus on large sizes & panels

Separate and independent pressure management. The pressure in each channel is regulated and controlled independently in both the firing and the cooling zone, thereby guaranteeing product consistency even after gaps in production. Maximum flexibility. The kiln is designed to function with a single channel without losing control of the process. In this case specific heat consumption is 7-10% higher. Energy recovery. The kiln uses hot air recovered from cooling as combustion air for the burners (expected savings of 7% compared to a kiln with cold air). Hot air recovery for use in the dryer. The hot air recovery system is also able to recycle hot cooling air for use in dryers, if present on the line. The reduction in heat consumption in the drying stage can be as high as 40-50%. High-efficiency burners. The same burners are used as those developed for the single-channel kiln. These intensive combustion burners generate the flame entirely inside the combustion cone, thereby optimising the efficiency and exit speed of the fumes and generating convective currents inside the channel to facilitate temperature uniformity and energy transfer to the material undergoing firing. Inverters. The fans are equipped with inverters, allowing the kiln’s sensitive variables to be controlled without using valves but simply so as to optimise electrical energy consumption. Consumption. Depending on the type, thickness and dimensions of the tiles and the firing cycle, heat consumption varies from 500 to 600 kcal/kg, while electrical energy consumption amounts on average to 0.04 kWh/kg. ❱❱ Production process advantages The first Welko twin-channel kiln has been in operation since September 2016 in the Laminam facility in Borgotaro for the production of large size tiles with thicknesses ranging from 6 to 20 mm; a second kiln was started up in Spain in January 2018 for the production of tiles with thicknesses of 3 and 6 mm. Experience in the field has demonstrated: • the possibility of producing the same product with the same colour in the two channels; • complete product changeover management with automatic changing of the temperature and pressure curve, • complete management of production gaps. In all conditions, consistent flatness and colour and zero kiln breakages are achieved at the kiln exit. 5 CWR INDIA 2018

Supera® and STS technology: creativity and technology in the decoration of large size panels and slabs

The rules of the game are changing and imagination is opening up new horizons for the ceramic tile industry. Supera® technology is Siti-B&T Group’s innovative solution aimed at the latest market frontier, the production of large size ceramic panels and slabs. Supera® is based on the STS® Structure & Thickness for Slabs concept, which combines design and technology to create unique products in a wide range of thicknesses and textures. The synergy between Group companies plays a vital role in improving product aesthetics. Digital Design develops visual design projects, which are then transformed into reality by cutting-edge digital decoration systems for panels and slabs from Projecta Engineering. And to complete the process, the market-leading finishing company Ancora supplies equipment for enhancing the surface of the panels. Supera® marks the culmination of years of research efforts focused on finished products rather than technology. A successful solution must achieve excellent aesthetic results while cutting production costs and ensuring high levels of efficiency and quality. Supera® does this by combining high production volumes with maximum flexibility in the production of porcelain panels and slabs with dimensions up to 1600x4800 mm and thicknesses ranging from 5 to 30 mm, while surface textures with depths of up to 6 mm can be created on large-thickness slabs. Supera® is designed and built in accordance with the innovative ISO Concept based on a number of key success factors, including zero product defects and uniform thickness and flatness due to evenly distributed shaping pressure over the en-

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Focus on large sizes & panels

tire surface of the slab. The innovative power-on-demand Start & Stop hydraulic power unit allows energy consumption to be reduced by up to 30%. Supera® is not just a multi-patented cutting-edge technology but a complete line that covers all steps in the process, from preparation through to the end-of-line stage. Fully integrated with the Group’s solutions for creating new and more refined aesthetics in the ceramic sector, it guarantees a high level of flexibility along with greater productivity, efficiency and quality and lower consumptions. Siti B&T Group’s technologies have long incorporated all the success factors of Industry 4.0, including remote support, data and production parameter management with remote control via an app and scheduled and preventive maintenance. Industry 4.0 criteria are now standard features of all solutions proposed by the Group. The R&D approach that involves identifying the best technical solutions for a specific end result provides an effective response to the demands of modern architecture and clients and to the needs of increasingly demanding ceramic manufacturers. A concrete demonstration of the enormous potential offered by the Siti B&T Group’s technologies can be seen at the Projecta Engineering headquarters, which hosts a permanent exhibition of ceramic panels and slabs with textured surfaces based on graphics by Digital Design. 5

