Ceramic World Review India 2017 by Kairos Media Group (div. ceramics)

C eramic W orld R eview

ISSN 1121-0796

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Hkkjrh; fljkfeDl 2017 esa Lokxr gS!

Welcome to Indian Ceramics 2017!

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Titanium the difference With patented innovations that guarantee record levels of performance and results, the new generation of Titanium kilns is the best possible choice.

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Drive your colour Inkjet printers, ceramic inks and colour management software

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March 1-3 Pav. B Booth 159

March 7-10 Pav. C Rua S Booth 477

contents

Year 27 Supplement to no.120 January/February 2017 Bimonthly Review

Cover picture by: Giancarlo Pradelli

Editorial 8

Kajaria strengthens its leading position in India

Sabino Menduni

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TECHNOLOGY

22 32 42 46

Alessandro Bianchini

A complete line for large sizes

cM+s vkdkj ds fy, laiw.kZ J`a[kyk Andrea Gozzi

Innovation in the field of large sizes

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Del Conca Group’s new grinding philosophy

Msy dksUdk lewg dh ubZ dM+h j.kuhfr Focus on digital decoration

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60 66

Paola Giacomini

Hkkjrh; fljkfeDl 2017 esa Lokxr gS!

16 Interview

Welcome to Indian Ceramics 2017!

Smart, robotised and 3D: Sanitaryware 4.0 comes of age

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Products

Publisher Administration and Editorial Office

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Editorial Board

Simona Armichiari, Claudio Avanzi, Luca Baraldi, Chiara Bruzzichelli, Cristian Cassani, Paolo Gambuli, Erminio Guiducci, Luigi Montermini, Fabrizio Raponi, Fabio Schianchi Advertising

TILE EDIZIONI: Tel. +39 059 512103 - Fax +39 059 512157 Paola Giacomini: Cell. +39 335 1864257 - E-mail: p.giacomini@tiledizioni.it Marco Calliari: Cell. +39 347 4921000 - E-mail: m.calliari@tiledizioni.it Elisa Verzelloni: Cell. +39 338 5361966 - E-mail: e.verzelloni@tiledizioni.it Translation

JOHN FREEMAN (EN) - DILIP KUMAR CHOUDHARY (Hindi)

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: 05/02/2017 Promoted by

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Up to 16 colour bars More than 650 pieces sold 30 R&D staff for machinery development 45 years of leadership in decoration

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

Hkkjrh; fljkfeDl 2017 esa Lokxr gS! Welcome to Indian Ceramics 2017! India, the world’s third largest tile producer with volumes close to the 850 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 2017 edition of Indian Ceramics & Ceramics Asia in Ahmedabad – 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 2017 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 7,000 visitors. Indian Ceramics 2017 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, Certech, Gabbrielli, ICF Welko, LB, Manfredini & Schianchi, Martinelli, Mectiles, Sacmi, SITI B&T, System, Setec, Smac, Surfaces Technological Abrasives, Syneco, Tecnoferrari, TekMak, Appel and Air Power representing the ceramic machine industry sector; Tecnofiliere and Icra from the heavy clay and refractory plant production sector; Colorobbia, Inco, 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, Dorst, Eirich, as well as the heavy clay machinery suppliers Verdes, Beralmar, Händle, Cleia and Sabo, and the raw materials suppliers Esmalglass-Itaca, Fritta, Torrecid, AKW, Imerys, Sibelco and Esan. WE HOPE YOU ENJOY INDIAN CERAMICS!

www.CeramicWorldWeb.it

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Kajaria strengthens its leading position in India by Marco Calliari - m.calliari@tiledizioni.it

Following the start-up of two new production sites in Rajasthan and Gujarat, Kajaria Ceramics has reached a production capacity of 68.6 million sq.m of tiles and a real production of 58 million sq.m for the FY. ended March 2016 (up 17% over the corresponding previous year). The Group has performed very well in terms of sales and profitability. It closed the last fiscal year (31/3/16) with a 12% increase in consolidated turnover to 400 million USD (26.96 billion rupees) and a 31% increase in the EBITDA margin, which reached 19.25% of Group net sales. This strong performance continued in the quarter to 30 June with further 9% growth in consolidated turnover. The Indian giant has continued to grow steadily for the last three years, ever since it launched its five-year investment programme aimed at reaching a production capacity of 100 million sq.m/year by December 2018. We met Chairman Ashok Kajaria to find out about the next steps in the Groupâ&#x20AC;&#x2122;s programme and the growth prospects for the Indian market. CWR: What were your latest investments and whatâ&#x20AC;&#x2122;s next in your expansion programme? ASHOK KAJARIA: A new ceramic floor tile line with a capacity of 3 million sq.m/year began production at the existing location in Gailpur (Rajasthan) in October 2015, then in January

Exterior view of Kajaria manufacturing facility at Gailpur (Rajasthan)

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Interior view of Kajaria manufacturing facility at Sikandrabad (Uttar Pradesh)

interview

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

2016 we started up a 6.5 million square metre polished porcelain tile greenfield facility in Malutana (Rajasthan). Our joint venture partner Taurus Tiles started commercial production of a 5 million square metre polished porcelain tile facility in Morbi (Gujarat) in June 2015. With this expansion we have reached a tile capacity of 68.6 million sq.m/year. We have also formed a joint venture with Floera Ceramics, which is building a manufacturing facility with an annual capacity of 5.7 million sq.m of polished porcelain tile in Andhra Pradesh. The new plant is expected to be commissioned by the end of 2017. CWR: Besides Taurus and Floera, what other companies belong to the Group? A. KAJARIA: Kajaria Ceramics has majority stakes in another four joint ventures, three of which are located in Morbi: Soriso Ceramic, with an annual capacity of 4.6 million sq.m of ceramic floor tiles; Jaxx Vitrified, which has an annual capacity of 10.2 million sq.m of porcelain tiles divided into two plants; and Cosa Ceramics, which has an annual production capacity of 5.7 million sq.m of polished porcelain tiles. Vennar Ceramics Ltd, based in Vijayawada, Andhra Pradesh, has an annual capacity of 2.3 million sq.m of high-end ceramic wall tiles. CWR: What are consumers looking for in India today? A. KAJARIA: Todayâ&#x20AC;&#x2122;s consumers are well-heeled and cosmo-

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interview politan and exposed to international interior design trends. They demand premium products and services and have ample knowledge of the choices available. To meet and surpass consumers’ expectations, it is imperative for us to keep step with the latest product innovations, for example by updating our ranges with larger sizes such as 80x120 cm, 60x120 cm and 80x80 cm in glazed and polished porcelain, and 80x80 cm and 40x80 cm in ceramic for niche customers. We also intend to launch 120x120 cm by early 2017. Traditional, volume-driven sizes such as 30x60 cm and 30x45 cm also continue to be important. CWR: How is the Indian ceramic industry evolving? A. KAJARIA: India is the world’s third largest ceramic tile producer after China and Brazil. In 2014, Indian ceramic tile production reached 825 million sq.m on the back of average annual growth of 12-13% over the last 4-5 years as a result of urbanization and replacement of natural stone. Growth was slower in 2015. The value of the Indian tile industry is estimated to be around 4 billion USD, 50% of which is generated by the small number of major national brands (which account for less than 40% of the country’s total production), while 60% of Indian output is manufactured by the majority of India’s ceramic producers which are located in Morbi (Gujarat), possibly the second largest tile cluster in the world. More than half of India’s production, about 465 million sq.m/year, consists of ceramic floor and wall tiles. In this segment Kajaria has a total capacity of 28.9 million sq.m/year in various manufacturing units (at Gailpur, Sikandrabad, Morbi and Vijayawada) plus some outsourced production from a few units in Morbi. In the porcelain tile segment, polished tiles account for 285 million

