C eramic W orld R eview
ISSN 1121-0796
technology news markets
Hkkjrh; fljsfeDl ,f’k;k 2019 esa Lokxr gS ! Welcome to Indian Ceramics 2019! 2018!
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Year 29 Supplement to no. 130 January/February 2019 Bimonthly Review
contents
Cover picture by: Giancarlo Pradelli
9
Editorial
Welcome to Indian Ceramics Asia 2019!
10
World News
22 Interview
Paola Giacomini
Hkkjrh; fljsfeDl ,f'k;k 2019 esa Lokxr gS !
Kajaria Ceramics confident in the recovery of the Indian market Milena Bernardi
dtkfj;k fljsfeDl dks Hkkjrh; cktkj ds fQj ls csgrj gksus dk foÜokl
TECHNOLOGY
30 36 40 44
MS-DryTech and Fusion granulation: the green alternative to wet grinding
,e,l&MªkÃVsd ,saM ¶;wtu xzSU;qys'ku% 'kq"d filkà dk gfjr fodYi
Migratech 4.0 microgranulation technology for the production of large-size slabs
cM+s vkdkj ds LySc cukus ds fy, ekbxzkVsd 4-0 ekbØksxzSU;qys'ku rduhd Giuseppe Cavani Durst True Digital Glazing Technology, the next ceramic revolution
MLVZ dh okLrfod fMftVy XysÇtx rduhd] fljsfed {ks= esa vxyh Økafr
LC-GLAZES digital and AIR: eco-friendly digital technology
Colorobbia
lh&XysTl fMftVy vkSj ,vkÃvkj % i;kZoj.k ds vuqdwy fMftVy rduhd dk fodkl
46
Ecoink-Cid®, the full digital solution for large sizes
50
Water-based engobes and glazes for digital printing
Torrecid
fo'kky vkdkj ds fy, laiw.kZ fMftVy lekèkku Ãdksbad&flM®
Esmalglass-Itaca
ped iSnk djus dh fMftVy çfØ;k ds fy, ty vkèkkfjr vèkksysi vkSj ped
52
Aesthetics passes by the most innovative finishing processes
54
Advanced technologies for tile sorting and packaging
BMR
lcls uà fQfuÇ'kx çfØ;k }kjk dykRed lqfoèkk
System Ceramics
Vkby NkaVus vkSj iSd djus ds fy, vkèkqfud rduhdsa
sanitaryware
56 64 66 Heavy Clay 68
Norbert von Aufschnaiter
Focus on
Stefano Schianchi
Energy-Efficient Firing of Ceramic Sanitaryware
Jörg Ridder
fljsfed lsusVjhos;j dk ÅtkZ cpkus okyk tykou The new Slip Heating Concept for the sanitaryware industry Paolo Marcheluzzo
lsusVjhos;j m|ksx ds fy, u;k fLyi ghÇVx fl)kar Verdés set up a new brick plant in Malaysia
Verdés
oMsZl us eysf'k;k esa b±Vksa dk u;k IykaV yxk;k
Products
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ADVERTISING
advertisers list Alteo 63 Certech 2-7 Publisher
Colorobbia Italia
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Cosmec 20 Durst 49
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
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Paola Giacomini
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Claudio Avanzi, Luca Baraldi, Chiara Bruzzichelli, Cristian Cassani, Gian Paolo Crasta, Paolo Gambuli, 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 Elisa Verzelloni: Cell. +39 338 5361966 - E-mail: e.verzelloni@tiledizioni.it Translation
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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.
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All rights reserved. Opinions expressed by writers are not necessarly those held by the publisher who is not held responsible. Editorial material, manuscripts, photographs,
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Date of going to press: 20/02/2019 Promoted by
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editorial by Paola Giacomini, Editor - p.giacomini@tiledizioni.it
Welcome to Indian Ceramics Asia 2019! India, the world’s second largest tile producer with volumes close to the 1.1 billion 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 2019 edition of Indian 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 Asia 2019 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. With about 300 exhibitors, it aims to exceed the figures registered for the 2018 edition, expecting more than 8,500 visitors. Indian Ceramics Asia 2019 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 Air Power, BMR, Breton/Tecnema, CMF Technology, ICF Welko, LB, Projecta Engineering, Ricoth, Sacmi, Smac, Surfaces Group, System, Tecnoferrari, TekMak, representing the ceramic machine industry sector; Colorobbia, Metco, Sicer, Smalticeram, Smaltochimica and Lamberti for glazes and additives. Some of these will exhibit inside the 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, Hito, Solar Turbines, the colour and raw materials suppliers Esan, Esmalglass-Itaca, Ferro, Fritta, Imerys, Megacolor, Sibelco, Torrecid and Vidres, as well as the heavy clay machinery suppliers Ar-San, and Verdés.
WE HOPE YOU ENJOY INDIAN CERAMICS ASIA!
www.CeramicWorldWeb.it
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DIGITAL INKS & EFFECTS • TECHNICAL GRITS • SPECIAL GLAZES
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CWR 127/2018
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dtkfj;k fljsfeDl dks Hkkjrh; cktkj ds fQj ls csgrj gksus dk foÜokl Kajaria Ceramics confident in the recovery of the Indian market Milena Bernardi - m.bernardi@tiledizioni.it
Kajaria Ceramics, India’s top tile manufacturer and one of the largest global groups in the sector, closed the fiscal year to 31 March 2018 with 6.3% growth in revenue following the previous year’s 5.6% upturn to 336.4 million euros (27.1 billion rupees). This reflected similar growth in sales volumes, up from 67.7 million to 72 million sq.m, more than half of which consisted of polished or glazed vitreous tile. Despite the general slowdown of the Indian ceramic market, this growth was a result of “our focus on improving our internal efficiencies, expanding our product basket with innovative products and new sizes, continually increasing our dealer network and strengthening our brand equity by investing in multiple brand and promotional activities”, chairman Ashok Kajaria explained. The group is also pursuing a capacity expansion programme. By March 2019 it is expected to complete work on a new facility in Andhra Pradesh which will produce 5 million sq.m/year of glazed vitrified tile for the markets of southern India. In July this year it completed the expansion in production capacity in the sanitaryware sector to 600,000 pieces per annum with the aim of meeting the fast-growing demand for high-end products of Sanitaryware. CWR: Mr. Kajaria, how has your group performed over the last year? What are your forecasts for 2018-2019? ASHOK KAJARIA: Fiscal 2017-2018 was a year of validation for Kajaria Ceramics. The small but satisfying growth (+6.3%) confirmed the solidity and resilience of the group. We successfully overcame a challenging year for the Indian industry and market. Demand was affected by continued stagnation in the real estate sector, while the newly launched GST (Goods and Services Tax) regime impacted the MSME (micro, small and medium-sized enterprises) sector, the heart of the distribution The Kajaria Ceramics group’s tile production segment in India, which reacted by putting off purchasing deciKajaria Ceramics has a tile production capacity sions. dtkfj;k lsjsfed lewg dk Vkby mRiknu of 68.4 million sq.m/year, consisting of 43% Gas prices increased signifdtkfj;k lsjsfeDl ds ikl 6-84 djksM+ oxZ ehVj çfro"kZ dh mRiknu ceramic tiles (29.5 million sq.m), 33% polished icantly for the entire indusvitrified tiles (22.4 million sq.m produced {kerk gSA blesa 43 çfr'kr lsjsfed Vkby ¼2-95 djksM+ oxZ ehVj½] in 4 factories in Morbi and in Rajasthan) try during the year under re33 çfr'kr i‚fy'M foVªhQkbM Vkby ¼2-24 djksM+ oxZ ehVj ekscÊ and 24% glazed vitrified tiles (16.5 million view. Unfortunately, the dampvkSj jktLFkku esa 4 QSfDVª;ksa esa mRikfnr½ vkSj 24 çfr'kr XysTM sq.m produced in 2 facilities in Gailpur and ened sentiments prevailing in foVªhQkbM Vkby ¼1-65 djksM+ oxZ ehVj xkthiqj vkSj fldanjkckn Sikandrabad) as on 31st March 2018. the tile sector thwarted our esa nks bdkb;ksa esa mRiknu½ 'kkfey gSaA ;s vkadM+s 31 ekpZ 2018 ability to pass this cost inflard ds gSaA tion on to consumers, thus im-
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interview
Talking to... Ashok Kajaria here with his sons Chetan (right) and Rishi (left)
pacting margins. The premium GVT (glazed vitrified tile) segment faced intense competition due to significant capacity addition by Morbi-based players, resulting in a drop in prices of this niche product and impacting Kajaria’s business profitability [EBITDA fell by 8% to 4.56 billion rupees, around 56.6 million euros, Editor]. The fiscal year 31 March 2019 has good potential for healthier growth of the business by following the strategy that has underpinned our success to date: the ability to come up with new designs for all price segments and the large distribution network of 1400 dealers and various touch points covering every region in the country. CWR: What are your main new product launches this year? A. KAJARIA: We continued to up the ante for the tile industry yet again. In our ceramic division, we launched in July (in Mumbai) more than 60 designs in 60x120 cm to optimise the product mix, along with 150 designs in 30x45 cm and 30x60 cm to cater the needs of emerging market of tier II and tier III towns.