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The value of a complete technological finishing process

In recent years the ceramic tile market has received a big boost from the production of large-size tiles and panels, which are now available in a range of thicknesses and sizes up to 1600x3200 mm and beyond. BMR has responded to the newly emerging needs of the sector with a wide and consolidated range of highly competitive machines and products. The growing number of Italian and international installations (more than 50 BMR lines for large size tiles are in operation worldwide) reflects the company’s position as a leading player amongst suppliers of technology for honing, treating, cutting and squaring/chamfering of ceramic surfaces. To achieve this important result, the company has focused on developing not just innovative and efficient machines but a complete end-of-line finishing process that takes all factors into account, creating solutions tailored to the customer’s specific manufacturing needs. The BMR technological process can be divided into 4 main stages: • pre-grinding • honing/polishing/treatment • cutting of submultiples • squaring/chamfering. The first step consists of pre-grinding using one or two squaring modules to prepare the surface prior to the honing stage. The next step is honing itself, a surface abrasion process that serves to create finishes with various gloss levels on glazed or porcelain surfaces. This process plays a crucial role in the development of the finished product and its aesthetic quality, and also contributes to the definition of the digital decoration process. The finished result of honing is determined by several different factors (swing speed, belt speed, tool grit size and head pressure), which are controlled by the operator according to the glazes and applied digital materials, especial-

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Focus on large sizes & panels

ly in the case of large size tiles where tool efficiency must be optimised. Resin and diamond abrasive tool technology has evolved in step with the development of honed ceramic products, increasing the flexibility of the process and allowing it to adapt more effectively to production requirements and the desired gloss level. After honing it is essential to perform treatment, the first stage of which involves using a roller to apply a protective acid pickling solution to prevent the formation of matt stains in the event of prolonged contact with acid pH substances. In collaboration with specialist companies, BMR has exploited its unique expertise in the field of tools, glazes and raw materials to develop three treatment lines that use acid pickling and pore-filling products to guarantee optimal cleaning and gloss. These differ according to the texture of the ceramic surface, which can be divided up between polished full-body and honed/glazed porcelain: TopCoat, which maintains the productâ&#x20AC;&#x2122;s original gloss level; TopFinishing, which increases the gloss level; SuperShine, a thermomechanical treatment carried out on the dry, clean tile which significantly increases the productâ&#x20AC;&#x2122;s glossiness. The BMR process ends with score-and-snap and squaring operations, which can be carried out using either wet or dry technology, the latter having the qualities of energy saving and low environmental impact. The Trasla Dry and Dry Cut dry cutting technologies are differentiated according to whether cutting is transversal (Trasla Dry) or longitudinal (Dry Cut). Both operations are followed by tile snapping. Squadra Dry and Top Squadra Dry are the two dry solutions for squaring, which are suitably sized for large size tiles. In addition to the benefits of dry technology (plant simplification, longer lifetime of parts and consequently of the line, improved working environment), BMR has recently added another advantage that is particularly significant for ceramic companies. It has been shown that it is possible to recycle the large volumes of dry grinding residues and reuse them as a raw material in the body formulation stage. Research conducted in collaboration with the Chemistry and Geology Department of the University of Modena and Reggio Emilia has determined the chemistry, particle size distribution and technological properties of the powders produced using dry squaring techniques, highlighting the vital role of the type of tools installed on the machine. 5 CWR INDIA 2018