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interview sq.m/year, whereas glazed tiles account for 75 million sq.m/ year. Kajaria operates in both segments with a total capacity respectively of 27.40 million sq.m/year (Gailpur, Malutana and Morbi) and 12.30 million sq.m/year (Gailpur and Sikandrabad). CWR: What are the imported volumes in India? A. KAJARIA: India imports about 50 million sq.m/year of tiles, including 10 million sq.m of ceramic floor and wall tiles, 35 million sq.m of polished porcelain tiles and 5 million sq.m of glazed porcelain tiles. CWR: How do you expect tile demand to evolve in India? A. KAJARIA: It’s no secret that the real estate sector has been a little stagnant in India. In spite of this, I believe that demand for tiles will continue to grow. The most important reason for this is that technological advances have improved the aesthetic appeal of tiles, making them an integral home improvement component. And as I said, in this segment tiles are replacing a lot of low and high end marble. The replacement market is growing as people aspire to better products which are now available in India at very affordable prices. Growing urbanization and easy availability of housing finance are other developments that will impact demand positively. Another factor that will have a positive impact on growth in domestic demand is the Government’s policies on housing, sanitation and smart city construction. Examples include the social housing project entitled “Housing for all by 2022” and the plan to construct 60 million toilets throughout the country by 2019 as part of the government’s “Swachh Bharat Abhiyan” (Clean India Mission) campaign. We should also remember that although India is one of the top consumers of tiles globally, it is also one of the lowest in terms of per capita consumption (0.59 sq.m/year compared to 4.2 sq.m in Brazil or 3.57 sq.m in China). The Indian Government has recently passed the much awaited historic GST Bill, which is going to benefit the ceramic tile industry due to lower taxation and shift the demand towards the branded tiles. CWR: With such high local demand, is there space for exports? A. KAJARIA: We are mainly focused on the domestic market. Exports make up only around 2% of Kajaria’s total sales volume, mainly to the gulf countries. Recently, we have begun exporting glazed porcelain tiles to Europe, Australia, Taiwan and the USA, but volumes are still very small. CWR: How has your business developed in the sanitaryware and faucet sector? A. KAJARIA: Sanitaryware is produced by our subsidiary Kajaria Bathware in Morbi, while faucet production is located at Bhiwadi (Rajasthan). In the last year we have expanded our product range enormously and it now consists of more than 200 SKUs catering for various market segments. Kerovit is a very young brand in the industry, but we have established a presence throughout India and have received a positive response from both customers and trade. 5

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A complete line for large sizes

A state-of-the-art forming system, high-performance kilns for efficient firing, outstanding size versatility, unlimited decoration potential, innovative end-of-line machining processes and suitable handling systems to optimise warehousing and logistics: each stage of the production process requires dedicated solutions and high-performance technical devices to guarantee the high quality of large-format ceramic tiles and slabs. Following its research efforts aimed at pursuing innovation and maximising efficiency and productivity, at Tecnargilla 2016 Siti B&T Group is presenting its complete modular line for the production of large-format ceramic tiles and slabs. Designed and built entirely by the Group’s various divisions, the line has a series of innovative technological features. ❱❱ The Supera® forming system To ensure high product quality and minimal waste, Supera® is designed and built in accordance with the innovative ISO Concept: zero product defects; uniform thickness over the entire tile surface; uniformly distributed pressing force; and uniform flatness thanks to a pressing system that uses hydraulic

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technology

cylinders to ensure isostatic crossbeam movement. The patented mobile front and side plate system guarantees the absence of waste and allows for a standard deviation in apparent density of less than 0.02, an apparent density of between 2.1 and 2.15 kg/cm3, a green breaking strength of more than 8 kg/cm2 and a variance in maximum thickness across the tile of 0.2 mm. The SuperaÂŽ range applies a pressing force of between 25,000 t and 44,000 t and produces sizes up to 1200Ă&#x2014;4800 mm with rapid thickness change from 6 mm to 25 mm. The line is mould- and foundation-free and achieves a productivity of up to 13,000 m2/day thanks to the super-fast pressing cycle. It ensures high energy efficiency with best-in-class consumption figures (<0.20 kWh/m2) thanks to the patented energy-on-demand Start&Stop system, the hydraulic power unit with inverter-controlled motors capable of eliminating consumption during the cycle stages in which hydraulic energy is not required, thereby guaranteeing maximum process efficiency. The aesthetic and surface finishing potential is virtually unlimited.

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technology ❱❱ The Jumbo horizontal dryer The tiles are dried by means of an innovative 7-layer “jumbo” horizontal dryer with an entrance with of up to 4000 mm and low specific consumptions of 1250 kCal/l of evaporated water (<70 kCal/kg product), whose unique construction solution allows for a significant increase in production. The VDN vertical dryer, with increased useful rack dimensions of 1750x2230 mm and a machine height of 11 metres, also guarantees excellent performance, minimum maintenance and high energy efficiency. This is a complete innovation, the first and only dryer capable of handling a rack load of four 800x800 mm tiles and with a loading capacity of up to 4 m2 per layer, as well as a high degree of flexibility in terms of production, sizes and thicknesses. ❱❱ The variable-roof Titanium XXL kiln For firing large-format tiles and slabs, the latest generation of Titanium® XXL kilns delivers the highest levels of energy efficiency (reducing fuel consumption by up to 30%) and productivity (25% higher than conventional technologies). The patented innovative aspect concerns the kiln’s variable roof. Thanks to its special shape, it is capable of stabilising the temperature in every area of the kiln and guaranteeing perfectly uniform firing. This ensures high quality and productivity and reduces the kCal/kg figure for unfired tiles to the lowest value ever. Titanium® kilns have entrance widths of 3,250 mm, 3,500 mm and 3,850 mm and guarantee minimal CO, CO2 and NOx emissions. Titanium® stands out from the wide range of burners produced by Siti B&T for its excellent temperature distribution in the kiln chamber, high energy efficiency and very low level of emissions. Fuel savings of up to 30% can be obtained by adopting mixed interventions with heat recovery systems (LHR, MHR, HHR) which guarantee a further reduction in consumptions and management costs, more consistent colour tones and calibres and a rapid return on the investment. Flatness control of the tiles during firing is also facilitated by

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technology a specially designed direct cooling section. It features automated management of two longitudinally separated areas and management of two separate sub-zones (high and low), which can be automated with percentage control. Each zone is controlled by modulating the air both above and below the rollers by means of blowing pipes with differentiated holes on the centre/sides. Gaps are managed by means of burners located at the end of the direct cooling zone using an active temperature control system. Cooling cracks are avoided thanks to the controlled indirect cooling process, which prevents internal non-uniformities in the tile from causing breakages. This precaution is particularly useful when producing large-format tiles and slabs and extruded products. ❱❱ Modular digital decoration with G5 The high-performance machines from Projecta Engineering are used for digital decoration, including G5, the first fully-modular digital decoration system custom designed to meet any production requirement. It has a sophisticated design and a very simple layout consisting of a belt between 4 and 6 metres in length and a Master module. G5 is designed and built to accommodate from 8 to 14 colours thanks to a series of independent modules that can easily be removed and replaced according to requirements. Each module effectively acts as an independent printing unit separate from the other elements and is capable of automatically placing itself on stand-by when not in use, thereby eliminating all risks of passive wear. At the beginning of the belt, the Master module (the only fixed module) complete with integrated monitor performs all the common functions required for interaction with the individual elements and incorporates the single or double row centring guide and the innovative laser-operated texture recognition system. The simple-to-use laser is positioned below the Master module and allows printing to be synchronised with the punch. At the end of the belt, the optional automatic sorting element with intelligent vision system is capable of recognising production defects even prior to firing. G5 ensures total expressive freedom thanks to the possibility of freely equipping the work table with any kind of element and any current or future-generation module, which adapts to the user’s needs and imagination without limitations. ❱❱ Dry polishing and honing Ancora offers an increasingly efficient and innovative range of XXL Polishing machines for large format tiles and slabs up to 1600x3200 mm in size. The complete calibrating and polishing line consists of a calibrating (or roughing) phase and a polishing phase. The combined roughing machine is equipped with a series of fixed rollers followed by at least two radial finishing heads or swinging rollers. The radial heads rotate at a speed of 60 rpm while the tools turn at a speed of 3800 rpm. The tile is subjected to virtually zero load, guaranteeing perfect flatness with a tolerance of 0.1 mm on the outgoing tile thickness. At Tecnargilla 2016 Ancora is unveiling its new dry honing