CWR INDIA 2019
23
interview As for the Eternity brand division, in August we organized an event in New Delhi to launch the 1x2 m size tile (our largest size till now), along with 350 new designs in 12 different sizes. This was the largest launch by any tile manufacturer in India and a one-of-a-kind event in the history of the tile industry. The Kajaria catalogue now includes more than 2,800 SKUs in different sizes in tiles and more than 250 SKUs in the bathware segment, consisting of both sanitaryware and faucets. CWR: How are you performing in Bathware sector? A. KAJARIA: Kajaria Bathware registered a robust performance in FY18 with 25% growth in revenue. The figures for the quarter April-June 2018 are also excellent with 69% growth over the corresponding previous quarter. We have teamed up with the young icon of Indian cinema Anushka Sharma as the brand ambassador for our Sanitaryware and Faucets segment, marketed under Kerovit brand. We are very positive in achieving healthier and sustainable growth going forward. CWR: How do you expect demand for ceramics to evolve in general in India? A. KAJARIA: India is forging ahead as the world’s fastest growing major economy. Urban clusters are driving this growth, with new consumers with greater purchasing power emerging beyond the metros, particularly in Tier II/III cities. This widening of the market potential across the expansive Indian landmass augurs well for the domestic tile industry in general and for the organised sector in particular. With increasing urbanization coupled with Government policies we should also see a recovery in the housing sector. CWR: Indian ceramic tile exports are growing rapidly. A. KAJARIA: Increasing demand from overseas market is definitely seen. We could see a good growth in exports for Indian ceramic tiles especially from Morbi based tile players. The low domestic consumption growth was compensated by a healthy uptick in exports. India’s export grew further in 2017 strengthening India’s fourth position amongst the world’s top exporter countries. CWR: Are imports still falling? A. KAJARIA: Yes, imports are very low compared to consumption, particularly from China after the government imposed antidumping duties on vitrified tiles for a period of 5 years to protect the domestic vitrified market. CWR: You mentioned earlier one of the consequences of the
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CWR INDIA 2019
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Visit us at stand B087
ADVERTISING
interview introduction of GST, the new Goods and Services Tax. A year after adoption, what other effects has it had on the Indian ceramic industry? A. KAJARIA: The Goods and Services Tax (GST) introduced by the Indian government on 1 July 2017 has made India a truly single market with a single level of taxation under the slogan “One Nation One Tax”. The most important economic reform in the history of India since Independence, it has simplified business activities by eliminating all barriers between the various Indian states and standardising the tax structure for all transactions. And that’s not the only advantage. With the GST rate reduced to 18% in November 2017, tiles and sanitaryware have become more affordable for consumers. Further, the implementation of the e-way bill promises to make GST more effective. This will create a level-playing field between the branded players and the informal segment and will help organised tile producers capture a larger share of the total domestic market in the medium term. 5
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,e,l&MªkÃVsd ,saM ¶;wtu xzSU;qys'ku% 'kq"d filkà dk gfjr fodYi MS-DryTech and Fusion granulation: the green alternative to wet grinding Stefano Schianchi - Manfredini & Schianchi (Sassuolo, Italy)
The results obtained from the dry body preparation process using MS-DryTech grinding technology followed by patented Fusion dry granulation confirm that it is possible to produce glazed porcelain tiles with the same characteristics as those made using conventional wet technology. It is an extremely eco-friendly process that ensures significant reductions in energy and water consumption while also allowing for major savings in terms of production costs. Drawing from its unique experience in the dry process raw materials preparation sector, Manfredini & Schianchi is able to propose the most suitable technologies according to the type of raw materials available and the required ceramic product quality. The following are the results of a study conducted at the Manfredini & Schianchi Technology Centre in collaboration with the University of Modena and Reggio Emilia and the ITC (Institute of Ceramic TAB. 1 - COMPARISON BETWEEN A GRANULATE Technology) of Castellón. PRODUCED WITH FUSION The aim of the study was to test the suitAND A SPRAY-DRIED POWDER ability of bodies ground with MS-DryTech Spray-dried Fusion granulate and granulated with Fusion for the propowder duction of tiles with technical characterisMoisture content % 5.7 5.7 tics similar to porcelain. Apparent density 0.95:1.00 1 For this purpose, the composition of Compression ratio 1:1.8 1:1.77 the dry grinding body was formulated in 3 keeping with the classic criteria of ceramic In-mould density (g/dm ) 1.33 1.25 body formulation, in other words without Particle size distribution Traces Traces making any changes with respect to the curve: 1000 µm formulations used for wet grinding. 800 µm 0.6 0.1 This was followed by an investigation of 600 µm 11.6 1.2 the quality parameters of ceramic prod500 µm 9.4 4.3 uct obtained with dry ground bodies and a comparison with those of a typical por400 µm 14.8 22.7 celain tile body produced by wet grinding 315 µm 4.0 9.2 and spray drying. 250 µm 14.4 31.6 The study investigated the mineralogical, chemical, morphological and particle 200 µm 10.0 13.3 size characteristics and sinterability of the 150 µm 10.4 8.9 resultant ceramic bodies, as well as the 100 µm 10.8 5.8 macroscopic and normative characteristics of products (linear shrinkage, water 63 µm 10.0 2.2 absorption, mechanical strength and inci< 63 µm 4.0 0.7 dence of black core defect). TOTAL 100 100 The following laboratory tests were con-
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technology
ducted: • Measurements of particle size distribution of body powders; • Chemical analysis of body powders; • Mineralogical analysis of bodies; • Morphological analysis of body powders after granulation and spray drying and corresponding in-press behaviour; • Characteristics after firing (linear shrinkage, water absorption) of products obtained from powders produced using the two different technologies; • Comparison between the consumption levels and savings obtained with the two technologies; • Comparison between the environmental impacts of the two technologies.