CMF XLT: Customised technologies for large size tiles

CMF Technology has been designing and building plant and automation for the ceramic industry for over 40 years. In the field of automation, it supplies ceramic tile conveying and handling lines, storage systems with laser guided vehicles and satin finishing machines that serve to functionalise the surfaces of sintered products. The range of equipment available for porcelain tile production includes raw materials storage, batching and mixing plants, behind-the-press technological towers for management and mixing of coloured bodies, dry colouring units, and single and double loading and “through-vein” press feeding systems. The growing demand for customised solutions for large-size tile and panel production together with CMF’s efforts to meet the needs of the market has led to the launch of CMF.XLT, the brand name used for the company’s many plant and process solutions specially designed and engineered for production, handling and finishing of large-size ceramic tiles and panels. CMF Technology has already completed a large number of orders for XLT brand equipment. Alongside the well-established TBOX and TFLAT lines of storage units for fired and unfired products and the Pegaso laser-guided vehicles, other automation segment solutions that have attracted considerable interest include the Rotox transfer table and the Magic Table panel rotation device. Rotox is used for the

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Focus on large sizes & panels

transfer and 90° rotation of ceramic panels and their submultiples, while Magic Table fulfils the need for safe rotation of ceramic panels and their submultiples and guarantees complete integrity of products at the end of the production cycle. For the production of unglazed porcelain panels, CMF Technology equips its Tech Tower range with two different types of press feeding system: the Spiller Evolution 3D decoration unit, a device that is suitable for the production of panels using the single- and double-loading process; and Spiller 2.0, a patented technology specially designed to create “through-vein” full body effects during the panel shaping stage using latest-generation pressing technologies. The Spiller 2.0 module was developed through the hard work of staff at the R&D laboratory, an integral part of CMF’s organisation. It has pilot plants for studying new processes and system solutions and offers training courses and customised research services. The XLT technologies for the ceramic tile finishing segment also include the Silktile dry satin finishing machines for the satin finishing of large size tiles and panels in sizes up to 1600x3200 mm. Silktile is produced in a wide range of models to meet many different requirements (matt or gloss finish for glazed porcelain tiles, satin finish for unglazed porcelain, etc.) and is attracting growing market interest. 5

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Digicol, the new generation of digital glues

Smaltochimica began developing products for digital decoration in 2014 when it launched its NIK series of solvent-based digital inks with a wide range of colours. In 2016, it added the SDM range of digital materials and special effects. With the growing use of digital technology, efforts to advance ceramic production and decoration increasingly focused on complete digitisation of the ceramic process and on the diversification of materials and sizes. One aspect that prompted keen interest was the surface application of grits and powders to produce innovative material and visual effects, from full-field honed surfaces to the finest graphic details. In 2017 Smaltochimica decided to concentrate on the development of digital glues, materials that combine extensive aesthetic potential with all the opportunities of digital technology. Digital glues offer numerous advantages compared to traditional grit pastes: • greater uniformity of the decorated surface, • possibility of applying high-definition shaded graphic designs, • superior aesthetic results from the grits in terms of applied weight (lower consumption) and the effect obtained after firing, • smaller quantity of water supplied during decoration, making them ideal for decorating large size tiles. These are the principles behind the Digicol series of adhesive products for grits and powders certified by all the leading manufacturers of digital printing machines and printheads. These glues are divided into 4 subcategories: organic, inorganic, eco-inorganic and water-based inorganic. All products in the Digicol series have excellent gluing capacity and perfect definition following application. In view of the many variables involved (printheads, rheological requirements, ceramic surfaces and graphic designs), a wide range of glues have been developed for each subcategory. With an average application of between 60 and 80 g/m2 of Digicol it is possible to glue grit weights ranging from 350 to 700 g/ m2 depending on production requirements. The first Digicol glues to be launched onto the market were the so-called Organic Digicol glues. The strengths of these products are their filtration simplicity and the absence of jetting issues on digital printheads; their main weaknesses are short bonding times (meaning that intermediate storage times must be kept short) and the difficulty in creating shaded graphic designs.