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Inks - Water Inks

I N C O I N D U STR I A C OL OR I SPA V ia Mont e bone llo 19/21 - 41026 Pa v ul l o (MO) T. + 39 0536 51021 - w w w.inc oc olours . i t

technology line. This innovative machine displays some major changes in terms of concept and operation. Like all dry processes, it offers a number of advantages. • In terms of energy: the fact that drying does not need to be performed after machining water-absorbent products brings significant energy savings. • In terms of the environment: the process does not generate sludge or waste water requiring purification. • Financially: the cost of the line is lower due to the absence of both a water system and a sludge treatment system, and building work for water conveyance is not required. • In terms of plant lifetime and maintenance: the machine’s life cycle is lengthened and maintenance is easier and less expensive. • The machine is cleaner and the workplace healthier due to the absence of humidity and salt spray. The honing module presented at Tecnargilla for sizes upwards of 1200 mm was developed in collaboration with Ancora’s tool producer partners, given that the starting point for innovation is the use of tools that are capable of avoiding excessively high temperatures and operating effectively in the absence of water. ❱❱ Cutting, scoring and snapping Also developed by Ancora, the DeepMotor Cut machine line for cutting or scoring/snapping combined with motorised discs and idle heads can be used for both conventional sizes and large-format tiles and slabs. This innovative technology is also capable of scoring and snapping materials with textured surfaces, bringing significant advantages in terms of costs and flexibility. This machine combines all the advantages of cutting with the simplicity and production efficiency of scoring, while avoiding the limitations of either solution. The ability to perform cuts close together thanks to the smaller transversal size of the vertical motor cutting units is another major benefit. The machine offers outstanding flexibility and can operate in several different modes: • cutting mode, in which the disc tools are used to cut through the entire thickness of material; • pre-cut and scoring mode, in which the disc tools perform partial cuts, at the bottom of which the scoring heads score the material ready to be snapped; • scoring mode, in which only the scoring heads make an incision on the surface of the material. ❱❱ Dry squaring Suitable for all kinds of ceramic materials, XXL Squaring Speed Dry achieves unprecedented levels of efficiency and productivity. Speed Dry uses an innovative patented system consisting of high-speed spin-

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technology dles equipped with a cooling system and tools which are kept clean by a compressed air jet. The new precise and rapid Front Edge positioning device enables the squaring lines to maintain very high production rates and produce perfectly perpendicular sides even in the case of large-format tiles. The new position operates in reverse with respect to the traditional device, aligning the tile from the front edge by means of two independent levers positioned on the two sides of the machine. This slows it down instead of pushing it from the lower edge. The length of the platforms is therefore entirely independent of the length of the tile. This brings two main advantages: complete elimination of the bulky positioner safety cage which obstructs operator access; and higher operating speed and consequently greater productivity. The Dual Drive system allows for rapid and easy belt replacement and eliminates the need for sliding splined shafts. In combination with the new Easy Change platform change system, the system significantly shortens stoppage times for belt and platform changing. ❱❱ Storage and handling BBOX XXL, the innovative box loading and unloading machine designed specifically for large sizes, extends vertically to guarantee practicality and smaller overall dimensions. Key characteristics include high product loading and unloading speed; the absence of local box changing devices; elimination of the compensator on-board the machine to reduce product handling operations; rapid and fully automatic size change; an electrical panel integrated into the machine’s structure; maximum safety during all operating stages. The fired tiles (or sub-formats) on the platforms are handled by Gripstrong, a machine capable of loading/unloading tiles up to 1600x3200 mm in size. The semi-finished tiles can be stored according to requirements and the way production is organised. Depending on the orders to be fulfilled, the finished products can be cut and packaged in small batches at the time of shipment. Department handling logistics are often performed by fully-automatic laser-guided vehicles (LGVs), which thanks to the enormous design experience of Siti BT Group, can be built in the widest range of configurations: from the standard forklift truck version for ground-level pallet handling through to highly efficient vehicles capable of operating on different vertical levels within a system of vertical shelving. Bigmover, an innovative laser-guided vehicle with a capacity of 4500 kg, high-speed operation and load lifting distance of 2800 mm, can be used to handle extremely large format tiles and slabs. ❱❱ Control systems Each machine is equipped with a new-generation operator interface with touchscreen technology. Line control can be performed by local management systems based on commercial PLCs and by department supervision systems which network with the individual devices. These latter systems allow for a higher level of company integration by means of dedicated and customised management software, including pallet card and finished product management. 5

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Innovation in the field of large sizes Andrea Gozzi, System Lamina (Fiorano, Italy)

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Less than 10 years ago, the most commonly produced tile size in Italy was 30x30 cm. In 2007 this size still accounted for 42% of national floor tile production, compared to just a 5% share held by the 60x60 cm and 90x90 cm sizes, which at that time were still considered extra-large formats. But all of this seems like ancient history now given the speed with which the high end of the industry and market have evolved. As a result, 60x60 cm is now considered a standard size and is classified amongst the so-called “traditional sizes” in contrast with the trend towards large-format panels and slabs. For many brands in Europe, Asia and the Americas, it is even seen as a kind of “minimum size”, a trend that is observed both amongst companies that have already moved into the large-format panel and slab segment and amongst those that are not interested in going down this path. These considerations and an analysis of the current needs of the ceramic industry laid the foundations for the development of LAMGEA, the System Lamina division’s new plant engineering project on show at Tecnargilla 2016. ❱❱ LAMGEA, a new pressing concept Based on the previous GEA technology for the production of large panels and slabs, LAMGEA marks a new step forward in

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the pressing segment. Thanks to its unique design and construction, it offers a valid alternative to conventional presses (for sizes from 60x60 cm upwards), an innovation that brings both technological and financial benefits. Moreover, it can be installed not only as the core technology of a complete System line but also as a mouldless press on existing lines. ❱❱ Size flexibility: from 60x60 cm to 160x480 cm The LAMGEA mouldless press is available in various models, all of which can be set to widths of 1000 mm, 1200 mm and 1600 mm simply by adjusting the pressing module, which allows for real-time switching between sizes. However, the models have different pressing forces and maximum panel lengths (2400 mm, 3000 mm, 3200 mm, 3600 mm and 4800 mm). Two of today’s most in-demand models are the LAMGEA 33,000 ton for sizes up to 160x360 cm and the new LAMGEA 22,000 ton for sizes to 160x240 cm, a highly compact machine that attains higher levels of speed and productivity. Thanks to the flexibility of these presses, a given machine can be used to produce panels with the maximum length permitted by the model and the width set during the configuration stage, after which submultiples can be obtained by cutting before or after firing. For example, a LAMGEA 22,000 is able to switch rapidly

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technology from a 60x60 cm to a 80x80 cm batch simply by changing the pressing module from 120x240 cm to 160x240 cm. ❱❱ Higher productivity: from 50 to 150 cycles per hour The new LAMGEA can perform up to 150 cycles/hour compared to the 50 cycles/hour of the previous GEA technology. This brings clear benefits in terms of productivity. Take for example the 160x240 cm size: LAMGEA 22,000 produces 150 pieces/hour whereas the previous technology (GEA 44000 for a 160x480 cm size) produced 100 pieces/hour but had far greater dimensions and much higher costs. Today, the daily production of the LAMGEA 22,000 stands at around 15,000 sq.m. In terms of construction, in-depth studies conducted by the System R&D department ensure that the higher speed of execution does not hinder the sensitive and precise operation of the hydraulic circuit. At the same time, the absence of a mould guarantees perfect de-aeration, ensuring that the ceramic surfaces are free of residual stresses. ❱❱ Variable thicknesses from 3 mm to 30 mm One of the biggest advantages deriving from the flexibility of LAMGEA is the variability of product thickness determined during the pressing stage. The already wide range of thicknesses (3-20 mm) has been further expanded (from 3 to 30 mm) to cater for any production requirement, from super-thin panels for interior wall coverings to extra-thick slabs for use as exterior paving or horizontal countertops. From a technological standpoint, this achievement should not be underestimated as it requires a guarantee of the total quality and uniformity of the panels. Indeed, another of the key strengths of LAMGEA technology is the fact that it guarantees constant calibre, flatness and thicknesses. ❱❱ Constant thickness, flatness and calibre Of all the innovations introduced with LAMGEA, one of the most important is the new laser-sensor-equipped device which guarantees constant thickness over the entire surface and between all panels. To do this, it measures the thickness of the powder on the belt and automatically corrects for any variations. This ensures precise powder application, and together with the subsequent continuous pressing force applied over the entire surface guarantees high product quality. Furthermore, the absence of internal stresses guaranteed by mouldless pressing ensures perfectly flat surfaces (a tolerance of 0.2-0.3 mm) and constant calibre. ❱❱ Surface decoration and finishing: from super-smooth to textured The designers of LAMGEA have also worked hard on the press belt characteristics with the dual aim of expanding the range of surfaces that can be produced and improving the level of quality. The surfaces range from perfectly smooth mirror polished finishes (an entire wall with this surface is on display at Tecnargilla) through to textured surfaces on which the laser-engraved rubber belt can produce relief with a depth of 2 mm, currently the only technology capable of achieving this.

