THE FUTURE OF CERAMICS
28.9.2020 - 2.10.2020 Rimini Exhibition Centre – Italy
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TILE EDIZIONI S.r.l. Via Fossa Buracchione, 84 - 41126 Baggiovara (MO) - Italy Tel. +39 059 512103 - Fax +39 059 512157 - info@tiledizioni.it Editor Paola Giacomini
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Date of going to press: 20/02/2020 Promoted by
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contents
Year 30 Supplement to no. 135 January/March 2020 Bimonthly Review
Cover picture by: Giancarlo Pradelli
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Editorial 6
Paola Giacomini
Welcome to Indian Ceramics Asia 2020!
Hkkjrh; fljsfeDl ,f'k;k 2020 esa Lokxr gS!
World News
16 Interview
Kajaria Ceramics records another growth year
Milena Bernardi
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Somany Ceramics, 50 years as an Indian market leader
Paola Giacomini
24 Economics
The Indian sanitaryware industry
Milena Bernardi
lksekuh fljsfeDl, Hkkjrh; cktkj ds usrk ds :i esa 50 lky Hkkjrh; lSfuVSjhos;j m|ksx
SPECIAL FEATURE: “THE FUTURE OF CERAMICS”
30 34
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36 THE FUTURE CERAMICS 40 OF SUMMIT 2019 International Business Forum
44 THE FUTURE CERAMICS OF SUMMIT 2019
The future of ceramics summit 2019
fljsfeDl f'k[kj lEesyu 2019 dk Hkfo";
Growth forecast for the Indian tile industry
Prem Narayan Trivedi
Hkkjrh; Vkby m|ksx ds fy, o`f) dk vuqeku Mariner, an example of smart industry
System Ceramics
eSjhusj] çkbe dk ç;ksx dj jgs m|ksxksa ds lg;ksx dk ,d mnkgj.k The path towards plant digitalisation
Paola Gatti
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The digital line and logistic 4.0 from BMR
Marco Sichi
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The digital factory by LB: improving the efficiency of the human-machine interface
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Industry 4.0 Logistic Plant Supervisors
International Business Forum
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60 62
64 Technology 68
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Giuseppe Cavani, Stefano Puccini Stefano Cudicio
m|ksx 4-0 y‚ftfLVDl IykaV lqijokbtlZ – pyu] vR;k/kqfud vkSj –f"Vdks.k Collaborative full-digital is the future
System Ceramics
Production flexibility and consistent quality
Sergio Marcaccioli
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mRiknu dk yphykiu vkSj fujarj xq.koÙkk Sacmi Deep Digital Line: synchronisation of the digital process Davide Medici
lSdeh Mhi fMftVy ykbu : fMftVy ltkoV çfØ;k dk lkeatL; Focus on new ceramic trends at TILE&STYLE
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Products
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editorial by Paola Giacomini, Editor - p.giacomini@tiledizioni.it
Welcome to Indian Ceramics Asia 2020! India, the world’s second largest tile producer with volumes over 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 2020 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 2020 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. Indian Ceramics Asia 2020 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 Group, Appel, BMR, Bongioanni, Breton, Cami, ICF Welko, ICRA, Inter Ser, LB, Luna Abrasivi, Mectiles, Sacmi, Smac, System, Tecnoferrari, representing the ceramic machinery industry sector; Colorobbia, Inco, 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 Esmalglass-Itaca, Ferro, Fritta, Imerys, Kaolin, Sibelco, Torrecid and Vidres, and as well as the heavy clay machinery suppliers Ar-San, Beralmar, De Boer, Lingl.
WE HOPE YOU ENJOY INDIAN CERAMICS ASIA!
www.CeramicWorldWeb.it
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dtkfj;k fljsfeDl ds fy, o`f) okyk ,d vkSj lky Kajaria Ceramics records another growth year 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 2019 with 9% growth in revenue to 378.7 million euros (29.5 billion rupees), following the previous year’s 6% upturn. It also posted double-digit growth in sales volumes, up by 12% from 72 million sq.m to more than 80 million sq.m. This contrasted with the lacklustre overall performance of the construction industry and ceramic sector in India. We spoke to the group’s chairman Ashok Kajaria. CWR: How did ceramic tile demand evolve in India during 2018 following the previous year’s slowdown? A. KAJARIA: The fiscal year to 31 March 2018 saw lots of regulatory transformations such as implementation of GST (Goods and Services Tax), RERA, E-way bill, invoice matching etc. to create a level playing field and healthy business environment. Currently, the economy is still in the process of digesting and incorporating the above changes. The dampened consumer sentiments in the real estate sector coupled with piling projects and low credit availability with the builders posed a challenging FY2019 for the building material sector, which in turn impacted the Indian
GresTough by Kajaria
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Ultima by Kajaria
interview
Talking to... Ashok Kajaria here with his sons Chetan (right) and Rishi (left)
ceramic sector. CWR: The Indian ceramic industry has reacted to the slowdown in domestic demand by further boosting exports. A. KAJARIA: Indian tile manufacturers have become highly competitive on all fronts compared to international players, whether it is technology, cost, design, etc. As a result, India is today emerging as a strong exporter of ceramic tiles. CWR: What are your forecasts for the current year? A. KAJARIA: Going forward we believe that we will see better days in the near term. The Indian government has taken important steps to create a level playing field between the organised players and the informal sector. In March 2019, for example, the National Green Tribunal (NGT) ordered all ceramic units that operate on coal gasifiers in Morbi, Gujarat to switch to gas. The improved compliance of unorganised players with the GST regime is also likely to accelerate formalization in the sector. These changes will help to narrow the price gap between organised and unorganised players and will provide an impetus to national brands to increase their share of the sectoral pie. CWR: How has Kajaria Ceramics succeeded in outperforming the rest of the sector?