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Focus on large sizes & panels

Inorganic Digicol glues stand out for the presence of a suspended solid and were developed to ensure optimal printing definition in even the smallest details and long-term bonding capacity. The defect of this class of Digicol glues is their odour and the type of molecules that are released in flue emissions, especially when the glue is applied over the entire surface of the tile. Based on studies conducted at the University of Modena and Reggio Emilia, Smaltochimica has further improved these products by introducing its Eco-Inorganic Digicol glues, a series of products designed to reduce flue emissions in terms of both the type and quantity of organic compounds emitted. A partnership with a leading ceramic manufacturer for in-situ analysis of the flue emissions of the various Digicol products has allowed Smaltochimica to verify the effectiveness of the research undertaken and to evaluate future steps. In addition to these analytical checks, Smaltochimica has already begun research on a line of water-based Inorganic Digicol glues. An initial product has been formulated and is undergoing the certification process by the leading plant and machinery manufacturers. These materials maintain the technical and application characteristics of solvent-based inorganic products but have the added benefit of potentially further improving the environmental impact of products. 5

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SETEC I I GROUP S.r.L.

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www.economick.eu SETEC Group - SE.TE.C. / VICENTINI / IPEG / COELTUNNEL • Via Enrico Fermi 6/18 • 01033 Civita Castellana (VT) • ITALY tel. (+39) 0761-540606/(+39) 0761-542141 • fax (+39) 0761-542022 • www.setecsrl.it • info@setecsrl.it

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iw.kZ fMftVy vuqĂ§;ksx ds fy, ty vk/kkfjr ped vkSj ,axksCl Water-based glazes and engobes for full digital applications

Ever since the first digital printer for ceramic tiles was introduced in 2000, the sector has undergone rapid, uninterrupted growth, leading to the digitalisation not just of the decoration stage but of the entire production process. It is in this context that Esmalglass-Itaca presented its water-based Full Digital process at this yearâ&#x20AC;&#x2122;s Cersaie, an innovative solution designed to make the process fully digital and suited to modern production lines. The Full Digital process essentially involves using digital technology to apply the initial engobe, the effect ink decoration and the finishing glazes. A fully digital approach of this kind brings countless advantages: formulations with a lower water content and smaller weights compared to traditional applications, more uniform glaze applications (especially in the case of large size tiles with widths of 60 cm upwards), selective glazing synchronised with the graphic design, reduction in personnel costs and loss of material on the line, increase in quantity of first choice product, etc. The decoration line digitalisation process was initially envisaged for large size tile production, which uses oil-based products suitable for existing printheads. These full digital production lines are being used with excellent results by large companies in Spain, Italy, Russia, etc.

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technology

However, if the applied quantities exceed certain limits, the application of glaze-engobe and the final oil-based covering may produce unpleasant odours at the kiln exit. To solve this problem, Esmalglass-Itaca group proposes the use of water-based formulations for the initial engobe and the final glaze. The development of new high-discharge printheads designed specifically for water-based materials has allowed for the production of a full range of engobes and glazes for digital printers that bring further advantages with respect to those of a Full Digital process. One of these is greater environmental sustainability. The use of water results in a significant reduction in atmospheric emissions and in odours caused by combustion, which in many cases are entirely eliminated. The olfactometric tests performed have given results of around 500 EOU (European Olfactor Units), almost 6 times lower than the levels established by the European standards (3,000 EOU) as not causing discomfort to humans. The water-based Full Digital process formulated by Esmalglass-Itaca is ideal for all sizes and types of product. The Spanish company began studying these products in 2011, when it won the Alfa de Oro award for producing the first tile in an entirely digital process. The process was patented that same year. 5

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bZdksbad&flM®] LFkk;h iw.kZ fMftVy lek/kku Ecoink-Cid®, the sustainable full-digital solution