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technology This makes for movement and geometries that are further enhanced by the high level of definition and quality of the details. Switching from one type of finish to another is very quick as it takes just 30 minutes to change the upper belts. This means that slabs and panels can benefit from virtually unlimited decorative potential thanks to digital technology, from high-definition decoration with Creadigit (400 DPI native) to full-digital systems with 2 or 3 digital machines for high-discharge ink application. Furthermore, additional products such as grits can be applied to create a material look and special effects. ❱❱ Zero-waste dry cutting and finishing LAMGEA technology involves limited edge trimming of the unfired edges, with trim amounting to no more than 7-8%. Due to the absence of residual stresses, the panel or slab leaves the kiln with uniform values of shrinkage, allowing just 2-3 mm to be removed from each side during the grinding stage.But this is not the only advantage in terms of waste reduction and finishing process optimisation. Thanks to the outstanding degree of flatness of the panels, it is even more advantageous to use new dry technologies both for scoring and snapping sub-formats and for squaring operations, which brings obvious environmental and economic benefits. ❱❱ A technology geared to smart manufacturing LAMGEA technology has many aspects in common with the principles of smart manufacturing inspired by the Factory 4.0 concept.The environmental sustainability of the process is assured by its extremely low energy consumption (0.10 kWh/ m2), around 70% less than that of traditional presses. At the same time, the use of spray-dried powders with standard moisture content (4-6%) allows fast drying cycles to be performed. When producing thin panels (3-6 mm), the technology ensures reduced consumption of natural raw materials and energy throughout the production process (from spray-dried powder preparation to pressing and firing). Moreover, the spray-dried powder does not contain any specific additives. As for the greater efficiency and optimisation in terms of plant management, we have already mentioned both the compatibility of the LAMGEA press with existing plants and the speed and simplicity of size changes. Added to this is the obvious fact that mould warehouse management costs are entirely eliminated. It is also worth looking at the opportunities for on-demand production that this technology offers to ceramic companies thanks to its flexibility. Although most users still prefer to cut submultiples prior to firing (with the exception of planks, which are generally cut after firing), LAMGEA technology lends itself perfectly to the post-firing approach in keeping with Industry 4.0 logic. In other words, panels and slabs are stored in the warehouse in a single size (and therefore with a single product code) and then cut on demand when an order is received. This enormously increases the number of individual items that can be obtained from each format. This approach naturally optimises all steps in the process, from production to the end-of-line stage (sorting, packaging, storage and warehouse logistics), and makes for faster order pro-

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KILN-WFRE UP TO 400 KCAL/KG

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technology cessing and shipment. ❱❱ Process control The operating principle followed on both the LAMGEA press and the entire System Lamina plant has created a simple-to-

FIRING HIGH-THICKNESS SLABS

Fulvio Baldini, Icf & Welko (Maranello, Italy)

The recent rapid growth in large sizes is revolutionising the ceramic tile sector. Although sales volumes continue to be dominated by conventional sizes, large formats are opening up new frontiers and potential for market development. In a context in which tiles are increasingly being seen as furnishing elements and the world of architecture is becoming ever more demanding, System Lamina pressing technology is able to produce panels and slabs in increasingly large sizes (up to 1.6x4.8 m) and thicknesses (up to 30 mm) and with higher levels of productivity compared to conventional presses, which are also limited to producing medium sizes. Drying and firing large-format slabs with a thickness of 30 mm is no simple matter. Because the slabs need to be shaped and cut, they must be free of all internal stresses. This is the challenge that I.C.F. & Welko has successfully overcome. The seven-layer dryer follows the slab along its entire path and adjusts the temperature at each stage to eliminate thermal stresses. But the company’s real success in the field of thermal engineering is its kiln for firing 1.6x4.8 m slabs

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with a thickness of 30 mm. In this case, the slabs are monitored at each stage and the parameters are subject to dynamic operating temperature and pressure control. Rather than a static channel where a firing curve is executed, the kiln becomes a channel with dynamic zones that follow the slab as it proceeds. This has proved essential in the critical temperature-reducing sections as a way of ensuring that the surface is always at the same temperature as the centre of the tile. The kiln features areas fitted with burners that heat the centre or walls, variable capacity to optimise consumption, heat exchangers, and controlled temperature air introduction where required in the channel zone. In the case of extra-thick slabs, thermal energy is introduced where and when it is needed and removed where it is in excess without affecting other points on the slab. The hi-tech kiln and dryer both maintain the simplicity and ease of operation typical of all I.C.F. & Welko machines. The 260 metre kiln and the 50 metre five-channel dryer have been in operation since September in the Castellón ceramic cluster.

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technology use machine-operator interface with a graphic type language. The process is controlled by touchscreens installed on the machine which are able to monitor and modify all the production cycle parameters. This type of interface makes for fully customisable supervision capable of tracking the day-to-day production of the line and providing advance warning when maintenance work is required. â?ąâ?ą Annual output of 65 million sq.m with System Lamina technology A total of 28 System Lamina plants have been installed (or are currently being installed) in Europe and Asia since 2005, making for a total production capacity of 65 million sq.m/year. Demand began to increase in 2013-14 (the year when System Lamina presented variable-thickness technology), then rose sharply in 2015 with a total of 5 plants started up that year. Growth has been even more rapid this year, with 10 plants ordered or already built in the first half of 2016. At the same time, the System group has stepped up its investments in this company division. As well as expanding the workforce by hiring engineers specialising in plant design and management and technicians with a high degree of expertise in the ceramic industry, the group plans to build a pilot plant which can be used both by customers for prototyping and training and by the R&D department for development and experimentation of new application solutions. The advances in Lamina technology presented at Tecnargilla 2016 are in perfect harmony with the spirit of innovation and research that has always been a hallmark of the System brand worldwide. 5 ADVERTISING

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The Del Conca Group’s new grinding philosophy When in 2012-2013 Del Conca Group began to study the layout of its new factory in the United States, it realised that this would also be the perfect opportunity to upgrade the raw materials grinding process adopted at its production facilities in Italy. This meant abandoning the traditional continuous grinding procedure and converting to the more modern process of continuous modular grinding. After conducting a comparative study of the two approaches, the company decided to opt for the new process. The facility in Loudon, Tennessee that began operation in February 2014 was consequently equipped with an MMC 74 continuous modular mill sized for an annual production of 3 million sq.m of porcelain tiles. “The analysis revealed a number of areas where continuous modular grinding would bring significant improvements compared to traditional continuous grinding,” explained Luca Costi, technical director of Del Conca Group. “The first improvement concerns the modularity of the system, which makes everything more flexible. With modular grinding, you can install the most appropriately sized mill for current grinding requirements and expand it at a later date.

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Focus on Raw Materials

In Loudon for example we installed a two-module MMC 74 mill but the project already makes provision for the addition of a third module. The second factor concerns the costs of the grinding process, which is a phase that has a major impact in terms of electrical energy costs. The feasibility study revealed a significant energy saving per ton of product, while at the same time reducing grinding media consumption per ton of product and wear of the interior mill linings. â&#x20AC;&#x153;The third essential aspect was of course the guaranteed quality of the semi-finished product. The fact that continuous modular mills have separate chambers, one for rough grinding of the raw materials and the other for refining, ensured greater control over the consistency of the grinding process and of the related technological parameters.â&#x20AC;? This means quality, flexibility and savings, goals that Del Conca Group achieved as soon as the plant was started up and which led the group to adopt the new grinding philosophy for all subsequent plant interventions at its various factories. For expansion of the Tennessee plant, commissioned in December 2016, the group installed a second two-module MMC

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Focus on

Raw Materials

74 mill identical to the existing machine with the option of adding a third module. The raw materials preparation department was also equipped with a new spray dryer, a plant for loading silos from the spray dryer and 30 new storage silos, as well as batching and press feeding systems. ❱❱ The new Pastorelli plants Concurrently with the expansion of the US facility, the Del Conca Group launched another major investment (35 million euros) in Italy, entirely concentrated at the Pastorelli facility in Savignano sul Panaro (Modena). The project was finalised between April and June 2016 and consists of two new production lines, one with traditional technology for large size tile production and the other based on Continua+ technology for the production of ceramic panels. Both lines will begin production in March-April 2017, raising the facility’s production capacity from 17,000 to 30,000 sq.m/day. When designing the layout of the raw materials preparation department, it was decided to maintain the existing single-chamber MTC 140 continuous mill, while the four old discontinuous mills were dismantled and replaced with a single MMC 74 continuous modular mill. “Grinding technology has evolved enormously over the years, first with the introduction of continuous grinding in place of the discontinuous process, and then with the advent of modular grinding,” said Luca Costi. “This means that today it is not just possible but also desirable to remodel plants that were installed perhaps 20 years ago.” This guarantees higher quality, a factor that is becoming more important than ever with the advent of large ceramic panels. “In this case the grinding stage is particularly crucial,” explained Costi. “It is essential to control the main technological parameters of ceramic slip such as residue, density and viscosity and to keep them within even tighter working tolerances. Only by doing this is it possible to ensure that the spray-dried product will meet the required quality standards in terms of moisture content and particle size distribution. By following correct procedures in the grinding and spray drying departments, it is possible to minimise the production of unfired waste, which in the case of large or very large sizes is at risk of increasing exponentially.” 5

SACMI CONTINUOUS MODULAR MILLS The continuous modular grinding technology developed by Sacmi is based on the principle of separating the various grinding stages. The modular mill consists of a series of independent cylinders, for each of which it is possible to set different speeds of rotation. This optimises energy consumption in each individual stage of the grinding process by establishing the ideal grinding curve for each body according to its specific physical characteristics. The modules are mechanically interchangeable and equipped with single and separate inverters. Each module is equipped with linings and grinding media tailored specifically to the grinding phase it is to perform. The connections between the modules allow grinding media and dissolved additives to be introduced in the intermediate stages. For the same useful volume, continuous modular grinding allows for a more than 15% increase in production compared to continuous technology.