Duratech by Kajaria
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interview A. KAJARIA: Despite the flattish industry growth in FY2019, we performed better than the previous year with revenue growth of 9% and volume growth of 12% YoY. Our growth was mainly driven by market share gain due to our continued focus on branding and the addition of more new exclusive showrooms. Also, in spite of tight liquidity scenario, we tightened our working capital and strengthened our balance sheet. In FY2020, we are again expecting volume growth of 12-13% on the back of market share gain. CWR: In the meantime you are continuing to pursue your capacity expansion programme in Andra Pradesh, is that correct? A. KAJARIA: Yes, we have set up a 5 million sq.m capacity of GVT (glazed vitrified tiles) in Andhra Pradesh, entrenching our presence deeper in the growing South India market. The project was delayed by few months and was commissioned in September 2019. CWR: What are your main new product launches this year? A. KAJARIA: At Kajaria, we love to innovate and take things to the next level. In the glazed porcelain tile segment, we launched larger format tiles (100x200 cm and 40x120 cm), while in the polished porcelain tile segment we introduced the 1000x1000 mm and 800x1600 mm sizes in multiple designs and finishes. We have focused on large format tiles, which produce better capacity utilisation and realisation. In the ceramic tile segment, we have added the new 60x120 cm format in the Grestough range, as it is the most desired tile size in the market. The new range adds elegance and suits the diverse aesthetic preferences of consumers, and is getting a healthy response from dealers. CWR: How is Kajaria Ceramics performing in the sanitaryware sector? A. KAJARIA: The division registered a revenue growth of 33% in 2018-2019 over the previous year. This growth was a result of an increase in sales volume consequent to focused efforts on branding and product awareness. New designs and value-added variants also generated interesting volumes. In September 2019 we further expanded our capacity in sanitaryware from 600,000 pieces to 750,000 pieces per annum. Having established a meaningful presence in the bathroom fitting space, we are working towards making this division an important business contributor. This transformation will be driven by growing volumes and increasing product value. CWR: What tools do you use to leverage your branding strategy? A. KAJARIA: Close contact with consumers is essential for strengthening brand awareness, for which purpose we are leveraging social, print and electronic media and also increasing the proportion of exclusive showrooms in our distribution network even as we continue to entrench our presence in the Indian landmass. 5
Kajaria Ceramics in figures As of 31 March 2019, Kajaria Ceramics had a tile production capacity of 68 million sq.m/year, consisting of 41.3% ceramic tiles (28.1 million sq.m produced in 2 factories in Rajasthan and Andhra Pradesh), 32.9% polished vitrified tiles (22.4 million sq.m produced in 3 factories in Gujarat and Rajasthan) and 25.7% glazed vitrified tiles (17.5 million sq.m produced in 2 facilities in Rajasthan and Uttar Pradesh). The company’s sales volume was 80.30 million sq.m, out of which 65.63 million sq.m was from its own plants and 14.68 million sq.m produced through outsourcing.
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lksekuh fljsfeDl, eDl, Hkkjrh; cktkj ds usrk ds :i esa 50 lky Somany Ceramics, 50 years as an Indian market leader Paola Giacomini - p.giacomini@tiledizioni.it
Founded in 1969 by Shri H. L. Somany, Somany Ceramics Limited is India’s second largest tile manufacturer. The company has its headquarters in Noida (Uttar Pradesh) and has a production capacity of 62 million sq.m/year at the two manufacturing units in Kadi (Gujarat) and Kassar (Haryana) and a further seven subsidiary and associate plants and arrangements with other manufacturers. Somany Ceramics also operates in the sanitaryware and bathroom accessories sector and has focused on innovation and technology to develop a complete range of home décor products, including ceramic tiles, polished and glazed vitrified tiles, tile laying solutions and bathroom fittings. Over the years, the brand has established itself not only in the Indian market but also overseas with a presence in 65 countries, particularly Africa, the Middle East, the United Kingdom and Russia. To discuss the company’s current situation and future prospects, we met Managing Director Abhishek Somany and International Business Head Amit Bhatnagar. CWR: The Indian ceramic market has slowed in the last two years. How has your group performed and what are your forecasts for the short term? ABHISHEK SOMANY: In the financial year ending 31 March
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interview
Talking to, from left... Abhishek Somany and Amit Bhatnagar
2019, revenue remained virtually stable at 2017-2018 levels (17 billion rupees, about 220 million Euros). Despite this, we expect to return to CAGR of 12-13% over the next 3-4 years. The big picture is that we want to become more profitable. Along with revenue growth, we also want to increase our margins by 300400 basis points, which we plan to achieve through capacity expansion for glazed vitrified tiles (up to 30%) and a greater retail footprint (5%). CWR: Do you think building activity is likely to recover in the short term? A. SOMANY: Yes, I think so. The process of urbanization in tier-2 and tier-3 cities (those with a million inhabitants or less) is growing rapidly and it is here that we are concentrating our expansion projects. At the same time the government is continuing its various initiatives in the field of affordable housing, including the project “A house for everybody for 2022�. Moreover, building renovation is also increasing in step with the improvements in living standards of large sections of the population. CWR: How is your distribution activity organised? A. SOMANY: We have more than 12,000 dealers and over 15,000 touch points across the country, including 350 franchise managed showrooms (Somany Grande, Somany Studios and Somany Exclusive stores) which display a wide range of our tile, bathware and sanitaryware solutions. We also have 20 state-of-theart experience centres located in the largest cities. Over the years Somany has established itself as a formidable player in the industry. Our legacy of 50 years of history based on ethical values and transparency has helped us to build strong ties with our trade partners and suppliers. Along with our excellent brand reputation and robust marketing strategy, we offer an extensive portfolio of products and services capable of catering for every need and every price segment. As a result, consumers are likely to choose our products when they visit a showroom. CWR: Who are your target customers? A. SOMANY: As I was saying, our collections cover all product segments, from the basic/classic range priced at US $3.5 per square metre through to premium products costing US $20/ sq.m, such as the Precious series of tiles in the Luxury collection. This allows us to cater both for price-conscious consumers and for higher earners. In any case there are huge swathes of the population looking for value-added premium products driven by features such as a huge range of designs, ease of installation and low maintenance. CWR: What are the latest product trends in India? A. SOMANY: For years, tile was known as the affordable alter-