In more than 50 years of business, the Torrecid group has been closely involved in a number of revolutionary technologies in the ceramic industry. These include single firing in its early years, followed more recently by the digital revolution and the growing adoption of the so-called Full-Digital ceramic production process. In this latter field the Spanish multinational has taken another important step forward in the last few months with the development of the Ecoink-Cid® range, the new water-based digital inks and glazes unveiled at Cersaie 2017. The first water-based Full-Digital solution to establish itself in the market, Ecoink-Cid® is already being adopted by several ceramic companies to perform completely digital glazing and decorating of ceramic surfaces. Ecoink-Cid® consists of a highly comprehensive range of water-based solutions capable of achieving the best possible finished product. These include glazes with different gloss levels, matt glazes with all kinds of finishes, inks extending over a full spectrum of colours, ceramic and metal effect inks and inks for vitrified surfaces, as well as glue solutions for grit application. The innovative nature of these products is not only evident in terms of the quality of the ceramic surfaces but also makes an important contribution to the environmental sustainability of the production process. For example, the Ecoink-Cid® solution facilitates waste management, which is simpler and more eco-friendly given that cleaning is performed with water. It reduces atmospheric emissions and improves the working environment, offering ceramic tile producers the very best solutions that comply with the latest legislation on emissions and environmental protocols. The new water-based inks and glazes produced by Torrecid offer clear advantages for the production process. In particular, the shorter drying time means that it is possible to reduce the distance between the various applications on

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technology

the production line. Ecoink-CidÂŽ products are also fully compatible with all other ceramic applications. Another characteristic that will improve the production process is ease of elimination during firing. Due to its low evaporation point, the aqueous base disappears shortly after entering the kiln, thereby facilitating the degassing process. A further aesthetic advantage concerns the superior integration of the coloured inks into the glaze. This is already leading to products with very natural finishes, better visual quality and greater definition and realism in terms of colours and effects. With the development of Ecoink-CidÂŽ, Torrecid has once again confirmed its leadership in terms of innovation and as a driver of future trends in ceramics, opening up a new chapter for the industry in the field of sustainability. 5

ADVERTISING

lsusVÂŞhos;j m|ksx ds fy, ubZ ,;jdaMh'kfuax bdkb;ka New air conditioning plants for the sanitaryware industry

The air conditioning plants guarantee ideal thermo-hygrometric conditions in sanitaryware production rooms regardless of whether traditional, spagless or high-pressure casting is used. Based on proprietary Marcheluzzo Ceramics technology (Caldogno, Vicenza, Italy), the plants feature a number of filtration stages to improve the quality of both the environmental and expelled air. A special cooling and humidification system together with control of fresh air replenishment ensures air changes and comfort regardless of the external conditions. A ducting system with calibrated and suitably sized diffusers ensures the same balanced flow throughout the department, avoiding air stratification and heterogeneity that would place product quality at risk. The plant is designed with a static pressure recovery system and is automatically balanced. Different kinds of air diffusers have been chosen carefully according to their position in the department (above the casting bench or in the piece storage area, height from the floor, etc.).

Air conditioning plants

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technology

â?ąâ?ą The anti-fog system The new anti-fog system installed in spagless type casting departments is attracting a lot of interest amongst sanitaryware manufacturers. The area where the benches are installed contains large volumes of humid air generated by the air pressure in the moulds at the time of demoulding. If left uncontrolled, this moist air (sometimes saturated and therefore present as mist) affects the humidity conditions of the environment as a whole. If allowed to recirculate directly from the air treatment units, this air can create problems with the machines as it is contaminated with traces of plaster and ceramic body originating from the moulds. The function of the anti-fog system is therefore to capture all the humidity immediately after the water has been ejected from the mould. The anti-fog system is naturally connected directly to the air conditioning plant because environmental conditions must be guaranteed at all times (the system logic takes account of all the units in operation).