FIG. 1 - DIFFRACTOMETRIC AND PARTICLE SIZE ANALYSIS OF THE POWDERS OF 2 PORCELAIN TILE BODIES Body produced by dry process and Fusion
Body produced by wet process
Diffractometric analysis: prevalent crystalline phases: quartz, sodium feldspar, potassium feldspar, clay minerals of a kaoliniticnature and clay minerals of an illitic nature
Particle size analysis
CWR 127/2018 CWR INDIA 2019
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technology
❱❱ The results The diffractometric and particle size analyses confirmed that there are no substantial differences between the results of the two grinding technologies. A comparison between the two technologies reveals that in both the dry and wet process the residue stands at about 5% at the grinding particle size of 44 micron (fig. 1). The powder morphology obtained with Fusion granulation was more compact and completely free of internal TAB. 2 - TECHNICAL PARAMETERS OF 60X120 CM PORCELAIN TILE air pockets. PRODUCED USING MS DRY-TECH DRY PROCESS Table 1 compares the two granulates (one a FuBody moisture content at the press 5.5 – 6.0% sion granulate, the other a spray dried body), Press operating pressure 370 kg/cm2 which despite their slight differences in morpholoNumber of press cycles per minute gy proved to be virtually 8-9 identical in terms of parFiring cycle ticle size distribution and 1210°C / 38 min. pressing parameters. Shrinkage The slightly higher in6.0 % mould density of the Fusion granulate confirms Absorption < 0.1 % the much more uniform moisture content between Green M.O.R. 23 kg/cm2 the coarser fractions (>600 micron) and the finer powDried M.O.R. 42 kg/cm2 der (<100 micron). This does not affect the Fired M.O.R. 690 kg/cm2 die cavity loading parameters and instead makes Coefficient of linear thermal expansion α 24°-400°C 78.5 x 10-7 for a much smoother and more uniform green tile surface. The analysis of the behaviour of the two TAB. 3 - COMPARISON BETWEEN CONSUMPTIONS bodies during firing (fired OF MS-DRYTECH PROCESS AND THE WET PROCESS with 38 minute cycles at 1210°C) likewise reveals Consumption MS DRY-TECH Wet process no differences. In detail, table 2 shows Water (l/t) 36 266 the technical and quality parameters of porcelain 45 million litres tiles of size 60x120 cm and Estimated annual water (out of annual production of 10 million sq.m saving thickness 10 mm manuof tiles) factured from a body produced with the MS-DryElectricity (kW/t) 39 55 Tech process and Fusion granulation using easi3.9 35 ly-sourced low-cost raw Natural gas (m3/t) (for average body moisture content of 15%) with energy negligible with energy recovery systems recovery systems materials. ❱❱ Conclusions The experimentation shows that the dry formulations granulated with Fusion technology can be
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CWR INDIA 2019
No. of workers per shift
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Maintenance, parts and labour cost in Europe (€/t)
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Use of deflocculants and additives in preparation
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From 2 to 3 kg/t
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used to create products with equivalent characteristics to ceramic materials obtained with traditional wet grinding technology followed by spray drying. In particular, the process developed by Manfredini & Schianchi allows for excellent reactivity, which is ideal for the production of porcelain tiles. If we also take into account the big difference in environTAB. 4 - COMPARISON BETWEEN EMISSIONS GENERATED mental sustainability between WITH MS-DRYTECH DRY PROCESS AND THE WET PROCESS the two processes (tables 3 and 4 show a comparison beMS DRY-TECH Emissions Wet process tween their energy and water dry process consumptions and emissions), 7.02 80.96 CO2 (kg) it will be evident that the dry (for gas consumption (for gas consumption pressure 1 bar, temp. 15°C process is superior to the wet of 3.9 m3/tonne) of 45 m3/tonne) process and is a particularly NOx (mg/Nm3) valid solution for ceramic tile 0 1500 pressure 1 bar, temp. 15°C producers wishing to focus on increasingly eco-sustainable Particulate (mg/Nm3) 10 30 production. 5 ADVERTISING
technology
cM+s vkdkj ds LySc cukus ds fy, ekbxzkVsd 4-0 ekbØksxzSU;qys'ku rduhd
Migratech 4.0 microgranulation technology for the production of large-size slabs Giuseppe Cavani, Lorenzo Battaglioli - LB (Fiorano, Italy)
Migratech 4.0 is the latest offering from LB in the field of microgranulation. Fully compatible with Industry 4.0 criteria, it consists of a range of four technological solutions which can be chosen to create an optimal plant configuration according to the raw materials used, the needs of the individual plant and the desired finished product quality. Migratech 4.0 microgranulation technology offers clear advantages over spray drying with regard to energy and water savings and lower environmental impact. It also delivers outstanding results in all configurations in terms of simplicity of the process and finished product quality, again depending on the raw materials used. Migratech 4.0 technology is capable of producing class BIa and large-size ceramic surfaces. ❱❱ Technical characteristics of the microgranulate and ceramic product quality The microgranulate has a similar particle size distribution to Possible configuration of Migratech 4.0 plant
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CWR INDIA 2019
TABLE 1: FLOWABILITY OF A SPRAY-DRIED POWDER AND TWO DIFFERENT MIGRATECH 4.0 MICROGRANULATES Spray-dried powder
Microgranulate LB 1
Microgranulate LB 2
15
14
15
sec
1000 µm
2.5
1.4
0.6
%
500 µm
14.7
28.9
23.0
%
250 µm
57.0
44.1
43.7
%
125 µm
19.2
19.5
24.5
%
63 µm
4.9
3.5
4.9
%
< 63 µm
1.8
2.6
3.4
%
Flowability
that of a standard spray-dried product. This assures an excellent degree of flowability, as demonstrated by the measurements performed with a special vibrating channel device designed and developed by LB. Table 1 shows the results for the flowability of a standard spray-dried body and of two microgranulates composed of different raw materials and produced using Migratech 4.0. Ceramic materials produced using Migratech 4.0 granulate also proved to be similar to those obtained with spray-dried bodies in terms of the technological characteristics of the finished product after firing (Table 2). Thanks to Freestile and LBXtra technologies, which were developed to satisfy the needs of even the most demanding manufacturers with regard to colour management of powders and through-body effects, Migratech 4.0 microgranulate is suitable for use in the production of both glazed and unglazed porcelain with different thicknesses and in any size. These technologies are able to replicate all production processes that currently use spray-dried bodies, creating products with analogous technical characteristics but with a lower environmental impact and considerable energy savings. By adopting these solutions simultaneously, it is possible to produce double- and single-loading full-body products with a through-vein effect or double- and single-loading products to be used as a base for subsequent supplementary inline applications.
1600x3200 mm slab produced with Migratech 4.0 technology and pressed with Lamgea press from System
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❱❱ Tests on large-size slabs Microgranulate has also been shown to be the best alternative solution to spray-dried powder for the production of large ceramic panels and slabs. Its excellent flowability allows it to be loaded uniformly on the shaping lines for the production of large-size products. LB recently used Migratech 4.0 microgranulate to produce a series of 1600x3200 mm size slab samples of thickness 12 mm. The slabs were pressed on a Lamgea mouldless press from System at a specific pressure of 400 kg/cm2. The pressing parameters used for the production of slabs with microgranulate are the same as those normally used with spray-dried powder. Following a 70-minute drying cycle at a maximum temperature of 180°C and a 120-minute firing cycle at a maximum temperature of 1205°C, slabs with 0.04% water absorption were produced. The straightness of the sides proved that the microgranulate was loaded correctly and uniformly on the press feeding belt. The photos show two examples of 1600x3200 mm slabs produced using Migratech 4.0 technology and different combinations of aesthetic kits. 5
TABLE 2: TECHNICAL CHARACTERISTICS OF CERAMIC MATERIALS MANUFACTURED WITH SPRAY-DRIED POWDERS AND WITH MIGRATECH 4.0 MICROGRANULATES Spray-dried powder
Microgranulate LB 1
Microgranulate LB 2
units
mean
st.dev.
mean
st.dev.
mean
st.dev.