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interview native to natural stone, a flooring staple largely restricted to kitchens and bathrooms. But over the last decade or so, tiles have totally taken off and have entered all living spaces in the home, beautifully replicating natural finishes and even expanding into new textures, larger formats and varied shapes. At Somany we take pride in leading the trends in the Indian market, for example by developing larger tile sizes with digital designs that combine aesthetic value with durability. These include the Max series of glazed vitrified tiles under the Duragres brand, which come in a 1200x2400 mm size to create a seamless look with minimal joints. CWR: At an industrial level, what is your approach to technological innovation and environmental sustainability? A. SOMANY: We are working relentlessly to enhance the efficiency and environmental sustainability of our products and the corresponding industrial processes, as well as worker health and safety. The locations of the manufacturing units are certified to ISO 14001 and OHSAS 18001 standards. Our environmental policy guides all manufacturing operations in an effort to reduce waste and create green infrastructure with low energy consumption. As for product and process innovation, in 2007 we introduced the revolutionary patented VC Shield technology for anti-scratch, antibacterial and non-slip treatment of ceramic surfaces. As I was saying, we have adopted digital decoration technology which has enormously expanded creative potential and allows for the production of marble and wood effect products which are proving very popular in the market, such as Duragres Tesoro, Duragres Slim 8mm and Goodwood & Stone 16. CWR: Let’s talk about your presence in international markets. AMIT BHATNAGAR: Somany is growing steadily in foreign markets, leveraging product quality (in accordance with international standards EN, ISO, CE and IAPMO) and capacity for innovation. Unlike the unorganised ceramic segment, Somany’s core strategy is always to sell as a brand. The same values that have driven our growth in the Indian market have been passed on to our international clientele, allowing us to establish solid relationships. Amongst the key competitive advantages that have contributed to our growth abroad are our large portfolio and product mix, including sanitaryware and bathware, competitive pricing, effective after-sale support and strategic stock points close to ports. Somany is a force to reckon with in the international market, we have been growing steadily in international business with wheels to support as brand, quality, consistency and product innovation. Today we have a brand presence in 65 countries worldwide and an export share of 4-5% of total turnover, and still increasing. The way our international business is growing we should certainly double sales in the next 5 years. We believe this is a good time to take a leap and go local in key international markets. 5
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economics
Hkkjrh; lSfuVSjhos;j m|ksx The Indian sanitaryware industry Milena Bernardi - m.bernardi@tiledizioni.it
With an installed capacity already in excess of 40 million pieces/year, India is the world’s second largest sanitaryware producer after China. Following the example of the ceramic tile sector, the rapid growth in sanitaryware production has been concentrated in the province of Gujarat, which in just a few years has reached a production capacity of around 30 million pieces/year, around 75% of the country’s entire production. However, India’s two largest sanitaryware producers, Parryware India and Hindustan Sanitaryware Industries Limited (HSIL), operate outside the province. Parryware India is the Indian subsidiary of TAB. 1 - INDIAN MAIN SANITARYWARE MANUFACTURERS Roca, the world’s largest sanitaryware producer, which acquired complete ownership Installed capacity in 2011. The company has 4 production facilCompany Location (pcs/year) ities with a total capacity of 6.3 million pieces/year, including 800,000 pieces at the fa1 Parryware India (Roca Group) 4 plants in Ranipet, Perundurai, Dewas, Alwar 6,300,000 cility in Rapinet (province of Tamil Nadu), 2.4 HSIL Hindustan Sanitaryware 2 2 plants in Bibinagar and Bhahdurgarh 3,800,000 million pieces in Perundurai (Tamil Nadu), Industries Limited another 2.4 million pieces in Dewas (Madhya 3 Cera Sanitary Ware Mehsana - Gujarat 3,300,000 Pradesh) and 700,000 pieces in Alwar (Rajast4 Jaquar India Bhachau - Gujarat 1,800,000 han). 5 Anchor Sanitaryware Thangadh - Gujarat 1,800,000 Hindustan Sanitaryware Industries Limit6 Simpolo Vitrified Pvt Limited Morbi - Gujarat 1,600,000 ed (HSIL) has a declared annual capacity of 7 Kohler India Jhagadia Gujarat 1,500,000 3.8 million pieces installed in its two facilities 8 Bell Sanitarywares Morbi - Gujarat 1,200,000 in Bibinagar (Telengana province) and Bhahdurgarh (Haryana) and in 2018 produced 3.3 9 Rak Ceramics India Samalkot (Andhra Pradesh) 1,100,000 million pieces. 10 Somany Morbi - Gujarat 1,100,000 The UAE-based multinational RAK Ceram11 Eros SanitarywarePvt Ltd Morbi - Gujarat 1,100,000 ics has chosen the city of Samalkot in the 12 New Anchor Ceramics Thangadh - Gujarat 900,000 Andhra Pradesh province for its tile and san13 Sunrise Pottery Works Thangadh Gujarat 900,000 itaryware plants (capacities of 30,000 sq.m/ 14 Ariston Ceramics Thangadh - Gujarat 800,000 day and 3,000 pieces/day, respectively). ❱ Production in Gujarat Most of India’s other sanitaryware producers are located in Gujarat, one of the country’s westernmost provinces with a population of 68 million. Cera Sanitaryware, the third largest sanitaryware producer in India with an installed capacity of 3.3 million pieces of mid-range and premium products, has its manufacturing unit in Mehsana.
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Confi SanitarywarePvt Ltd
Morbi - Gujarat
800,000
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Coto Bathware
Morbi - Gujarat
800,000
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Dev Doot SanitarywaresPvt Ltd
Morbi - Gujarat
800,000
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Lalpar Potteries
Morbi - Gujarat
800,000
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Paradise Pottery
Thangadh - Gujarat
800,000
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Kajaria
Morbi - Gujarat
750,000
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Aqutop Ceramics
Morbi - Gujarat
700,000
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Delphi Ceramics
Morbi - Gujarat
700,000
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Toto India
Halol - Gujarat
500,000
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Duravit India
Tarapur - Gujarat
500,000
economics
The Jaquar’s manufacturing plant is located in Bhachau, in the Kutch district. Founded in 1960, the Jaquar Group is active in the bathroom sector with the production of fixtures, faucets and other accessories. It entered the ceramic sanitaryware sector in May 2017 by acquiring Euro Ceramics with an investment of around 15.5 million US Dollars. The yearly production capacity of the plant was increased in 2018 from 1.2 to 1.8 million pieces of medium to high-end range. The Kohler India facility (1.5 million pieces/year) is located in Jhagadia, where in 2018 it opened a brand new Tech Centre to act as an incubator for ideas, a showcase of the latest product designs and a training centre for the sanitaryware production process. The Indian subsidiary of German company Duravit is also located in Gujarat. Duravit India started up its first factory in 2010 in Tarapur, where it produces around 200,000 large ceramic pieces per year with a planned annual capacity that may reach 500,000 pieces. Another sanitaryware giant that has chosen Gujarat for its Indian operations is the Japanese group Toto. Its ultra-modern manufacturing plant in Halol was started up in 2014 and was built with an investment of 6 billion yen (around 49 million euros), the largest investment made by the group in South Asia. The Toto India plant is initially designed to produce 500,000 sanitaryware units a year with the possibility of further expansion. Toto India manufactures products for both the domestic and overseas markets. � The Morbi and Thangadh clusters Two of the most dynamic sanitaryware production areas in Gujarat are the ceramic clusters of Morbi and Thangadh, two
Showroom Somany
Showroom Parryware India
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economics
small towns located about 100 km apart and about 200 km from the provincial capital of Gandhi Nagar. Key factors behind their industrial development include their proximity to highways, seaports and airports, the availability of local clay in Gujarat and in the neighbouring province Rajasthan, and the easy availability of manual and skilled labour. These advantages are enhanced by the typical characteristics of industrial clusters, which facilitate the sharing of resources, knowledge, infrastructure, logistics and suppliers, creating highly efficient and cost-effective networks and production hubs. The sanitaryware producers located in Morbi and Thangadh have a good and rapidly improving level of technology thanks to the customer support provided by numerous offices and representatives of European machinery manufacturers, especially in Morbi. Many local company owners regularly attend international ceramic fairs and are well informed about the latest technology. The start-up of sanitaryware production in the Morbi area about ten years ago was also facilitated by the presence of a well-established tile manufacturing cluster, and in many cases it was the tile producers themselves who began producing sanitaryware. According to data from Morbi Ceramic Association, there are currently 76 sanitaryware manufacturing units in operation with an installed capacity of between 100,000 and 400,000 pieces/year. Total annual production stands at around 9 million units of finished sanitaryware products per year aimed at the mid range of the market. Somany Ceramics’ joint venture company (1.15 million pieces/year) is based in Morbi, as well as Kajaria Ceramics’ one, whose production capacity was increased to 750,000 pieces/ year in October 2019. The Thangadh cluster dates back to the 1990s and now consists of about 220 small and mid-scale companies that employ a large portion of the town’s 43,000 inhabitants. Total annual output is estimated in the range of 14-16 million pieces of sanitaryware, 40% of which is produced by the largest 15 companies. Products manufactured here are sold in the lower end of the market and are mainly used in government projects, in rural areas of the country or exported to Africa. 5