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we are innovation Gruppo TECNOFERRARI S.p.A. con socio unico - Via Ghiarola Vecchia, 91 - 41042 Fiorano Modenese (MO) - ITALY Tel. +39 0536 915000 - Fax +39 0536 915045 - info@tecnoferrari.it - www.tecnoferrari.it

Advances in ceramic product design Davide Medici, Benedetto Spinelli, Sacmi-Intesa

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The increasingly widespread use of digital decoration has led to drastic changes in a number of product prototyping processes. In particular, analog systems have been replaced by digital processes that provide a virtual and physical simulation of the finished product and reduce development times. The production layout has also changed considerably, transforming the glazing and decoration line into an often integrated set of digital devices capable of depositing powders, grits, glazes and colours according to the instructions provided by the graphics file. In this field, Sacmi has followed two different research strands, one being a digital line with traditional pressing, the other a line with Continua+ technology. In both cases, it provides an advanced automated system that allows for digital production of ceramic products and guarantees a high level of efficiency, control and repeatability of models. Starting out from pre-press digital powder decoration, the piezoelectric deposition technique is used for both traditional lines and the new Continua+ lines. In the first case, the DGD (DiGiDrawer) system is used with 3 colour bars to deposit coloured powders according to a predetermined digital design during the final loading stage. In the second case, the Digital Dry Decoration, DDD device is used to apply up to 4 materials in the dry stage directly onto the soft ceramic body. Raw materials, glazes and the decoration are applied according to the predefined graphic sequence and are coordinated with both the three-dimensional structure created during shaping and the subsequent wet digital graphic applications. Proceeding to the glazing line, dry digital decoration is performed using the DDG (Digital Dry Glazing) system, which features two colour bar modules positioned before or after wet decoration. The DDG system is able to perform standard deposition or considerably increase definition through the application of digital glues. This has the advantage of reducing the quantity of material that needs to be removed, thereby improving efficiency and savings. In the field of wet digital decoration, the latest generation of DHD printers is equipped with an extremely advanced electronic control system that ensures total operational flexibility and is able to manage ever larger graphics files. Real-time data transmission allows for the processing of large quantities of information (projects with numerous images which vary according to the tile size) within

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digital decoration

timeframes consistent with the highest production speeds. However, speed is limited by the need to coordinate the images with a variable body texture. The colour bar can be removed completely to ensure simplicity of maintenance. The hydraulic and electronic components are located on the bars, while the ink refill is housed in the lower section. The operator interface is simple and intuitive and allows for automatic collection of production data and statistics on process costs and efficiency. The device is equipped with generous self-diagnostics to indicate the printer status and the need to replace components such as filters, degasser and pumps. The degassing system is managed automatically by the central control system and guarantees optimal pressure reduction at all times, performing automatic self-adjustment and indicating the need to replace the filter when the pre-set limits have been reached. Raster image processing (RIP) is performed extremely rapidly by an industrial PC installed on the machine, even during the production cycle. A reduced version of the Crono colour management software is able to implement a number of choices in terms of printing method and graphics/ image management. Various shear, randomisation and toning methods are available for specific printing and tone variation choices. The high waveform quality has allowed for the development of a new printing screen which ensures extremely high definition and efficient rendering of both softer and more intense tones. This is a result of the sharp and consistent drop shape, superior drop arrangement and selection strategy (grey levels) and the absence of satellite droplets. For more consistent print quality, a process to pre-linearise each machine has been introduced. This ensures more reliable adjustments and the possibility of simulating printing by other machines. Last but not least, Crono Process Management is responsible for controlling the entire sequence of devices, as well as managing colour, materials and production.

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Creavision: advanced technology and innovation for digital printing Gianluca Poli, System

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At Tecnargilla 2016, System unveiled a powerful vision and self-regulating image system for digital printing called Creavision. Creavision monitor tiles as they enter the printer and adapts the graphic design to the real position of the tiles to ensure perfect printing to within a tenth of a millimetre. Building on the Group’s many years of experience in vision technology, System’s Ceramics division has developed a unique self-regulation process based on a sophisticated system of video cameras which observe, analyse and control the tile’s position to ensure perfect printing every time. Definition, precision and savings are three crucial aspects of digital decoration. Creavision is able to meet all three criteria thanks to the expertise acquired by System over the years in the field of vision systems for fired and unfired ceramic bodies. The unique feature of Creavision is its ability to identify the tile’s spatial position on the printing system’s infeed belt. Especially in the case of strips and long formats, current decoration methods can be used to print a larger area of the printable surface so as to avoid edge defects, although there remains a risk of imprecise centring of the graphic design with respect to the edges of the tile. Thanks to Creavision and its powerful video cameras which view, analyse and control the position of the tile, the collected data (x,y,α) are transferred to the Creadigit digital printer which performs perfectly centred printing on all 1. The video cameras detect the tile’s position on the belt, then process the geometric data and send them to the Creadigit printer, which transfers the graphic design in real time. 2. The digital printer rotates the position of the graphic design according to the values provided by the software. 3. Without Creavision: smudging and centring defects. 4. With Creavision: a sharp and clearly-defined image.

1 48

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digital decoration

tiles. This ensures that the desired definition is achieved as the tile is perfectly centred and the quality of the graphic design remains unchanged. The vision process also guarantees the maximum precision due to the possibility of synchronisation between the various groups without the need to have all applications installed on a single unit (glazes/effects-colours-effects/material). In this case there is no need to determine the optimal distance between the machines or the distance between the various series of application units according to the product being printed, thereby ensuring outstanding versatility. Another key aspect concerns ink savings, given that Creavision eliminates excess ink application and edge overflow and significantly reduces rejects at the sorting stage. The benefits of Creavision therefore include perfect centring of printing on the tile, elimination of guides, extremely precise centring, ink savings, greater cleanliness, and synchronisation between the various systems, which can be positioned within the plant layout with complete flexibility. Creavision is a perfect example of Systemâ&#x20AC;&#x2122;s ongoing efforts in the field of technological innovation aimed at delivering solutions suitable for new applications. Creavision and Creadigit combine technology and graphic design to transform an image into a unique and original work. The ceramic surface becomes an empty canvas, a blank sheet of paper on which artists, designers and architects can fully express their creativity.