Linear shrinkage
cm/m
6.6
0.2
5.3
0.1
5.5
0.1
Water absorption
%
0.76
0.60
0.82
0.06
1.24
0.19
g/cm3
2.360
0.019
2.391
0.002
2.384
0.003
%
1.78
1.41
1.96
0.14
2.95
0.46
Linear shrinkage
cm/m
6.9
0.2
5.2
0.4
5.5
0.0
Water absorption
%
0.14
0.10
0.27
0.04
0.17
0.02
g/cm3
2.377
0.002
2.391
0.003
2.398
0.000
%
0.34
0.24
0.64
0.10
0.40
0.06
Linear shrinkage
cm/m
6.9
0.1
5.4
0.0
5.6
0.1
Water absorption
%
0.08
0.05
0.09
0.03
0.04
0.01
g/cm3
2.366
0.003
2.386
0.005
2.384
0.006
%
0.18
0.12
0.21
0.06
0.09
0.03
Firing at 1185°C – 60 min.
Apparent density of fired product Apparent porosity Firing at 1200°C – 60 min.
Apparent density of fired product Apparent porosity Firing at 1210°C – 60 min.
Apparent density of fired product Apparent porosity
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MLVZ dh okLrfod fMftVy XysÇtx rduhd] fljsfed {ks= esa vxyh Økafr Durst True Digital Glazing Technology, the next ceramic revolution Norbert von Aufschnaiter, Durst Phototechnik (Bressanone, Italy)
RockJet™ is the printhead technology for true digital glazing entirely developed and produced by Durst. It has undergone non-stop testing for several years, confirming the desired performance in terms of reliability and durability. This technology was the starting point for the development of single pass systems for digital glazing at an industrial level. The Durst Rockjet™ printheads are mounted on the new Gamma DG 4.0, the heart of Durst’s Full Digital Glazing line and the first single pass printer with a high-performance open system for digital glazing and the creation of textures on tiles. Gamma DG 4.0 is designed to handle water-based glazes with large size particles (> 45 microns) and high viscosity, allowing for the use of low-cost glazes with very similar characteristics and properties to traditional products. The printer has a glaze jetting capacity of up to 1 kg/m² per bar and achieves very high image resolution and high-quality details, as well as being reliable and flexible. The design is modular and configurable with 1 or 2 glaze bars and different printing widths.
2010 - Durst Gamma 75HD
2004 - Durst Gamma 60
World's first digital ceramic printer for pigmented ceramic inks
First ceramic High Definition printer with Contone Grayscale Technology
2006 – Digital Glaze Printing Technology Development Start
2014 - Durst Gamma XD Series
Innovative next generation XD ceramic printer platform – best rated ceramic printers for print quality, uptime and low maintenance
2010 - Pictocer HD
2007 - Gamma 70
2016 - Durst Gamma XD 4.0 Series New platform with patented dual color bar extraction system and Durst Analytics for real-time printer data and Industry 4.0 interconnectivity
2017 - Durst Gamma DG / RockJet™
Tecnargilla 2016 – Large scale presentation of tile samples printed with Durst RockJet™ Digital Glaze Printing Technology
2017 – ColorGATE CMS Durst Edition Revolutionary TRUE Ceramics Color Management Solution for fast color matching with flat and structured surfaces. Patented “Fingerprint” technology
Tecnargilla 2014 – Presentation of first tile samples produced with Durst RockJet™ Digital Glaze Print Head Technology, fully developed and manufactured by Durst
Industrial test in ceramics of world’s first single pass digital glaze/structure printer to test the technology under ceramics production conditions
FIRST TRUE CERAMICS COLOR MANAGEMENT SYSTEM
2018 - Durst Gamma DG / RockJet™ Fieldtest with tile production in ceramics of world’s first single pass digital TRUE glaze/structure printer with proprietary Durst RockJet™ ultralarge drop size print heads First TRUE “FULL DIGITAL” TILE PRODUCTION 2018 – Industry 4.0 Interconnectivity Durst Analytics and real-time industry standard printer data & instructions exchange with central factory supervision systems
2010 - Gamma 75HDS
2009 - Gamma 70M
2015 – Gamma 148 XD
2011 - Gamma 120HDS
2015 – Durst DM Technology
2011 - Gamma N-Series
Durst Ceramics Milestones
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Large drop print head technology for digital material decoration. Best performing technology with unreached nozzle stability, even with 100% coverage and non-stop printing
2018 – Workflow Solutions for high Production Efficiency • Gamma Vision System for image/structure recognition • Hotfolder Operation – for automated job preparation, management & control • Gamma Synchronization - Innovating Digital Ceramic Tile Decoration
technology
Durst Gamma DG Print Engine
â?ąâ?ą An innovative technology already in operation in Italy The Durst Full Digital Glazing, the long-awaited completely digital glazing line, was installed for the first time in the factory of a well-known Italian ceramic producer. Many ceramic companies are keen to adopt a fully digital production process. Along with the advantage of unlimited scope for developing innovative and unique products with extremely natural design, it allows the production process to be managed in such a way as to optimise sales and warehouse batches while meeting Industry 4.0 standards. Durst Full Digital Glazing works with glazes that have very similar characteristics to those currently in use and is considered an even more significant revolution to that of digital decoration. For the first time ever, this innovative technology is able to perform high-resolution digital glaze application with the laydown of significant quantities and with a high degree of precision. It is the most delicate part of the process because a lot of value is added to the product in this stage, creating visual and tactile effects and textures that make for a more natural and less photographic look than products decorated using digital printers alone. Along with excellent high-definition printing quality, it offers a high degree of versatility due to the possibility of decorating the tile with two different glazes at the same time. The textures reproduce the graphics in the files perfectly and are printed in synchronisation with the design in a random mode (i.e. changing continuously) and independently of
Durst Gamma DG Single Pass Digital Glaze Printer
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technology Top Layer → today applied traditionally & in combination with digital glue To increase resistance against abrasion and anti-slip (fllor tiles). To create additional effects and to get a more natural look. → Future: digital material printing with Durst Gamma DG
Decoration → Today: digital (Gamma)
With Gamma, Durst was the pioneer starting the first digital revolution in ceramics by introducing the first single pass printer for pigmented ceramic inks in 2004. Now almost all ceramic tiles are decorated digitally.
Glaze → today applied traditionally
A nonporous, protective glass coating. The decoration is printed directly onto the glaze and encapsulated in the firing process. Ensures hardness and water impermeability. → Future: digital glazing with Durst Gamma DG obtaining a flat or structured surface (press with flat mold and „digital“ structure)
Engobe
Thin layer applied before the glaze (mostly white color) to cover defects and unevenness of the body and to block the body color.