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
2 DAYS 14 HOURS 6 ROUND 40 SPEAKERS ITALIAN&INTERNATIONAL 500 GUESTS
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VIDEO INTERVIEWS
TABLES
VIDEO-INTERVIEWS AND ABSTRACTS
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Prem Narayan Trivedi
GROWTH FORECAST FOR THE INDIAN TILE INDUSTRY “India’s GDP expansion slowed to a six-year low of 5% in the quarter to 30 June 2019, prompting a downward revision of the year’s GDP growth forecasts to 6.1%. The government has introduced a slew of measures to revive economic growth, including a massive cut in corporate taxes, easing credit, recapitalising banks, speeding up repayments and supporting exports. As for the ceramic industry, the economic slowdown has adversely impacted domestic tile demand [750 million sq.m in 2018, -1.3%, Editor], but there are many factors that are already fuelling a recovery in consumption. The most significant are the government’s investments in infrastructures and residential building, including a project to develop 100 smart cities as well as the “Clean India”, “Housing for all by 2022” and “Rural Housing Fund” programmes. Further factors that will help push up demand for ceramic tiles include the new real estate regulation and development act (RERA), the growth in urbanisation, the rise in disposable income of households and a favourable demographic profile. Moreover, the high growth potential of the domestic market is also attributable to the fact that tiles still account for a small share of the flooring market, with per capita consumption standing at just 0.6 sq.m/year. Indian tile production [1.145 billion sq.m in 2018, +6%, Editor] will continue to grow at an estimated rate of +8% in 2019 and +13% in 2020. The most organised companies will receive a boost from the tax reform aimed at combating unfair competition (Goods & Service Tax and e-waybill regulations) and from the introduction of antidumping duties on Chinese tile imports. On the other hand, India’s manufacturing operations will be hindered by the volatility in the price of natural gas, which accounts for between 15% and 30% of production costs, and ever higher transportation costs. Exports are also expected to continue the upward trend that has enabled India to double its volumes in 4
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Prem Narayan Trivedi Indian Council of Ceramic Tiles & Sanitaryware
years [274 million sq.m in 2018, +20%, Editor] and become the world’s fourth largest exporter country (compared to eleventh in 2013) with exports amounting to 24% of its total output. This growth has partly been driven by the ability to win market shares previously held by China in countries and regions that introduced antidumping duties on Chinese ceramic tiles (EU, Brazil, Taiwan, Chile, Vietnam and South Korea, amongst others). This in turn has been made possible by the continuous investments in technology made in the last five years in the Morbi district with the aim of modernising factories, increasing production capacity and improving product quality, including that of the most innovative products such as large slabs, while maintaining the lowest production costs of any exporter country. While exports may continue to grow and expand into new geographical markets, they face the same obstacles and challenges that affect the Indian ceramic industry as a whole. The tariff barriers against China that have buoyed Indian exports in some markets will effectively exclude Indian tiles from the Gulf states (Bahrein, Kuwait, Oman, Qatar, Saudi Arabia and UAE). In November, the Cooperation Council for the Arab States of the Gulf (CCASG) expressed its support for the introduction of antidumping duties on tile imports from India, China and Spain, choosing to impose the highest tariff rate (42.9%) on Indian tiles compared to the 24% applied to Chinese products. Given that almost all Indian exports originate from the Morbi district, it is highly likely that average export prices (currently amongst the lowest in the world at 3 euros/sq.m) will tend to increase. Over the next 3-5 years, the less organised companies in this district will see a sharp rise in production costs as they are forced to comply with more stringent anti-pollution and workplace regulations and also face costs deriving from the tax reform. The business environment in the Morbi district has gradually improved in recent years, partly through the creation of joint ventures between local small and medium-sized unorganised companies and the larger, well-established Indian ceramic groups. Nonetheless, it is calculated that around half of India’s total tile production is attributable to small family-run businesses that were attracted to the sector by the relatively low barriers to entry (low fixed capital investment and availability of raw materials, technology and low-cost labo-ur)”. ✕
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by System Ceramics
MARINER, AN EXAMPLE OF COLLABORATIVE INDUSTRY USING PRIME The need for customised production, smaller batch sizes and even the ability to process a single product are the latest challenges facing the manufacturing industry. Complete digitalisation of processes, the use of shared resources and efficient data management are key elements for sustainable development of a new industrial model centred on flexibility and sustainability. Based in Roteglia (Reggio Emilia) in the Italian ceramic district, Ceramiche Mariner has promoted this new industrial model by creating the first fully digitalised ceramic tile production facility. This digital manufacturing concept was put into practice using the Prime software platform developed by System Ceramics. Prime manages the entire production flow from raw materials processing through to the creation of the finished product by means of advanced IT systems capable of monitoring the entire process using a single latest-generation graphic interface and 3D technologies. This is the age of decentralised intelligence in which new ceramic production standards are being defined. To develop Prime, System Ceramics adopted edge computing, an approach in which IT resources are positioned close to the data source to form a collaborative ecosystem where machines learn how to interpret and anticipate the relationships between processes from humans. This allows for solutions that would previously have been unimaginable. Ceramiche Mariner is a perfect example of horizontal integration and Digital Collaborative Industry. The new facility represents the evolution towards an open architecture and an archetype of communication and collaboration that goes beyond the confines of the factory itself. The choice of using Prime reflects a new human-centred manufacturing concept in which the information generated inside the factory stands at the heart of the industry of the future. This information must be managed and transformed through human intervention from simple data to useful knowledge for improving the process and the value chain. “With Prime it was love at first sight,” says Giulia Cat- Giulia Catti Ceramiche Mariner ti, owner of Ceramiche Mariner. “The 3D interface is
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Cristian Mattioli System Ceramics (Fiorano, Italy)