Anti-fog system for spagless bench

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technology

Anti-fog system for spagless bench

The system is based on Marcheluzzo Ceramics technology and is specifically designed for all kinds of casting bench, whether new or existing. ❱❱ The pre-dryers The pre-dryers are able to minimise the time between demoulding and the piece entering the dryers, freeing up the space normally required for parking the cars prior to drying. This is done when it is not possible to introduce the piece into the dryer immediately after demoulding due to the type of piece or specific production requirements. The plant features a single indirect combustion chamber with a gas burner for multiple cells (which may include a hot water battery) and a nebulisation system capable of increasing the humidity of each cell to saturation. The cycle times may vary according to the desired final moisture content. The airflow inside each cell is guaranteed to be as uniform as possible to avoid air speed differences which may have a negative impact on the first critical phase of piece shrinkage. ❱❱ Marcheluzzo Ceramics for American Standard Mexico As part of the investments in technological upgrading of its plants, American Standard Mexico (Lixil Group) recently commissioned Marcheluzzo Ceramics (Caldogno, Vicenza, Italy) to supply a fifth air conditioning plant complete with anti-fog system for installation on spagless casting benches in the traditional casting department. This latest order brings to 16 the total number of air treatment units and distribution systems supplied by Marcheluzzo Ceramics to the Mexican company. The order also included 20 pre-dryers, some of which are already in operation while others are nearing completion. 5

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SE.TE.C. Group SE.TE.C. Group, for more than 20 years a leader in the field of services and technology for the production of ceramic sanitaryware and tableware, has long been committed to developing innovative systems and new products through Italian and European research projects. One of these is the Life - Economick project, co-funded by the European Union and launched in 2016, which aims to reduce greenhouse gas emissions in the ceramic sector by building an innovative shuttle kiln for the production of ceramic tableware and sanitaryware. Partners in the project are Kerasan, a ceramic company based in the district of Civita Castellana (Viterbo), and Life Cycle Engineering, a consulting firm which will evaluate the prototype in terms of environmental and social sustainability in keeping with regulatory compliance. The prototype is expected to consume around 45% less energy than shuttle kilns currently on the market and significantly reduce CO2 and NOx emissions and the use of raw materials thanks to computerised management of air and gas flows, complete reuse of hot air and the use of advanced materials for thermal insulation. The shuttle kiln prototype design was com-

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pleted in July 2017 and construction will now go ahead. The prototype offers innovative technological solutions that ensure uniform heat distribution throughout every stage of the firing cycle regardless of the loading characteristics. The insulation ensures an excellent compromise between thermal conductivity and weight. A study performed using dedicated software during the materials selection stage allowed the best linings to be selected to minimise thermal inertia. The mass to be heated is minimal, resulting in low energy consumption while fully complying with worker safety and protection regulations. Three different solutions were chosen and taken into account during the design stage to allow for an external wall temperature of less than 60Â°C. The kiln is equipped with an Ipeg patented system for recovering heat from

the flue gases, which is used to preheat the combustion air. This technology does not use flues or additional pipes and above all does not alter the fluid dynamics in any way, which remain identical to those of a traditional shuttle kiln. A flame speed regulation system has also been introduced into the project to optimise the fume/piece heat exchange without affecting firing uniformity and energy savings at low temperatures. A dedicated software package developed by SE.TE.C for recovering heat and optimising air/ fuel ratios has been inserted into the firing system control panel. It is also capable of memorising the different firing curves and allows for complete computerisation of the movements of all the installed equipment. The same kiln will be tested in sanitaryware refiring cycles by a Romanian ceramic company and by

a ceramic tableware producer located in the Civita Castellana district in Italy. This will make it possible to test the technical specifications and characteristics in different ceramic sectors, thereby guaranteeing the highest standards of finished product quality and efficiency of the entire plant and consequently the production process. The data collected over the course of the entire project will allow for an effective comparison with existing intermittent kilns and assessment of the prototype construction. The project will comply fully with the EUâ&#x20AC;&#x2122;s policy priorities in terms of reducing emissions by energy-intensive industries and updating the best available techniques reference documents (BREFs) for the ceramic sector. For further information go to the Life-Economick project website: http://www.economick.eu/it

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SETEC I I GROUP S.r.L.