4 CWR INDIA 2017

Colorobbia: A perspective vision Fabio Avoni, Colorobbia

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In the current stage of development of ceramic process technology, large sizes, full digital, digital effects and new digital materials are seen as the keywords that will define the future of the sector. Technological progress has influenced not just the ceramic production line but also digital application systems. Printheads have evolved rapidly, bringing to market systems that deliver higher discharge quantities. More importantly, however, printheads offering excellent levels of performance in terms of definition and discharge even at high line speeds have gradually become established. The resultant process is not just decorative but also involves the application of effects and materials. Moreover, studies of digital application of dry materials have begun in earnest. With this in mind, Colorobbia has developed a specific range of materials for digital application which can be combined with all the standard products (frits, pigments, glazes, grits, etc.) to create an unlimited number of ceramic combinations/solutions, as well as surface effects and functional materials capable of meeting the growing demand for high discharge quantities. In particular, the range of digital decoration materials includes the ETR (Extended Temperature Range) series which evolved from the EHP series. The inks present in the series ensure a wide colour space, high intensity and high colour stability in extreme firing cycles. Another crucial aspect is the ability to maintain high levels of performance in severe production conditions. This series can be used with

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digital decoration

any piezoelectric digital decoration printhead. Both the ETR series and the SPS (Special Particle Size) series include numerous digital effects such as white, glossy, matt, sinking, water-reactive and metallic inks, as well as the so-called multifunction ink. The effect inks present in the SPS series have a specially designed particle shape and grain size distribution that enables large quantities of material (up to 50-100 grams/m2) to be deposited using dedicated medium and high discharge printheads. Colorobbia also offers the HQ (High Quantity) series of water-based digital glazes for the high-discharge digital glazing process. This series consists of various water-based materials that can be applied in specific combinations to create different kinds of ceramic surfaces. Numerous glazes are already available including matt, glossy, white, lustre, metallic and other materials suitable for both floor and wall tiles. Alongside these solvent- or water-based liquid digital products, Colorobbia also offers a range of materials for dry digital application. Customers are seeking specific effects and decorations that are created in-body and not just after pressing. With this in mind, Colorobbia has developed the DDA (Digital Dry Application) series of granular materials capable of producing innovative surface designs and textures. These materials consist essentially of pellets and grits. In particular, Colorobbia has developed a wide range of new grits capable of creating many different natural surfaces including stone effect surfaces, soft non-reflecting surfaces with a pleasant tactile effect, and marble effect mirror surfaces. These hi-tech grits meet the requirements of abrasion and chemical resistance while guaranteeing optimised digital colour intensity and maximum transparency (even on dark colours). By applying combinations of different materials and studying their individual functions and compatibilities, Colorobbia is able to meet all its customersâ&#x20AC;&#x2122; needs in terms of optimising finished product development using either a combined process (traditional and digital) or a full digital process. In order to deliver industrially-tested solutions, Colorobbia partners with leading industry OEMs who certify its products and perform industrial experimentation on materials using technologies provided by the plant and machinery manufacturers.

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Full Digital: glazing, texture, decoration and finishing Norbert von Aufschnaiter, Durst Phototechnik

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Durst Full Digital Glaze Line is the end result of five years of research and development efforts aimed at creating a complete glazing line capable of integrating a fully digital process based on an open system. The solution incorporates latest-generation Durst glazing, printing and finishing technologies and can work with glazes that are very similar to conventional products. The resultant line guarantees maximum versatility, flexibility and quality, as well as extremely competitive management costs, space rationalisation, optimisation of production and a high degree of management control through process automation. By perfectly synchronising the entire process as part of a 4.0 solution, Full Digital Glaze Line adopts the Durst Gamma DG 4.0 digital glazing systems and the new 8-colour inkjet printers from the Durst Gamma XD 4.0 range within a single workflow. Controlling the entire cycle from file processing through to the finishing stage is essential in order to optimise the advantages of digital glazing and to ensure perfect registration between the variable textures and the printed graphic designs. Based on single-pass inkjet technology, the Durst Gamma DG 4.0 glazing system incorporates proprietary printheads patented by Durst for handling high-viscosity water-based glazes. It is designed to deliver large particles with a grain size of around 45 µm without any reduction in productivity. This characteristic allows a large variety of glazes to be used, including those with similar formulations to conventional glazes and low-cost products. The reliability of the system guarantees high-quality glaze application on tiles even at very high temperatures (up to 70°C and higher) without clogging the nozzles. This ensures that output remains stable over the entire production cycle.The key strength of the Durst glazing system is its modularity, allowing the machine to be configured with a single or double glaze bar and with different printing widths. Each colour bar is designed to deliver up to 1 kg/m2 of glaze. The double colour bar configuration allows for the simultaneous application of two different glazes for effects that could not previously be achieved on the glazing line. When the bars are used individually, the one that is not in operation can be prepared for the subsequent print job without interrupting the production process, thereby increasing overall productivity. Glaze changing is guaranteed in under an hour and the variable speed of the conveyor belt can reach 20 metres per minute in the single-bar configuration.Durst Gamma DG 4.0 is able to apply

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digital decoration

a layer of glaze with total coverage starting out from a smooth mould. This makes it possible to create authentic textures with extremely high definition and significant relief, giving a material look and tactile effects to the ceramic surface and allowing for the production of unique on-demand textures such as realistic simulations of wood grain, stone, concrete and textiles. The Gamma XD 4.0 printer is an integral part of the Full Digital Glaze Line and is designed to fully exploit the potential of digital decoration with the use of material effect inks. This system is capable of achieving a speed of 76 m/min. and is part of the Gamma XD series, the new generation of 8-colour ceramic inkjet printers. High quality is guaranteed by the one-of-a-kind print engine which delivers unique levels of reliability and productivity while maintaining the ability to deposit large quantities of ink. This function is guaranteed by the DM â&#x20AC;&#x153;Digital Material Printing Technologyâ&#x20AC;? capable of applying more than 100 g/m2 of ink, essential for the application of glossy, lustre, matt and metallic inks, glue and other effects.The machine is equipped with Durst High Definition technology featuring double ink circulation, electronic alignment and a self-calibration function. The integrated Adaptive Dot Placement Technology produces banding-free images with high quality and colour uniformity over the entire print area. The transport system helps to maintain colour uniformity and avoid production stoppages, thereby reducing the need for operator intervention. The exclusive integrated long-interval self-purging system guarantees the stability of the process and a long printhead lifetime. Durst Gamma XD 4.0 allows for printing widths of between 319 and 1404 mm and is the only system with a patented dual-side colour bar access and extraction system. It can be configured for Dual Line mode, allowing it to print two rows and simultaneously decorate tiles with different sizes and/or designs.

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ETP technology for digital printing of ceramic tiles Alberto Annovi, Gruppo TecnoFerrari

vycVksZ ,Uuksoh] xzqIiks VsDuksQsjkjh ¼fQvksjkuks] bVyh½ In today’s global digital ceramic tile printing market, innovation means not only improving products in both technical and aesthetic terms but also optimising the manufacturing process. Productivity, flexibility, speed in starting up production and reduction of management costs are becoming urgent requirements for ceramic tile manufacturers, who are increasingly mature and attentive in managing the inkjet printing process and in evaluating the various offerings from machinery manufacturers, glaze and colour producers and designers. Long renowned as a leading supplier of digital printers, TecnoFerrari recently launched its VivaJet® models which fully demonstrate its ability to innovate and deliver the performance and reliability required from latest-generation machines. The company also provides a concrete response to the needs of maximum process optimisation and outstanding aesthetic quality of finished products. The use of latest-generation printheads featuring exclusive ETP (Extra Thin Piezo) technology and capable of working at extremely high frequency ensures unrivalled overall performance: greyscale printing with 15 pl minimum drop size for higher definition designs, full-field designs with 22 g/sq.m per individual colour or the use of high-discharge effects (more than 50 g/sq.m), printing speed of up to 50 m/min. with maximum resolution and stability for extremely high performance production lines. All of this is achieved using the same printhead model. In practical cases where the use of effects such as Glossy, Matt, Lustres and Glues previously required the installation

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Focus on

digital decoration

of specialised printheads or resulted in limited coverage, discharge or resolution, the proposed solution brings significant advantages in terms of flexibility. Moreover, ETP technology delivers extremely precise construction, high speed and clean jetting, while the distribution of nozzles over 16 rows allows for oversized chambers, internal recirculation channels and nozzles. For the end user this means absence of defects, uniform printing and maintaining registration, even in the production of challenging designs with high line speeds. Fully exploiting digital technology also means streamlining the workflow, from inception through to production of a design, especially in modern process that focus on small batches and just-in-time production. TecnoFerrari has taken an allround approach in addressing this issue and has developed a printer capable of increasing overall performance while maintaining characteristics of resolution, drop size and grey scale that allow for simple reproduction of products previously performed using other printing technologies. The entire process is managed with the utmost simplicity and guided by the GeCoÂŽ software package. The tools available for reducing timeframes, wastage and ceramic process fluctuations include profiling, linearisation, colour curve management, creation of dedicated machine configurations, proofing, consumption estimates, local and remote RIP, test runs, on-the-fly print job changing and in-line colour adjustment and correction. Thanks to the innovative HMI interface and the use of smart sensors as well as the collection of machine data and production statistics and their accessibility to the company network, VivaJetÂŽ printers can be installed on production plants optimised as part of an Industry 4.0 vision. TecnoFerrari combines innovation with the maximum ruggedness, reliability and reduced maintenance operations and costs. The VivaJetÂŽ printer is equipped with a frame and conveyor systems specially designed for large size tiles as well as new and truly efficient automatic cleaning, filtering, extraction and belt washing systems, enabling it to eliminate manual cleaning and dripping and to print uninterruptedly for several hours with complete reliability. The excellent technical support (including remote assistance) and the network of local service centres enable customers to choose between on-demand servicing and regular checks designed to keep printers efficient and reliable for a long period of time.