simple and clear to use and makes anyone in the company who uses it feel perfectly at ease. It’s a tool that we all use, from the line operator and department manager through to the technical director and production manager, from laboratory technicians to the quality department, and even top management. When I saw Prime in operation, even before we adopted it, I was struck by the visual immediacy and high degree of fidelity with which the entire production plant was represented. A further benefit was the fact that we could adapt the platform to our needs, like a tailor-made suit. Today, we use Prime for all aspects of factory management. Regardless of where I am in the world, I can show my customers the state of production in real time and display a series of information such as yields, tones, problems encountered and defects. It’s an authentic digital twin of the factory. The response from my customers has been extraordinary.” “When we began building the factory in 2016, we had in mind the principles on which it needed to be built, namely flexibility, performance, quality and interconnection,” explains Giulia Catti. “With Prime, we fully achieved this goal. Just think that in October alone we produced over 130 different items! People working in our sector will know just how difficult it is to manage such a wide range of products. This is just one of the many demonstrations of the high levels of flexibility and performance offered by Prime, which processes data in order to provide the information we need to make strategically important decisions. In some departments, product changeover is done with a click, something that would have been unthinkable just a few years ago. “Another crucial aspect is the potential for analysing each individual item. This is fundamental for determining the precise production costs, even taking account of water and energy consumption, so it is clearly of great commercial value. “System Ceramics has created a powerful system for improving industrial efficiency that involves interconnecting all departments, from the entry of the raw materials to pallet shipment. But we are only at the beginning, Prime still has much to offer,” concludes the entrepreneur. “We are proud of what we have achieved so far in our local area, with our own workforce and with a leading technological partner like System Ceramics. Mariner represents a state-of-the-art industrial project, a true Industry 4.0 and 100% digitalised manufacturing operation that testifies to a forward-looking business vision and the search for a new way of doing business.”
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
This innovative approach marks a real step forward for System Ceramics, which has transformed its role from a manufacturer of plants and machines for the ceramic industry to become a supplier of cutting-edge services. The organisational structure and the business model are redesigned in accordance with the principles of mechatronics, which has allied itself successfully with digital transformation. As for hardware, System Ceramics is focusing strongly on robotic automation to allow settings to be changed entirely by software and without operator intervention. For several years, the company has been engaged in a process of digitalisation aimed at offering the market innovative smart manufacturing solutions which until recently were highly complex. Computerisation of production systems, automatic reconfiguration of machines and full traceability have now become reality for System Ceramics, bringing the company success and recognition amongst international professionals. System Ceramics has played a pioneering role in this epochal turning point for the ceramic industry, building on its more than 50 years’ experience in developing innovative processes capable of creating new standards. Prime reflects a new manufacturing concept in which humans and machines interact through the software platform, bringing to completion one of the cornerstones of the new industrial paradigm: that of Smart Industry, meant as Digital Collaborative Industry. It is a manufacturing model, where the Human-Machine interface is essential because times change, work changes, but human knowledge and intellectual creativity remain fundamental for conquering still unexplored territory. ✕
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Paola Gatti
THE PATH TOWARDS PLANT DIGITALISATION The process of digitalising an industrial plant offers plenty of potential but at the same time can be challenging and highly complex. What can be done to limit the risks and what are the key factors for success? First of all, it is important to remember that data are only valuable to the extent that they can be translated into useful information for users. Collecting a large quantity of data without a precise objective and/or without adopting the appropriate mechanisms for selection and interpretation overburdens the systems without bringing any real added value. A second key aspect is to remember that technology alone is not sufficient. Processes, people and technology must all cooperate synergistically for a digitalisation process to achieve its real potential. This means it is important not to neglect training, engagement and the promotion of a change-oriented culture. It is equally important to realise that largescale digitalisation projects require re-engineering of production processes, otherwise there is a very real risk of automating wastage. For these reasons, a digital manufacturing project is often successful when following a stepwise approach. This means breaking the project down into simpler elements and developing the product over time in a process
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Paola Gatti, SACMI (Imola, Italy)
of collaboration and mutual adaptation between customer and supplier. The HERE platform, SACMI’s solution for digital manufacturing projects, fully meets these needs. This modular software platform becomes the link between production plant and ERP (Enterprise Resource Planning), between the world of operations and that of information technology. For example, it is typically used in production management. Starting out from the production orders sent by the ERP system, the system tracks each production batch during the various processing stages, automates a large number of operational and logistics procedures and provides the ERP system with information on warehoused products. It is also capable of automatically analysing data, calculating performance indicators and managing maintenance activities. This is all done using web technologies and usability criteria to ensure ease of use of the software, even on mobile devices. These types of software improve plant performance by focusing on several aspects, including: • rapid problem solving thanks to automatic data collection, monitoring and processing of real-time information; • automation of production and logistic procedures, reducing operators’ workloads and the risk of error;
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
• integration of production-related information flows, both within the production department and between the data management software present in the plant (ERP, WMS – Warehouse Management System, customised systems), thereby reducing the time and resources necessary for the transfer of information. Overall, these elements bring economic benefits and a real competitive advantage for the company. There are many possible practical applications. For example, in one case it was necessary to solve connectivity issues on a number of outdated sorting lines. An ad hoc solution developed by Sacmi according to the real needs of the customer was used to create a semiautomatic procedure for transferring information on product pallets to the ERP, just as for the other lines of the system. This solution was achieved in collaboration with the customer for a very low cost, especially compared with the potential cost of upgrading or replacing the lines in question. In another case, the customer wanted to optimise logistics flows. The chosen solution was to introduce automatic management of operational scheduling and the phases of supplying materials to the processing lines, including picking and packaging. Finally, it should be remembered that this platform is evolving constantly, largely with the aim of integrating and interfacing with other typical Smart Factory technologies such as innovative plant solutions (e.g. tracking, full digital), machine learning and analytics algorithms, digital twin and computer vision techniques. ✕
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SACMI: experience and complete solutions for your product
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ENDLESS INNOVATION SINCE 1919
THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Marco Sichi
THE DIGITAL LINE AND LOGISTIC 4.0
FROM BMR