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Latest technologies Fritta

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DIGITAL CERAMIC D E C O R AT I O N

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Latest technologies Smac

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Latest technologies Smalticeram

Syneco

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EXPERIENCE AND INNOVATION

Sieving and deferrization systems

VIBRATING SIEVES FOR LIQUIDS AND FOR POWDERS

TROLLEy UNIT FOR GLAzING LINES

ELEcTRONIcALLy cONTROLLED DISSOLVER

IRON REMOVERS FOR LIQUIDS AND FOR POWDERS

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 int. 412 Fax +39 0536 812009 www.vibrotech.biz info@vibrotech.biz

Latest technologies

ICF&Welko

CWR INDIA 2018

Tekmak

CWR INDIA 2018

Latest technologies

Manfredini & Schianchi

CWR INDIA 2018

Latest technologies Projecta Engineering

CWR INDIA 2018

M UN IC H,

10 -1 3

AP RI L2 01 8

YO U

INNOVATION starts with a great IDEA

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

Latest technologies Tecnoferrari

CWR INDIA 2018

The 7th Edition Of Aseanâ&#x20AC;&#x2122;s Only Dedicated Ceramic Event

15-18

MARCH 2018

at Jakarta Convention Center, Indonesia

Co-located with:

OUR 2017 ACHIEVEMENTS (combined statistics)

37,276

Countries

30,000

Sqm of exhibition space

Visitors

keramika indonesia keramikaid keramika indonesia keramikaid www.keramika.co.id

POWER PACKED SEGMENTS

CALL OUR REPRESENTATIVES

The perfect one-stop platform that showcase a full range of ceramics technology, building materials, design solutions, systems and technology for the fast growing Building & Construction Industry in Indonesia. KERAMIKA WORLD OF CERAMICS

HVAC + M&E

SECURITY

& FIRE SAFETY

Co-organised by :

KERAMIKA

WORLD OF TECHNOLOGY

MARBLE & STONE

ROOF

& FLOORING

LANDSCAPE

DOORS

& WINDOWS

BUILDING MATERIALS

BATHROOM & KITCHEN

CONS RUCTION MATERIALS

DESIGN

LIGHTING

Ms. Hellen Woon

Mr. Handy Sohan

+62 21 2556 5000 hellen.woon@reedpanorama.com

+62 21 2556 5022 / +62 8177 7714 5456 handy.sohan@reedpanorama.com

Mr. Riyan Haritama

Ms. Desi Lestari

+62 21 2556 5012 / +62 812 1075 0353 riyan.haritama@reedpanorama.com

+62 21 2556 5026 / +62 8380 8767 755 desi.lestari@reedpanorama.com

INTERIOR

FURNISHING

Supported by :

In-conjunction with:

Media Partner:

Latest technologies Poppi Clementino Spa

CWR INDIA 2018

China International Ceramics Technology, Equipment, Building Ceramics & Sanitaryware Exhibition

By CCPIT BUILDING MATERIALS SUB-COUNCIL

CERAMICS CHINA 2018 to meet over

Come to

1000 global exhibitors with new tech,new idea and new gear!

2018.05.30-06.02 China Import and Export Fair Complex Guangzhou

Contact: CCPIT Building Materials Sub-council Tel: 0086 10 88082338 Fax: 0086 10 88082338 e-mail: info@ceramicschina.net liuyan@ccpitbm.org www.ceramicschina.net

Surfaces Group Absolute finishing

Discover unparalleled slab surface shine thanks to CONTINUA+ technology. Matchless surface quality with immediate post-compaction shine and lustre, a result unattainable with traditional technology. Thanks to CONTINUA+, only with CONTINUA+

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