Body
A mixture of clay compositions and other inorganic raw materials (Quartz, Kaolin, Feldspar, etc. to obtain desired body properties) Top surface can be flat or structured (depending on mold)
Application of Durst Digital Glazing & Decoration system
quantities, allowing for on-demand production of small batches so as to optimise warehouses. This result was achieved thanks to collaboration with two prestigious external partners, Colorobbia for the development of dedicated glazes and Tecnografica for innovative designs. This have led to the creation of Durst FREE D tiles, the brand for finished products manufactured to industrial standards using Durst Full Digital Glazing technology. Finally, there are a number of factors that make this technology cost-effective, including reduction in glaze wastage (-20%) and machine stoppages for product and glaze changes and the possibility of using low-cost glazes with very similar properties to traditional materials. Durst Full Digital Glazing also automates and optimises the production cycle and is able to operate in perfect sync with Gamma series systems, creating a high level of synergy between digital printing and glazing. This is a real innovation that opens up new opportunities for developing designs that would be unfeasible with currently available digital technologies. 5
Example of a ceramic surface decorated with Durst Gamma DG with a Tecnografica design
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Durst Gamma DG Dual Glaze: example of printing with two different glazes at the same time
Example of a ceramic surface decorated with Durst Gamma DG
lh&XysTl fMftVy vkSj ,vkĂ&#x192;vkj % i;kZoj.k ds vuqdwy fMftVy rduhd dk fodkl C-GLAZES digital and AIR: eco-friendly digital technology Colorobbia (Sovigliana Vinci, Italy)
At Cersaie and Tecnargilla 2018, Colorobbia presented a preview of its new C-GLAZES digital series of special products designed for the preparation of water-based glazes for high laydown digital application systems. Following close collaboration with Durst on the application system and with Tecnografica in terms of design, these products have already been adopted at an industrial level by a major Italian ceramic producer and have demonstrated their ability to create 3-D reliefs on smooth tiles digitally and without the use of moulds. This, together with the possibility of combining different finishes on the same tile, results in truly distinctive designs. They also allow a much wider range of materials to be used than with effect inks, making it possible to satisfy the needs of both ceramic technology suppliers and tile manufacturers. C-GLAZES digital products also produce a much more pronounced ceramic effect than effect inks. The new C-GLAZES digital series is specially designed to allow a combination of different surfaces to be created on the same tile (e.g. a matt and a glossy glaze). Moreover, the possibility of digitally synchronising 3-D relief with graphic designs allows for the creation of a potentially infinite number of totally different tiles, resulting in a more faithful imitation of natural materials such as wood and stone. All these performance characteristics have been developed
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while devoting the utmost attention to the environmental aspects of the manufacturing process. Colorobbia maintains its commitment to promoting and investing in the development of new ceramic tile production technologies while focusing on care for the environment and safety at work so as to minimise the impact of ceramic manufacturing activities. In the case of inkjet inks, for example, Colorobbia has always used non-hazardous organic solvents such as esters of exclusively plant origin that contribute to the circular economy. For years Colorobbia has been strongly committed to developing a form of digital technology in which water can be used as an important part of the vehicle in glazes and in coloured and effect inks with the goal of reducing ceramic tile manufacturersâ&#x20AC;&#x2122; atmospheric emissions. In addition, the high water content of the new digital products guarantees a significant reduction in VOC emissions when compared to digital products based on conventional solvents. Following these major R&D efforts, this year Colorobbia has launched its AIR (Air-friendly Inks Range) concept for 100% digital decoration of extra-large porcelain tiles. Thanks to their high water content, AIR range inks are capable of drastically reducing atmospheric emissions compared to organic inkjet inks. The complete set of coloured and background/protection inks gives the best results in terms of image quality due to the perfect compatibility between the inks while significantly reducing unpleasant odours. Both the AIR series inks and the C-GLAZES digital products can be cleaned simply with water without generating toxic waste. This eliminates the need for organic cleaners and allows packaging to be recycled conveniently and cheaply. Alongside the environmental benefits, all digital products containing water are mutually compatible, allowing for the production of high-value finished ceramic tiles decorated in high definition and with excellent image sharpness. Colorobbia Groupâ&#x20AC;&#x2122;s sustainable growth is largely a result of the unflagging efforts of the Research & Development team and the Groupâ&#x20AC;&#x2122;s comprehensive know-how, leading to the adoption of strict production procedures and the most eco-friendly technologies. This policy also enables Colorobbia to comply with all international laws and national regulations of the countries where its production centres are located. 5
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fo'kky vkdkj ds fy, laiw.kZ fMftVy lekèkku Ãdksbad&flM® Ecoink-Cid®, the full digital solution for large sizes Torrecid (Castellón, Spain)
Ecoink-Cid®, the first water-based Full Digital solution for the glazing and decoration of ceramic tiles, is now in its second year of life and is already well-established in the ceramic industry. Launched by Torrecid at the beginning of 2017 and winner of the Alfa de Oro award at Cevisama 2018, this new range of products has contributed to the growing popularity of large-size tiles and slabs, which now have a very promising future. The market demand for large-size ceramic tiles has grown enormously in recent years, prompting more and more ceramic companies to adapt their production plants to these new types of products. During these first few years of the 21st century, we have seen a growing trend towards the production of ever larger sizes (up to 150x350 cm or more) with thicknesses as small as 3 mm. But above all the production of large sizes today means Full Digital, the complete digitisation of the ceramic glazing and decoration. This disruptive innovation has made ceramic production more agile and efficient while significantly increasing production. Torrecid has been working in this field since 2011. In this context, the water-based Ecoink-Cid® solution has introduced numerous advances into the production processes, including shorter drying times, simplification of subsequent applications and easier removal during the firing process. Moreover, the greater weight of the applied products ensures more nat-
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ural surface finishThe launch of Ecoink-Cid® coincided with the 55th es, while the imanniversary of Torrecid, a multinational group proved integration that has been directly involved in many of the most of the inks into the important technological revolutions in the ceramic glaze makes for industry, from the introduction of the porous single firing process to the recent digital revolution and more intense colthe development of Full Digital technology. ours. Torrecid continues to see steady growth and But perhaps the has factories and branches in 28 countries and most interesting customers in more than 130 countries worldwide. aspect is the fact that all these technical and aesthetic characteristics have been developed in accordance with the need for products with minimal environmental impact. Ecoink-Cid® marks a major step forward in the development of the Style-Cid® range because it combines extremely high aesthetic quality and elegance of the designs with greater care for the environment thanks to the introduction of water-based solutions. It has been demonstrated that Ecoink-Cid® products drastically reduce atmospheric emissions of organic compounds and eliminate odours, as well as simplifying cleaning operations and waste management and improving the factory working environment. It was this environmental sustainability that persuaded several ceramic companies to choose the Ecoink-Cid® solution, especially when production plants are located close to urban areas. Greater care for the environment translates into added value for companies, which can now make use of a long-awaited solution that fully complies with the new regulations on emissions. The Ecoink-Cid® range includes a wide variety of products with water-based formulations, including glazes with various gloss levels, matt glazes for all types of finish, inks that cover the entire colour spectrum, inks for ceramic and metallic effects and vitrified surfaces, glue solutions for granule application, and many more. Moreover, Ecoink-Cid® products can be combined with any materials developed by Torrecid to produce large size tiles, including body frits, flakes, spray-dried powders, whiteners, Glucid, polished granules, materials for full-field lappato and metallic effects. They mark a further step forward towards the production of ceramics without limits or barriers. ❱❱ Towards Ceramics 4.0 The Full Digital solution offered by Torrecid is a vital tool for ceramic companies setting out on the path toward a production process based on Industry 4.0 parameters. The use of digital
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technology
systems provides real-time production data and allows for total process monitoring in which machines are able to self-regulate, thereby increasing their level of efficiency. This makes it possible to anticipate the various stages in the production chain, from materials ordering to the type of products that need to be manufactured, thereby optimising the entire production line. This allows companies to improve their competitiveness by responding more rapidly to market demands and by delivering products with higher technical, aesthetic and environmental value. The change is so noticeable that Full Digital large sizes are gradually replacing traditional materials in the most exclusive areas of architecture and interior design. They are suitable for new applications as diverse as furnishings for restaurants, hotels, shops, kitchens and offices, as well as the external faรงades of hotels and prestigious buildings. 5