The BMR digital line is a new concept in the ceramic endof-line stage. Dynamic, digital, sustainable and efficient are the keywords of a technology that has established itself in the sector over the years and is now an integral part of the production plant. The increase in demand for product customisation, the growing complexity and ever shorter life cycle of products, and the need for small batches coupled with the uncertainty of an unstable economy are all factors that have driven development strategies towards maximising line flexibility while maintaining and if possible improving production efficiency and quality. Whereas until recently the finishing, cutting and squaring processes were outsourced, they are now carried out internally by the ceramic companies themselves. In the space of just a few years, these operations have seen advances that have completely transformed the end-of-line stage. Some technologies, such as squaring and cutting, have completed the transition from wet to dry processing in just 4 years. This exclusive BMR technology has transformed the process, optimising all aspects including plant engineering, production, working environment, costs and finished product quality. The cutting and squaring processes have also undergone upgrades dictated by the Industry 4.0 revolution. Digitalisation and automation are the keywords of the new Smart Factory and BMR has integrated cutting and squaring with a patented video camera system. The operator interface allows access to all sensitive process information with just a few clicks. This set-up brings numerous advantages: BMR digital line
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Marco Sichi, BMR (Scandiano, Italy)
• The system always ensures that the tools function in the best conditions, bringing significant savings in terms of the grinding wheels. • The size change operation is performed very rapidly and troubleshooting is instantaneous, guaranteeing an increase in productivity. • Quality is also improved: automation and control using video cameras ensures less chipping and breakage, less downtime, greater production continuity and less wastage of material during size changeover. • The machine is managed remotely: thanks to network connectivity, all operator interventions are performed outside the cabin (except for grinding wheel changing), including the creation and automatic loading of the removal cone (recipes). • The video camera system also allows the processing operations to be monitored constantly, resulting in the need for fewer interventions on the part of the operator who can therefore focus more on problem solving. • Finally, all information on grinding wheel wear, lifetime and efficiency is continuously recorded and saved. This ensures a high degree of control over production data, which can be used to produce customised reports. The lapping and treatment stages have also evolved in keeping with Industry 4.0 criteria as part of a systematic industrial approach characterised by simplicity and sharing, thereby guaranteeing efficiency and quality at all times. The use of automation on Leviga Plus, BMR’s flagship finishing technology which is also suitable for large slabs, allows Squadra Dry
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
Display of grinding wheel wear
the grinding wheel’s grit size to be saved on the touchscreen of each head and the data to be saved in customisable recipes. The belt speed, the forward-backward oscillation travel and speed, the grinding wheel grit size, the head pressure and the height of the abrasive can all be memorised. The machine is loaded automatically: after the machine has been turned on, the heads automatically descend when the first slab passes through. Then when the head is turned on, reduced pressure is applied for a pre-set time to allow the new abrasive to be run in after the tool change. Finally, greater flexibility is also achieved by the forward-backward oscillation, divided into 3 zones, each of which can be adjusted in terms of size, speed/acceleration and pressure. Lapping is concluded with the treatment stage, a process
Leviga Plus
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
in which SuperShine is the benchmark technology. SuperShine is a true dry polishing machine that uses natural silica and a thermomechanical process to increase the gloss level of the tile coming from the lapping process by 30 degrees or more. Equipped with 10 satellite heads and six tools, SuperShine applies the product and then carries out polishing with the first 7 heads, which also dose the product. Next come two free positions to allow the product to penetrate the tile, followed by the final 3 heads devoted to washing. The end result is a product with great aesthetic appeal that maintains the functional characteristics of porcelain stoneware. The BMR 4.0 finishing line is therefore a complete automated process that interconnects with the entire plant and brings the various operational functions together in synergy, resulting in full digitalisation of a high added-value manufacturing process. ✕
Teste STESURA e LUCIDATURA
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Composition of SuperShine line
Result of treatment with SuperShine
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Giuseppe Cavani, Stefano Puccini
THE DIGITAL FACTORY BY LB: IMPROVING THE EFFICIENCY OF THE HUMAN-MACHINE INTERFACE Whereas software system development has until now mainly concentrated on the IT side of automation, the focus is now shifting towards interconnections between IOT systems, the development of MES systems and structured data. In this architecture the system is interconnected transversally with all the production structures and vertically to different users: production, quality, materials, maintenance. In this scenario it is important to ensure that the various users receive the correct information in real time. LB has proactively developed its PLUS software platform solution, equipping it with new functions and coupling it with a STAR mobile system to further enhance the performance of the human-machine interface and thereby improve the efficiency and availability of machines and plants. Human-machine/plant interaction efficiency, data quality and availability times, intervention quality, reduced in intervention times and greater knowledge of use are all factors that contribute to improved efficiency and availability of the machine. Plus is defined as a platform because it is a modular software solution that serves the entire range of LB technologies. As well as automating process management, PLUS focuses
Plus Platform and STAR mobile System
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Stefano Puccini, LB
Giuseppe Cavani, LB (Fiorano, Italy)
on the real-time supply of structured data in a suitable format for consultation by a user wishing to improve the efficiency and availability of his plants and machines. The architecture consists of a decentralised system with distributed data collection. The data can be shared in the cloud and viewed on STAR mobile systems. The key elements of the PLUS software for the various LB technologies are: • effective information formatted for the user, • structured data aggregated efficiently for the production process, • speed of access to information and simplification of the user experience. The STAR (Superior Technology Augmented Reality) software for mobile systems is fully integrated into the PLUS software solution and serves to provide correct and precise data in real-time and improve direct interaction with the machine. STAR was developed to resolve the main issues behind the reduced efficiency and availability of systems. The application is able to optimise plant management by exploiting the advantages of 3D interaction and augmented reality. It allows for clear and immediate use of the technical and operating data of the machine or component undergoing analysis. It transmits precise real-time information on the machine’s technical data and process parameters. It increases operator know-how because the fact that the same information is received for the management and maintenance of the systems means that knowledge is distributed through the organisation. The functions of STAR are performed by a series of functional modules: • Information: clear and immediate consultation of information on the machine or individual component. • Technical documentation and video tutorials: machine tech-
Plus software platform