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The smart solution for ceramics: Fiery proServer for Cretaprint Victor Asseiceiro, Efi

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EFI™ specialises in the transformation of print from analogue to digital. The EFI Fiery® proServer for Cretaprint® Digital Front End is leading this transformation in the ceramics industry for digital tile production. It supports the brand-new Cretaprint D4 with up to 12 print bars, and provides tools and value from design creation to final print. Fiery proServer for Cretaprint is a dedicated colour management solution for digital tile decoration that produces the most accurate colour results, with the lowest ink costs, independent of final production conditions. A key part of the only complete printer, ink, and colour management solution in the digital ceramics industry, it offers tile producers many unique benefits: Shorter design development times with paper prototyping; Accurate and consistent colour quality in different production conditions; Lower ink consumption and costs. ❱❱ Accelerate design development For greater productivity, the client/server architecture allows designers or operators from different departments to work and use the Fiery proServer tools at the same time. The designer is able to convert a design for a specific printer and print out a proof, while a colour technician is reading in test charts and profiling for another production condition. Operators don’t need to stand up and to go somewhere, but can do everything right from their desk through a Mac or Windows Fiery proServer client. The colour management system also allows users to profile monitors so they act as a softproofing system to allow operators to see what will come out on press live as they retouch or edit an image. EFI’s exclusive Fiery Image Editor tool allows the accurate editing of final multi-channel separations, meaning on-screen changes can be made accurately and easily right up until production. In addition, precise simulation of final decoration on inkjet paper using Fiery ColorWise® technology provides fast, lowcost, and accurate paper prototyping, which reduces design development time. ❱❱ Accurate and consistent colour quality in different production conditions The overall colour of any tile run you produce has to match the original design. Ink set, printer, glaze or kiln differences can be compensated for with the Fiery’s easy but accurate de-

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Focus on

digital decoration

sign conversion tools, meaning tile producers can guarantee consistent results no matter where production happens. Fiery ColorWise® technology helps them do all that and more. In addition, the Fiery Calibrator allows users to linearise EFI Cretaprint devices and devices from other manufacturers for a consistent response from highlights to shadows before creating the printer profile. Matching floor and wall tile production need a common colour gamut in order to facilitate good product matches. Developing one involves taking into consideration the ink types, printers, and kilns to be used, and creating a gamut that fits within two device capabilities. The Common Gamut feature automatically considers the feasibility of colours for both print conditions, reducing valuable development time while increasing efficiency. ❱❱ Lower ink consumption and costs As a result of the multi-channel colour-separation strategy Fiery ColorWise delivers separations with the lowest ink cost compared to regular ICC separations. Combined with EFI Cretacolor Inks Fiery proServer achieves lossless-quality production with ink cost savings of up to 30%. With Smart Ink Savings, EFI is opening a new area of ink cost savings for customers who want to save more ink. Fiery proServer’s industry-first feature can reduce ink costs further by considering the actual cost of each ink, and calculating the most affordable ink combination possible for a design. Users can configure real ink prices, and control their acceptable colour deviation per job, plus see a report on the actual ink volume and cost savings prior to producing the tile. Fiery proServer helps users compensate for different ink sets, printers, glazes, or kilns, so they can guarantee consistent results - no matter where production happens. It lets users share individual printer profiles among multiple Fiery proServers to standardise colour and quality for global tile production. Plus, users can export conversion and proofing workflows with all the needed settings to any location, so producers can save on shipping, cut turnaround time, and balance production workloads without sacrificing consistency. With Fiery proServer for Cretaprint, manufacturers are not tied to one production environment or location. Rather, it adds essential flexibility to digital ceramic tile manufacturing businesses.

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Is Digital Ceramic Printing on “Main Street”? Gerard Winn, XAAR

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In his book “Crossing the Chasm” (1991), the author and consultant Geoffrey Moore introduced the concept of The Technology Adoption Lifecycle to describe how new technologies are adopted into a market – initially by innovators who are keen to experiment, closely followed by early adopters looking for a competitive advantage, then the late majority who wait for the technology to become well established before buying, and finally laggards who resist change. We can model digital ceramic decoration onto Moore’s lifecycle – from the first experimental digital ceramic printers in the late 1990’s, then the breakthrough into the mainstream in 2007 with the first recirculating printhead – the Xaar 1001. Digital inkjet technology has enabled tile manufactures to replicate natural materials and produce highly creative and textured tiles as well as larger and thinner tiles. By 2012 the technology had become widely accepted and now, by the end of 2016, almost full digital adoption has been achieved and even laggards have converted. Having completed the technology adoption lifecycle, Moore describes the next phase as the Mature Market Phase, characterised by tough competition where only the fittest survive. Innovation is not an optional nice-to-have, he says – it’s a requirement for differentiation and growth. Luckily innovation can take many forms – product innovation, marketing innovation, process innovation, and more – so it’s certainly not doom and gloom in the ceramics printing industry and we can look forward to many innovations in the industry in the years to come! So how is Xaar innovating? Xaar introduces the new Xaar 2001+ family of printheads, which delivers ultimate versatility in ceramic tile decoration by combining unrivalled production flexibility, market-leading print quality and industrial reliability. With 2000 nozzles, the Xaar 2001+ can jet one colour at 720 dpi or two colours at 360 dpi each – tile manufacturers benefit from high print quality and high productivity, so they can easily manage a very wide range of ceramic tile designs. Fast line speeds of up to 50 m/min enable high production throughput and a fast return on investment. Available in three drop sizes, manufacturers can select the printhead combination that meets their exact needs: choosing the Xaar 2001+ GS6C printhead for fine details, the Xaar 2001+ GS12C to balance detail and laydown for a wide range of tile designs, and the Xaar 2001+ GS40C to achieve the highest laydown for spe-

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Focus on

digital decoration

cial effects. Companies using printers featuring the Xaar 2001+ family of printheads will also benefit from industrial reliability delivered by multiple technologies unique to Xaar printheads. Xaar’s leading TF Technology® ink recirculation ensures continuous ink flow at a high rate directly past the back of the nozzles during drop ejection; air bubbles and unwanted particles are carried away. The XaarGuard™ nozzle plate provides highly effective protection from mechanical impact so that production interruptions are minimised, and coupled with other design innovations, achieves the longest maintenance-free production runs in the industry, typically once per shift or less. The new XaarSMART™ technology reports ink temperature and printhead status so that printer performance can be optimised in real time, providing consistent print quality throughout the production run even as factory conditions change. Plus, actuator performance in each printhead is optimised with Xaar’s Tuned Actuator Manufacturing. This process ensures full scalability with a simple and quick set up, streamlining printhead replacement, and achieves consistent print quality across long print bars with multiple printheads, at different greyscale levels. Xaar’s market-leading printheads for ceramic tile decoration are the result of Xaar’s commitment to continuous improvement. For over 25 years, Xaar has led the way in inkjet innovation. With state-of-the-art manufacturing facilities in the UK, Xaar exports its products to manufacturers all around the world.

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Smart, robotised and 3D: Sanitaryware 4.0 comes of age Sacmi Sanitaryware (Imola, Italy)

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What drives us? What is guiding us towards the future of ceramic sanitaryware? This was the theme of the day organised by Sacmi on 26 September (the first day of Tecnargilla), when more than 140 managers and representatives of companies from 40 different countries had a chance to visit the factory and research facility in Imola. The purpose of the event was to offer participants a close-up view of the group’s latest solutions for the Sanitaryware industry and to enable them to appreciate the new features and technical characteristics of machines in operation. At the same time it aimed to promote networking opportunities between leading international companies to enable them to discuss and share knowledge about the latest developments in technology, plant engineering and market trends. ❱❱ Robotics, the final frontier A leading player at Tecnargilla with cutting-edge solutions exploring the new frontier of collaborative robotics, Sacmi decided to show international customers the significant improvements made to the AVI high pressure casting cell unveiled at