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ped iSnk djus dh fMftVy çfØ;k ds fy, ty vkèkkfjr vèkksysi vkSj ped Water-based engobes and glazes for digital printing Esmalglass-Itaca (Castellón, Spain)
Ever since the first digital printer for tile decoration was introduced in the year 2000, digital technology has been developing at a constant pace. The rate of growth has in fact been so rapid that the technology is now not only capable of performing decoration but can actually produce complete ceramic surfaces using an entirely digital process. In step with this technological progress, industry-leader Esmalglass-Itaca has developed a complete range of water-based engobes and glazes for use in digital glazing processes, a highly innovative development long awaited by the market. This Full Digital system brings numerous benefits: elimination of odorous flue emissions thanks to the lower quantity of carbon compared to solvent-based formulations; greater application uniformity on surfaces wider than 60 cm; and ease of producing large sizes with thicknesses of between 3 and 6 mm thanks to the smaller quantity of water applied to the body. These advantages have already been demonstrated in practice by the experience of a number of ceramic companies. During 2018, numerous tile producers in Italy and
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the United States have begun using these materials on their production lines, reporting excellent results that confirmed their effectiveness at an industrial level. Significantly, the water-based Full Digital process developed by Esmalglass-Itaca is suitable not only for large panels and slabs but for all kinds of materials in all sizes, which means that the advantages of the process are available to all manufacturers in the industry. The Spanish glaze producer has been developing these new products since 2011, the year when Esmalglass-Itaca won the Alfa de Oro award for pioneering the first tile produced using a fully digital process, a solution that was patented the same year. â?ąâ?ą Digital effects Esmalglass-Itaca has also developed materials for digital effects including Deep-Ink and Cola Digital. Deep-Ink combines design, structure and material perfectly to create digital relief with a high degree of definition. These materials are simple to apply and can be used to create surfaces with stone, fabric, leather, wood and concrete effects in a wide range of decorations and versions, thereby simplifying the new product development process. An additional advantage is the fact that the design is always synchronised with the texture. Another noteworthy product is Cola Digital, a digital glue capable of achieving a wide range of effects with the utmost simplicity. All the operator has to do is load the glue into the digital printer and then use any kind of digital device for depositing powder. This means that all kinds of grits and granules can be applied in synchronisation with the design, allowing for the creation of any desired effect or finish. 5
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lcls uà fQfuÇ'kx çfØ;k }kjk dykRed lqfoèkk Aesthetics passes by the most innovative finishing processes BMR (Scandiano, Italy)
The BMR finishing technology has among its objectives the realization of highly competitive finished products on the most important international markets. The treatment is one of the phases that contributes to giving added value to lapped and polished products and is developed by BMR according to advanced technological standards. BMR’s attention to the production process is aimed at the ceramics industry achieving high quality and highly competitive products both from a technological and aesthetic point of view. To this end, the finishing segment of which BMR is an international leader includes an important surface treatment phase that gives added value to lapped and polished surfaces. In general, the first treatment is that of acid pickling, carried out to preserve any shadings deriving from subsequent washing with aggressive detergents. With pickling, the surface is treated with an acid solution applied through a sponge roller and is then simply rinsed with water. Subsequent treatments are distinguished according to the different surface types, which can be classified into two macro categories:
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• polished technical porcelain, full body or double loader; • lapped/glazed technical porcelain. Thanks to the collaboration with companies specialized in tools, glazes and raw materials for treatment, BMR has developed three lines of treatment machines, with the main purpose of improving cleanability and shine: TopCoat, TopFinishing, SuperShine. TopCoat applies products that include acid pickling and fillers to preserve the product’s original gloss from the lapping process. TopFinishing is a 6-head machine that allows the dry application of filler fluid. Thanks to the balance of weight, speed and type of product applied, TopFinishing allows the increase of Gloss during the process. SuperShine is a mechanical heat treatment able to increase the degree of gloss coming from the lapping of 30 points and more. The mechanical heat process takes place in consideration of: • advancement speed of the machine belt; • tilting speed of the upper bridge for polishing heads; • ability of the tool to absorb and release process fluids; • drying time of the process fluid; • head pressure; • control and management of the operating temperature generated by tile/tool friction. SuperShine is based on the use of 10 satellite heads with diameter ø 580 mm with 6 tools diameter ø 160 mm, each of which applies an adjustable amount of natural silica in fluid suspension that is pressed by the force and weight of the heads themselves. Specifically, the first 7 heads have the function of spreading and polishing the product, while the following 3 are for washing. The result is continuity in the quality of the finished product. Thanks to all its technical and technological features, SuperShine can be defined as a real dry super-polishing process. The main technological end-of-line processes innovations by BMR will be present in the Pavilion 2-Stand B-081 at Indian Ceramics, the Gandhinagar (India) fair from February 27th to March 1st 2019. 5
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Vkby NkaVus vkSj iSd djus ds fy, vkèkqfud rduhdsa Advanced technologies for tile sorting and packaging System Ceramics (Fiorano, Italy)
Amongst the flagship machinery manufactured by System Ceramics are the quality control and packaging automations, such as Qualitron XXL and Multiflex. Qualitron XXL is the vision system developed by System Ceramics for quality control of large ceramic surfaces. One of the most advanced processes in the world, it films the ceramic tiles using two digital cameras, one black and white and the other colour. The tiles are illuminated by a special light generated by a lighting system purpose-designed by System Ceramics to allow for accurate inspection of structural and decoration defects. A special micrometric positioning device aligns the inspection system perfectly with tiles and slabs of different thicknesses. The system is able to examine the surface textures and decorations of large-size tiles and slabs and submultiples in meticulous detail. The automatic sorting process is designed to operate even without an operator present in keeping with smart manufacturing and Industry 4.0 principles. One of the most important features of Qualitron is the powerful software developed entirely by the internal team of IT engineers, who have created one of the world’s most extraordinary machine learning programs in the ceramic tile industry. An automated procedure allows the product to be set up completely automatically. The software recognises the various types of defects and transmits them to the control logic of the sorting machines downstream of the Qualitron XXL. Each machine is equipped with an industrial PC specially designed by System Ceramics and a 21” Copilot human-machine interface complete with a full HD high-resolution graphic display. In the field of packaging, System Ceramics has developed a technological update for its Multiflex packaging system which allows for greater flexibility and customisation. Multiflex is an advanced packaging machine designed to pack ceramic tiles
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of various sizes using neutral or pre-printed cardboard sheets. Starting out from the neutral flat sheet, the machine creates a box by adapting the packaging according to the stack of tiles so as to manage any variation in terms of calibre and stack height. The material used to obtain the necessary strips comes in a standard 120x120 cm size and is subsequently cut to create a totally tailored package. The machine then automatically forms the cardboard packaging that encloses the tiles of sizes up to 120x180 cm. The control panel is fitted with a latest-generation industrial Copilot PC with 15.6â&#x20AC;? full HD touchscreen and simple and intuitive management software. Multiflex is able to produce up to 10 boxes a minute with considerable savings in terms of cardboard (up to 80% depending on the size). Designed with a focus on anti-waste packaging and reduced consumptions, the technology allows for optimised production costs, while protecting our environment, thanks to energy and raw material savings. The new version of Multiflex adds further process innovation to the characteristics described above. The first major change is the positioning of the 4 carton storage units, which can be managed either in a single row (right or left) or on both sides (2 on the right and 2 on the left). The dimensions of the storage units have been increased to enable them to handle pre-printed sheets and consequently operation in submultiples. Secondly, boxes can be formed for different sizes with extremely rapid size change operations, while the graphics printed in real time on the package can be customised on the machine. This is largely achieved thanks to the simplified mechanics, which are capable of producing the final package in a small number of steps. 5
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fljsfed lsfuVSjhos;j dk ÅtkZ cpkus okyk tykou Energy-Efficient Firing of Ceramic Sanitaryware Jörg Ridder, Riedhammer (Nuremberg, Germany)