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nical documentation and maintenance and setup tutorials. • Real-time functional data: real-time display of operating parameters; the information is immediately available and filtered. • Intervention scheduling and reporting management: creation of maintenance activities with guided procedures; report of the interventions performed. • 3D diagnostics and alarm location: the alarm condition is displayed inside the machine or system’s 3D model. • Maintenance guides - Check list: graphic maintenance and control procedures based on check lists. • 3D spare parts selection: direct selection of spare parts by navigating within the component 3D drawing; bill of materials. One of the benefits of STAR software is that it clearly improves production efficiency thanks to optimised use of resources and ease of access to machine technical data, video tutorials, real-time process data, 3D maintenance guides and spare part selection from 3D drawings. STAR is also extremely simple to implement and use: complete information can be accessed in seconds simply by pointing at the machine with a smartphone camera or selecting the part from a 3D drawing. STAR also improves efficiency in achieving production goals thanks to organised and more efficient maintenance and consequently fewer process interruptions. Dynamic user interfaces that adapt to experience, augmented reality technologies and mobile solutions are all key aspects for improving the efficiency of interactions between humans and machines and plants and thereby improving the efficiency of the machine itself. LB’s goal is to invest in complex architectures that facilitate and allow for immediate use of information by users operating on LB technologies. ✕
Architecture of STAR system
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emi
THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Stefano Cudicio
INDUSTRY 4.0 LOGISTIC PLANT SUPERVISORS The Logistics Solutions division of Toyota Material Handling Italia has a highly qualified team specialising in the development and construction of cutting-edge integrated logistics systems. The division delivers a range of customisable hi-tech turnkey solutions for optimal management of the logistics system. Key strengths include enormous experience and know-how acquired over many years of operation in the sector and a constantly evolving Research & Development department that designs new technologies and their applications in the logistics sector. From our own perspective, we are seeing a number of trends relating to field technologies that are already being used within logistics systems and will be increasingly adopted in the future. These include smartwatches for communicating with operators and supervisors and goggles for use with human-machine interfaces based on augmented and virtual reality. We are seeing a lot of interest in operator and veLogistici Integratisystems 4.0: Stato dell’Arte Architettura hicle geolocation used by active safety and assist-TMHIT ed guide systems. Also worth noting is the imminent devel-
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ILOG
Stefano Cudicio (Toyota Material Handling Italia)
opment of long-range connectivity solutions, which may reach maturity as early as 2020. As for architectures, the market is showing growing interest in cloud and hybrid-cloud solutions, although they are not yet completely reliable. This reflects growing demand for “pay-per-use” type solutions implemented on on-premises servers. The client-server model is now recognised as best practice, with logics and databases on the server and presentations on the client. There is an increasingly strong focus on the Industry 4.0 model. With this in mind, the Toyota Material Handling vision is oriented towards a potential best-in-class architecture for the coming years. This consists of a “big data” type data bus capable of receiving and collecting data in an a priori unstructured and unpredictable format reflecting the heterogeneous nature of the sources, including IoT objects, legacy operational systems such as ERP/CRM/ WMS/MES and geolocation devices. It features an interface layer with standard public and documented protocols, on which third parties can create apps to be made available to users. Our solutions are based on a platform that already has these features and is constantly evolving towards this model. We have implemented a middleware software layer that enables us to use any field system regardless of its technology, making device operation abstract with respect to functional logics. The field signal decoding algorithms and their transformation into a normalized logical format are all wired within the layer, thereby allowingSistemi Logistici Integrati 4.0: Vision new devices to be added transparently to the application modules. The communication protocols are based on international standards, as required by the best practice of the Industry 4.0 model and by the Italian legislation for hyper-amortisation tax concessions. For example, this approach already enables us to guarantee product traceability from raw materials through to the finished product, from source batches to destination batches and vice versa and spanning intermediate production transformations, including semi-finished products shared by various finished products. It is an open and integrated ecosystem with regard to the collection and transformation of data into the information required to support decision-making by human and artificial intelligence. ✕ :
Osservatorio IoT IOT -–Politecnico di Milano Fonte:Source: Osservatorio Politecnico di Milano
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by System Ceramics
COLLABORATIVE FULL-DIGITAL IS THE FUTURE The future of digital decoration can be summed up in a simple question: What’s next? It is a question that combines the concept of a timeline with a keyword of the Basic programming language. “What’s next?” is the question we ask at a moment in time when the process of digital innovation in the field of decoration appears to have reached completion. Most production lines now use digital decoration machines, there is widespread knowledge of digital technology and printers, and analysts consider the digital printer market to be mature, placing the technology in the “late majority” phase of the Rogers innovation adoption curve. System Ceramics’ answer to this question is to complete the process of full digitalisation of the line, in other words to go beyond DOD digital printing to generate added value and bring enormous benefits. Because it’s one thing to focus on the adoption of a technology, quite another to consider the concept in its entirety. In other words, we must not confuse inkjet printing with the broader concept of digitalisation. In terms of infrastructure, System Ceramics has concentrated on the development of a new digital printer called Creadigit Infinity which represents the future of digital decoration for the ceramic sector. Infinity has unprecedented computing power provided by the new CoreXpress platform, the processing unit (one for each colour bar) that oversees all operations necessary to reproduce the image on the ceramic surface. It is a latest-generation processor with rapid and immediately available memory that brings a further significant increase in performance. Digital technology needs data, which often depend on the tile passing through the printer or along the line in general. The information is collected by various pieces of equipment, which use a dedicated network of sensors to supply the data rapidly to the part of the machine that performs the processing. The R&D department has further improved the machine’s performance to guarantee a high-speed real-time data flow to the printheads, even in the event of significant manipulation of the image during printing (such as management of tone uniformity, printhead joins, colourways, , deformation or addition of specific variable components for each tile). It is a well-known fact that high computational power is key to enabling digital technology to operate effectively and exhaustively.
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Paolo Casarini System Ceramics (Fiorano, Italy)
The innovative computing platform adopted on the Creadigit Infinity printing process is called CoreXpress. It is a latest-generation processor with rapid and immediately available memory that brings a further significant increase in performance. Digital technology needs data, which often depend on the tile passing through the printer or along the line in general. These data are collected by various pieces of equipment, which use a dedicated network of sensors to provide the information rapidly to the part of the machine that performs the processing. The future of ceramic decoration is collaborative digitalisation. Today every printing machine must complete a digital process in which each ink contributes to the end result, and with this in mind Creadigit Infinity can be fitted with 12 or more printing modules.