During the visit to the Sacmi research facility

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Focus on Sanitaryware

the last edition of the show and now featuring a major process automation upgrade. The latest version of the casting module, designed to handle WCs with stick-on rims using moulds with between 4 and 7 parts, requires no worker intervention. All casting, mould handling and mould replacement tasks are performed by anthropomorphic robots, with changeover times now reduced to under 15 minutes and the capability of managing two separate casting modules in parallel with just one robot. This solution provides the best possible response to the sanitaryware marketâ&#x20AC;&#x2122;s natural need for flexibility. In all cases, the changeover time is shorter than the cycle time and downtimes are eliminated. Process repeatability and quality are improved and work is simpler (the operator never has to physically enter the casting cell as all casting and mould changeover tasks can be conveniently managed via the user-friendly interface). Sacmi envisions automation in sanitaryware as a dual frontier. On the one hand, it has developed ever-more advanced integrated production centres in which the robot plays a pivotal role, handling every aspect of production, eliminating any need for manual intervention, raising product quality and im-

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The Sacmi Sanitaryware division at Tecnargilla 2016

proving workplace safety. On the other, it is exploring the new frontier of collaborative robotics in which robots work shoulder-to-shoulder with personnel, ‘borrowing’ solutions already used extensively in other sectors such as the automotive industry. One of these was recently included in the Sacmi Sanitaryware Division’s plant engineering range. Equipped with cutting-edge safety systems, the robot used by Sacmi for sanitaryware applications is built by the industry-leading multinational Fanuc and is designed to help workers handle the fired pieces to be inspected. Due to its ability to work closely with humans, the robot can carry out all the product handling operations dynamically, eliminating at source any repetitive, tedious and unnatural activities and thus bringing the sector into line with the latest European directives on workplace ergonomics. ❱❱ The new ADI for large sinks and console washbasins One complete innovation unveiled in 2016 was the new ADI casting cell, designed for casting sinks and large console washbasins. With this unit the robot controls all the casting and mould opening/clamping tasks, while mould replacement is handled by two workers in under 15 minutes in complete safety and with the aid of a simple forklift (this is necessary because of the high weight of the moulds, which in some cases are heavier than 1,000 kg each). This solution offers outstanding flexibility as it is compatible with existing moulds already produced by Sacmi for the established ALS, ADS and ADM units. Although some manual intervention is required, as with the AVI cell mould replacement tasks can be completed in the same or shorter time than the production cycle. A single robot is able to handle up to three different casting modules. On request, the integrated casting centre can be equipped with a latest-generation Sacmi pre-dryer (FPV or FPL depending on whether single- or multi-mould cells are used) capable of reducing residual moisture by up to 35% and thus providing pieces already mature enough to be transported and placed on cars before they are sent on for final drying and firing. The innovative ALV casting cell was designed for casting ele-

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Sanitaryware

gant designer washbasins that need to be cast horizontally, a process that visitors had the opportunity to observe during the visit organised by Sacmi. In this case the ALV module was coupled with the ADI in the same robotic island, but in principle it can be configured in a fully customised way in the robotized casting centre. The ALV module likewise boasts shorter changeover times than casting times. â?ąâ?ą Modelling and 3D scanning for total process digitalisation In more than 30 years of business in the industry, Sacmi has developed and sold some 30 complete plants, 280 WC casting systems, 170 washbasin and shower tray casting systems, 51 driers, 1,040 robotized glazing solutions plus 375 kilns and 6,228 moulds worldwide. 2016 brought another major step forward with the launch of 3D digital modelling using advanced product and mould design solutions. This was the principle behind the various solutions demonstrated to visitors during the visit to the sanitaryware R&D lab: from digitalisation of the designerâ&#x20AC;&#x2122;s preliminary drawing through to perfect digital reproduction of the piece, then physical prototyping using a 3D printer and advanced mould design software. The mould (usually finished on site) can be refined by means of a real-time, error-free scanning solution that records, to an accuracy of one thousandth of a millimetre, all the modifications that will subsequently be replicated on the die. Likewise, the ultra-new GAS (Glaze Application Scanning) technology uses advanced software to make the glaze spraying cone both visible and measurable, simulating all process parameters and allowing further re-

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Sanitaryware

duction of overspray. It also provides feedback control of line operation (via real-time observations of any changes in glaze rheology, glaze nozzle clogging, etc.). ❱❱ Smart solutions for robotized glazing Alongside the launch of GAS, the latest new product from Sacmi in the field of robotized sanitaryware glazing, 2016 also brought extraordinary success for the new GDA 80 (Gaiotto Diaphragm Automatic Gun) needleless glazing gun. Extremely popular in the market with no fewer than 110 solutions recently shipped, it eliminates the need for maintenance while simultaneously boosting quality and process repeatability. At the same time, Sacmi has taken robotized glazing solutions a step further with the latest Gaiotto GA-OL robot series, which as early as 2014 adopted the new smart software release for off-line robot programming. This feature revolutionises the production process as it allows the operator to program glazing recipes in advance on the PC (thus modelling gun trajectories and setting all the spraying parameters) while eliminating the downtimes deriving from the need to reprogram the robot during size changeovers. Once executed, the program can be simulated and optimised without having to intervene directly on the line. Programs executed in self-learning mode can also be imported, modified and optimised. ❱❱ Sanitaryware 4.0: quality, energy and zero downtime Zero downtime, energy efficiency and quality are the Industry 4.0 principles that Sacmi is putting into practice in the sanitaryware industry. Automation, improved worker skills, digitalisation and quality control with process feedback are all aspects that are being adopted alongside new systems for optimising consumption. Energy consumption is reduced by 30%, while wasted time is cut by more than 65% thanks to elimination of downtimes (due to synchronization between casting and mould changeover) and reduced storage and handling requirements (thanks to utilisation of advanced pre-dryers etc.). Lastly, processing residues are reduced by 25% compared to traditional solutions, bringing significant advantages in terms of process efficiency and lower disposal costs. For a number of years now, Sacmi has seen Sanitaryware 4.0 in terms of the development and provision of advanced after-sales services provided through its worldwide sales and spare parts network. This goal is also achieved by installing cutting-edge remote support software on the machines, enabling customers the world over to benefit from the real-time support of specialised Sacmi technicians to resolve all the most common problems. Sacmi offers customised solutions right from the design stage and continues to provide close support throughout the working life of plant and machinery. 5

The Sacmi Sanitaryware division at Tecnargilla 2016

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Latest technologies

Megacolor

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Esmalglass-Itaca Group

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Manfredini & Schianchi

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Latest technologies Smac

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Tekmak

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Latest technologies Poppi Clementino Spa

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INNOVATION starts with a great IDEA

DIES AND RELATED PRODUCTS FOR THE HEAVY CLAY AND CERAMIC INDUSTRIES

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

Latest technologies Gabbrielli Technology

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Latest technologies Setec

Syneco

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Colourservice

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Standards: UNI EN ISO 10545-4, ASTM C 648, DIN 51030, EN 100, UNI EN 14617-2, UNI EN 12372:2006, UNI EN 1339-1340 New updated series of instruments for the determination of max load and flexing modulus of rupture and breaking strength of ceramic tiles, agglomerated materials and natural stones. Automatic instruments with patented adjustable and extractable supports rods to make easier and quick the positioning of the samples to be tested. Especially recommended for big and heavy sizes of tiles and thickness. The instruments come with patented easy moving base and touch screen for easy use and recording data. We produce a wide range of models from samples test from 650x650mm. Up to 1250x1250 mm and over on request. Load cell breaking strength range: 1000-3000-5000 kg. GABBRIELLI TECHNOLOGY SRL Via delle Bartoline, 43 - 50041 - Calenzano (FI) - Italy Tel: +39 055 88 11113 - Fax: +39 055 8861551 www.gabbrielli.com - info@gabbrielli.com

The Largest and Major Ceramics Industry Exhibition in the World with 100,000sqm Exhibiting Space !

CERAMICS CHINA @ Unifair 2017 Date: June 1st - 4th, 2017 Venue: Canton Fair Complex, Guangzhou

Organized by

overseas@ceramicschina.com.cn www.ceramicschina.com.cn

THE FUTURE OF DIGITAL PRINTING IS HERE

KNOW-HOW

TECHNOLOGY

OPPORTUNITIES

ELECTRONICS

SOFTWARE

The Sacmi Imaging division has developed an in-depth understanding of ceramic digital printing file processing.

A special team identifies the properties of the inks and the most suitable wave forms to maximise sharpness of the droplet and so achieve the highest possible definition.

Tr i e d a n d t e s t e d incorporation of Xaar technology is now joined by the new Dimatix option, guaranteeing full satisfaction of production requirements.

All-proprietary design and production of control electronics. Real-time data transmission.

The control software is developed on the shared Sacmi programming platform to ensure optimised handling of upgrades a n d i n te r- sys te m communication.

Thanks to Sacmi know-how, the new DHD-X and DHD-D printers with Xaar and Dimatix technology offer all the advantages of digital printing, specially enhanced for ceramics. www.sacmi.com