In recent years, the issue of energy efficiency has become firmly established in the production process of ceramic sanitaryware, especially in the firing process. The rising price of energy, the efforts to reduce costs accompanied by the necessity for the conservation of resources and environment protection are leading to a rethink and a series of measures in order to improve efficiency in every respect. ❱❱Introduction Over the last 30 years, the global consumption of raw materials for primary energy generation has increased by around 70%. By the year 2030, an increase in the global primary energy consumption by a further 45% compared to 2006 is expected (World Energy Outlook 2008). An almost 50% increase in consumption makes natural gas the fastest growing fossil fuel, and energy efficiency therefore plays an important role in curbing growth in the global energy demand to a third by 2040, while the global economy is growing by around 150% (World Energy Outlook 2014). Natural gas is used predominantly as a fuel in the ceramic sanitaryware industry. The combustion of carbon and hy-
Fig. 1 Tunnel kiln with EMS
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Focus on Sanitaryware
drocarbons leads to the formation of nitrogen oxides and especially to carbon dioxide gases. CO2 gas is associated with the term greenhouse gas, characterizing the damage effects on the environment. As a result of the absorption of the infrared radiation of the earth crust, it warms the air near the ground and cools the higher spheres as a result of radiation. At the G8 Summit in 2008 in Japan, “longterm goals” were defined, like, for instance, halving emissions by 2050, which is not possible without an increase in energy efficiency (World Energy Outlook 2014). The emission of CO2 is related directly to fuel consumption. Low percentages in the exhaust gas are not an indication of a low CO2 emission, but an indication that the exhaust gas has been thinned down with additional air. The alternative of improving the heat transfer coefficient with high air excess cannot be applied as the increase in the amount of air brings an increase in the energy consumption that cannot be offset with better heat transfer. ❱❱Situation in kiln technology with regard to energy and CO2 saving The above-mentioned requirements are leading to new developments that have been realized Fig. 2 Model of a tunnel kiln with EMS by Riedhammer GmbH and can be summarized as follows: • Energy-efficient engineering (EEE) • Energy Management System (EMS) in the new generation for all continuously operated kilns • Reko shuttle kilns • Combined heat utilization of the firing equipment with energy consumers in a plant. ❱❱Energy-efficient engineering (EEE) Another milestone in the development of thermal process equipment is the introduction of 3D-based design systems. Today, it is possible to represent the plant as an integrated model, as a result of which collisions can be
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Focus on
Sanitaryware
reliably avoided at the installation site. The key advantage here is the representation of the design of a plant with every interesting detail such that all necessary sections can be viewed from every perspective. Such a view, complemented with available calculation and simulation techniques, enables the designer to perfect detail solutions. The interconnection of 3D design programs and the ever-growing capacity of modern computer systems have made the simulation of thermal processes attractive for kiln engineering too. Although a complete simulation of the transient heat and flow processes in a continuous kiln cannot yet be realized at a reasonable cost, partial simulations of certain special solutions are already performed at Riedhammer within the scope of pre-engineering. ❱❱The new generation of the Energy Management System (EMS) Based on the continuous kilns which have been successfully operated in the market for years, Riedhammer has concentrated its amassed experience and integrated this into a new generation of EMS systems as follows (Fig. 1–2). EMS400-4.0 In this new EMS version, the same results are achieved in respect of energy saving and CO2 reduction, but with half the investment costs for this system compared to the previous EMS400. This new EMS400-4.0 system is based essentially on a combination of the following individual components: • Pulse burners in the preheating zone with combustion air preheated to 200 °C, • Continuously operating burners in the main firing zone with combustion air preheated to 400 °C, • Electronic gas/air ratio control, • Combined heat-related operation with the relief and waste heat systems. Tables 1 and 2 show a consumption/cost and emission breakdown for a tunnel kiln and roller kiln with EMS400-4.0 based on a production capacity of 30 t/ day at the same natural gas price compared with standard tunnel kilns. EMS700-Cyber This new EMS version EMS700-Cyber built completely on the EMS400-4.0 is based essentially on a combination of the following individual components: • Pulse burners in the preheating zone with combustion air preheated to 200 °C,
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Fig. 3 Latest-generation Reko shuttle kiln
SACMI: experience and complete solutions for your product
Innovation
Product Development
Sorting Modelling
Firing Resin moulds
Off-line Technology
Casting and handling Glazing
SACMI manufacturing technology: the advanced sanitaryware production solution, from single machines to complete lines. www.sacmi.com
TAB. 1 COMPARISON OF ENERGY AND EMISSION DATA OF TUNNEL KILNS WITH EMS400-4.0 AND TUNNEL KILNS WITHOUT EMS
TAB. 2 COMPARISON OF ENERGY AND EMISSION DATA OF ROLLER KILNS WITH EMS400-4.0 AND TUNNEL KILNS WITHOUT EMS
• Continuously operating burners in the main firing zone with combustion air preheated to 700 °C, • Controlled recuperator system in the rapid cooling zone, • Electronic gas/air ratio control, • Combined heat-related operation with the relief and waste heat systems. Tables 3 and 4 show a consumption/cost and emission breakdown for a tunnel kiln and roller kiln with EMS700-Cyber on the basis of a production capacity of 30 t/day at the same natural gas price compared with standard tunnel kilns.
Organic Rankine Cycle
Hot oil
Fig. 4 ORC scheme
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Turbine
Regenerator (condensator)
Evaporator
Pump
Generator
Cooling water
Focus on
Sanitaryware
TAB. 3 COMPARISON OF ENERGY AND EMISSION DATA OF TUNNEL KILNS WITH EMS700-CYBER AND TUNNEL KILNS WITHOUT EMS
TAB. 4 COMPARISON OF ENERGY AND EMISSION DATA OF ROLLER KILNS WITH EMS700-CYBER AND TUNNEL KILNS WITHOUT EMS
❱❱Riedhammer’s Reko-shuttle kiln 2.0 Among the intermittently operated kiln plants, in the ceramic sanitaryware industry the shuttle kiln has become established as an important element in the production for first firing, refiring and decoration firing. In the past, energy consumption and CO2 emissions were much higher than for continuous kilns. However, this difference has become much smaller in recent years on account of highly efficient combustion systems, like the Reko system described here (Fig. 3). One reason for the still existing difference is the bigger ballast mass of kiln insulation and kiln cars that have to heated up in every cycle from the start to the end temperature, another reason are the exhaust gas losses, which are naturally highest at maximum temperature. Kiln wall and kiln car insulation in modern kilns are designed and optimized according to the principles of transient heat conduction with the latest computer technology. With special computer programs, the flow conditions in the kiln chamber can be determined so that optimum burner positions and burner operating modes can be defined, while further improving temperature homogeneity in the kiln chamber at the same time. In Table 5, the energy data of a shuttle kiln designed according to the above-mentioned methods are compared with those of a conFIG. 5 COMPARISON OF ENERGY AND EMISSION DATA OF SHUTTLE ventional shuttle KILNS WITH AND WITHOUT NEW RECUPERATOR BURNERS kiln. Already with the measures described, energy savings and CO2 emission reductions of around 45% can be achieved. As a basis for the calculation, here a price of 0,3 EUR/m³n fuel gas was used. This enables the plant operator to achieve
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an enormous reduction in production costs and certainly gives him advantages over the global competition. In the Reko shuttle kiln, with consideration of the results of the above-mentioned calculation methods, novel patented burners have been introduced additionally. For every burner, the volumes of gas and air are measured on the cold side of the fluid feed so that a temperature correction is not necessary. The electronic modules for the gas/air volume control guarantee the required optimum combustion for the total firing process. Instead of one recuperator in one common exhaust gas line as often installed as standard, now for every individual burner a heat exchanger is fitted in the kiln wall for the preheating of combustion air and gas. As the energy transfer takes place directly within the kiln structure, the otherwise high line losses are eliminated. With these measures a considerable improvement in energy efficiency is achieved. The goal of the developments presented is primarily to save energy and minimize CO2 emissions. As an optimum combustion of fuels according to physical laws is associated with a very extreme CO2 reaction, the CO2 emission in the exhaust gas cannot be reduced in terms of concentration, but only in the amount as a result of a lower supply of energy. â?ąâ?ąConclusion The efficient and environmentally compatible use of energy has gained significantly in importance in process of ceramic sanitaryware production. Possibilities for improved energy efficiency result first from the optimization of individual kiln functional groups, e.g. the combustion system, and secondly from the no lesser potential of the linked processes, e.g. utilization of waste heat. Energy efficiency in the process has now a significant influence on the economic efficiency and competitiveness of the manufacturers of ceramic sanitaryware and will increase in importance in the forthcoming years. 5
Fig. 5 Energy balance with and without cogeneration
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ALTEO ALUMINAS fOr cErAMIc AppLIcATIONS
IdEAL fOr zIrcON rEpLAcEMENT
With 120 years of expertise, Alteo is a world leading fully-integrated supplier of specialty alumina. Alteo aluminas provide many advantages such as high mechanical resistance, hardness, and different surface effects depending on the customer needs. For example, specially tailored alumina can replace totally, or partially, zircon sand in formulations to give whiteness and opacification.
www.alteo-alumina.com
These aluminas are used in the ceramic industry in a wide variety of materials such as frits,engobes & glazes, pigments, stoneware, tableware, etc. and in newer applications such as inks for digital printing. Meet us at Indian ceramics - Hall 1 Booth A-415
lsusVjhos;j m|ksx ds fy, u;k fLyi ghÇVx fl)kar The new Slip Heating Concept for the sanitaryware industry Paolo Marcheluzzo, Marcheluzzo Ceramics (Caldogno, Italy)
Marcheluzzo Ceramics, a historic Vicenza-based company specialising in industrial automation and thermal treatment for drying and environment control in the ceramic sanitaryware, insulator, refractories and brick industries, has designed and launched its new Slip Heating Concept, an exclusive system for heating slip in mixing tanks for the sanitaryware industry. ❱❱ Introduction It is a well-known fact that to guarantee optimal stability in traditional, spagless and high-pressure casting processes for sanitaryware production it is important to maintain the slip temperature at between 35°C and 38°C. However, this temperature must be reached over a clearly determined period of time during and after filling of the individual tanks (normally 24 h but sometimes 12 h) and maintained at these values for the entire storage period before the slip is transferred to Slip Heating Concept operating diagram
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Focus on Sanitaryware
the casting hall. This setting must be made independently of the temperature of the incoming slip arriving from the body preparation room, the ambient temperature of the area where the tanks are located, and the exterior environmental conditions in summer and especially winter. Other equally important measures include performing the least invasive possible operations on the existing tanks, for example by using hot water already present in the factory. ❱❱ Slip Heating Concept: operation The Slip Heating system designed by the Marcheluzzo Ceramics engineering staff is based on an energy transfer mechanism involving a hot water circuit and the steel slip tanks. Transfer occurs by means of a semi-permanent conduction process involving simultaneous heat transmission, heat conduction and irradiation. A series of coils of high-conductivity PE-XA pipe are wound around the steel tank. Hot water is circulated through the pipe and is regulated by means of a feedback valve and a temperature probe located inside the tank. The most complex aspect of this solution is determining the number of coils required and their characteristics according to the mass of the slip that needs to be heated and the thermal gradient required by the specific manufacturer. Energy transfer from water to the slip occurs by means of: • the hot water circulating in the pipe; • heat passing through the thickness of the pipe; • the stagnant air around the pipe covered by an insulating layer; • the steel wall of the tank containing the slip needing to be heated, which remains in constant motion driven by mechanical agitators. The lifetime of the pipes varies according to the temperature of the water circulating inside: from 50 years in the case of water at 70°C to 15 years with water at 90°C. Once the coil has been positioned, the tanks are insulated and protected with aluminium sheet. The temperature of the incoming water is controlled by a bleed system with valve to ensure that the temperature of the water around the pipes remains independent of that of the main factory circuit. Flexibility, efficiency and the possibility of controlling multiple tanks at the same time make this system a valid alternative to the various water-slip heat exchangers, which force the slip continuously through pumps and alter its rheological characteristics. The system is also available in conjunction with Visco S.M.A.R.T., an instrument patented by Marcheluzzo Ceramics for automatic temperature correction according to the viscosity and thixotropy of the slip. 5
Steel tank
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oMsZl us eysf'k;k esa b±Vksa dk u;k Iy‚UV yxk;k Verdés set up a new brick plant in Malaysia Verdés (Vilanova del Camì, Barcelona, Spain)
A new clay brick plant has been recently set up in Malaysia, equipped with Verdés machines. It belongs to Hap Kee company, a long-standing Verdés customer who again trusted the solutions and experience of the Spanish machinery manufacturer to give shape to its new project. The new factory has a capacity of 700 ton/day of fired product and will produce mainly solid facing and structural clay bricks. Verdés supply covers the entire clay preparation and shaping line which has been designed for carrying out a direct setting on kiln cars, which was one of the client’s requirements. It is a semi wet clay preparation process that has the following main stages: clay reception and primary crushing, secondary crushing and mixing with water addition, stocking, fine rolling and finally, the extrusion. For the primary grinding phase, it has been set a primary crusher 117-FT that allows reducing the clay lumps under 80 mm. Following this machine, a disintegrator 127-C reduces again the material until 5-10 mm by accomplishing a shearing action. During the secondary grinding, granulometry gets even more reduced and right after, the clay is stocked in a ground storage room, where its humidity content gets homogenized and its properties improves. From the ground storage room, the clay is conveyed to the shaping area that starts with a mixing and homogenizing equipment 046-C and continues with a roller mill that en-
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heavy clay
sures a particle size without neither crusts nor aggregates. And finally the clay, perfectly conditioned, is processed by two extruders Magna 675 with vacuum chamber, specially designed to work with stiff extrusion beyond 30 bar. Direct setting consists of using the same kiln cars for transporting the raw or green bricks from the extruder to the dryer and after that to the kiln, without any loading and unloading in between. It is a process used in several installations as it allows low investment in loading and unloading mechanisms, it reduces overall maintenance at the plant, optimizes the production process and it permits continuous and simultaneous production processes. VerdĂŠs has decades of experience in the supply of machines and solutions for brick plants that perform direct setting on kiln cars. At Hap Keeâ&#x20AC;&#x2122;s plant this system is designed for loading bricks produced with clays with low drying contraction, high mechanical strength and the option to extrude with little humidity under high-pressure. Something that can only be performed by extruders specially designed and prepared to work with beyond 30 bar, as both VerdĂŠs Magna and Magnabloc extruders are. 5
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Sacmi Continua+® is the latest technology developed by Sacmi for large size tiles production; the production line is composed of a metallic conveyor belt wherein powders can be deposited by many feeding devices and “continuously” compacted at high specific pressure, as required for porcellanato tiles. It is undoubtedly a revolutionary technology as ceramic slabs are formed without a traditional press, thus overcoming the concept of tile size related to a specific die. Looking at Continua+ line in production, its simplicity and the huge advantages with respect to the alternative solutions present in the market are immediately evident.
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Continua+® grants utmost flexibility of size and thickness and the highest productivity. Finished product width ranges from 1000 to 1600 mm, thanks to easy and fast setting of the line (rapid change in 20 minutes) and final length can be chosen and fixed just changing the green cutting position of the pressed material (typical values: 1200, 2400, 3000, and 3200 mm). There is the possibility of further green cutting to smaller sizes down to a minimum of 400 mm tiles (i.e: 600x1200, 600x600, 800x800, 800x240, 1500x1500, 750x1500, 750x750, …). Variable thicknesses range from 3 to 20 mm, with rapid setting adjustment (30 minutes).
By setting the maximum width of forming (1600 mm), a single line can produce up to 14.000 m2/day! Continua+® offers specific costs reduction and lower environmental impact. The line does not require any groundwork (foundations); vibrations and noise are absent; installed power is less than 50 kW as the electrical specific consumption is just 0,06 kWh/m2; scraps originated by green cutting are lower than 3%. Man-power costs are also reduced. Continua+® grants the widest possibility for aesthetic designing of finished products, thanks to: • Whole thickness and mul-
ti-layer powder decoration, • Dry digital decoration with coloured powders, grains, flakes and glazes, • Outstanding finishing of the surface pressed by upper steel belt, • 7500 mm long continuous structured upper belt for surface texturing, • Perfect integration with following decoration machines, with the advantages of multi-dimensional personalization with the SACMI Deep Digital line, that digitally generates all the information for the decoration processes. On-surface images are coordinated automatically, resulting in the first digital slab with a profoundly natural look.
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