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However, System Ceramics has now turned its attention to a new collaborative digital printing concept in which the process is even more flexible and adaptable and is based on a modular printing infrastructure distributed along the same line. New-generation digital printing will be performed by a system of independent machines each equipped with their own set of inks positioned in sequence along the production line. This arrangement will allow for greater creative freedom but at the same time will require an adequate technological infrastructure. System Ceramics is already capable of installing collaborative full-digital lines. The equipment necessary for this new approach has been developed in-house and will consist of systems complete with software to further enhance creativity, resulting in a unique, high added value ceramic printing process. In keeping with its pioneering tradition, System Ceramics has completed a concrete example of full collaborative digitization of ceramic decoration and once again demonstrated its leadership role in creating real innovation in ceramic manufacturing. ✕
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Sergio Marcaccioli
PRODUCTION FLEXIBILITY AND CONSISTENT QUALITY Production trends in the ceramic sector are evolving constantly and growing ever more complex. Whereas in the past the ceramic tile industry was characterised by large production batches and mass deliveries, the situation today is very different with manufacturers making increasingly specific and ad hoc requests. Both now and in the immediate future, production processes must be able to meet requests for small batches (1500 m2) of extremely high quality products (95%) within very short timeframes. This means changing product type several times per day on a given production line, which creates greater difficulties in terms of set-up and error minimisation. The fact that ceramic is now used in the furnishing segment for products such as bathroom and kitchen countertops has further increased the required quality criteria and reduced the margin for error. In this scenario, glaze and colour producers play an increasingly strategic role for ceramic companies and a strong partnership between the two parties is the only valid solution. With this in mind, Sicer is not just a supplier but acts as a full-scale partner for its customers. Only by establishing close collaboration and teamwork is it possible to provide dedicated customised solutions that guarantee research, innovation and consistent quality. One example of the excellent results achieved through this process of continuous technological improvement is the development of new ceramic bodies and substrates. Rather than just simple structural bases, these materials now serve as a starting point for creating specific aesthetic effects (white, super-white and bleached bodies, coloured bodies, porcelain bodies, etc.). With its in-depth technological knowledge of the type of body and of the technical characteristics of the glazing line and kiln, Sicer is able to offer a customised package that the ceramic producer company can elaborate and personalise. One of the tile manufacturers’ key goals is to stand out and
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Sergio Marcaccioli, Sicer (Fiorano, Italy)
make themselves immediately recognisable in the market, which they can achieve by conducting research into material surfaces and delivering stress-free products with excellent chemical and physical characteristics and good levels of transparency in the case of polished materials. Sicer is able to measure and study these parameters thanks to the important investments in cutting-edge technological instrumentation it has made in recent years and its policy of expanding its team of laboratory staff with both experienced professionals and freshly graduated technicians. For ceramic glaze and colour producers, research results in a high degree of fragmentation of offerings and products, while the situation is made even more complex by the pressure of on-demand deliveries and the limited planning allowed by the market. In a scenario where it is no longer sufficient simply to supply compliant materials, it is clear that only real collaboration with customers can provide a basis for lasting and mutually beneficial relationships. The development of digital printing technologies has brought excellent results, including expanded colour gamut and depth, flexibility, application of multiple digital materials (glossy, matt, metallized), full-field and non-full-field digital glue, etc. Scope for adding decorative effects has been expanded, along with the increased consistency of application and consequently perceived value. At the same time, however, it has reduced the potential for differentiating products and brands. While Full Digital is without question the ultimate goal, it is important to manage the change by developing a mentality that combines ceramic expertise with a knowledge of the specific aspects of the digital process. A number of key aspects must be taken into consideration, including the fact that improving production efficiency is not always a successful strategy whereas increasing the percentage of first choice products is always beneficial, so all possible measures must be taken to achieve this. ✕
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THE FUTURE OF CERAMICS SUMMIT 2019 International Business Forum
by Davide Medici
SACMI DEEP DIGITAL LINE SYNCHRONISATION OF THE DIGITAL PROCESS Interconnecting the various stages in the production process is one of the cornerstones of Sacmi’s vision of plant construction for the modern ceramic factory. For this purpose, the HERE software provides complete technical and technological management of the process from a single control and digitalisation platform. One of the key steps in this highly integrated and monitored process is ceramic surface finishing, which uses innovative digital technologies to create graphic designs and to apply materials. Sacmi Deep Digital Line is the solution for fully digital management of all decoration phases. With this solution, the decoration process is no longer limited to printing with inks, but includes glazes, effects and powders. The available materials are applied using digital devices synchronised by the same HERE process supervision tool. Whether using traditional configurations (PH presses) or the Continua+ line for large slabs, the installed sensors are able to uniquely identify each individual piece in transit and apply the various materials according to the specific product recipe. This process differs from traditional decorating lines in two ways. Firstly, with the Sacmi Deep Digital Line the surface finish is no longer created by a series of stand-alone decoration devices but by a single integrated decoration line. The second aspect is the Sacmi Deep Digital Line’s ability to coordinate with the pre-press loading devices, which means that the surface decoration can be synchronised perfectly DEEP DIGITAL
DEEP DIGITAL è la tecnologia innovativa di SACMI per la realizzazione
digitale di piastrelle/lastre ceramiche, perfette sia in superficie, sia in massa.
Sincronizzazione del processo di decorazione digitale
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Davide Medici, Sacmi Intesa (Italy)
with three-dimensional decoration of the substrate. For example this makes it possible to create very thick ceramic slabs where the graphic texture of the surface coordinates perfectly with the through-body vein. The Sacmi digital devices adopted on the Deep Digital Line consist of DHD series ink and effect printers. The series has been expanded with the new 12-bar versions available for sizes with a width of up to 2,000 mm. One totally new product on the market is the new DDG series of machines for digital application of effects in both a dry and wet process. The system offers the unique feature of selective grit application, which together with wet glue application allows for the design of innovative products based on the combined use of two dry materials. With DDG it is also possible to apply two additional wet materials, which can be useful for surface finishing of the piece or for further decoration with other ceramic effects. All of this is achieved while coordinating perfectly with the other digital devices on the line. Sacmi’s range of offerings also includes the DGD and DDD powder loading devices (DGD for traditional PH presses and DDD integrated on Continua+ upstream of the compactor), which are capable of coordinating the decoration and glazing process with the other phases and thereby extending the concept of surface finishing to all the phases upstream of the press. In the pre-forming phase, these systems can make a significant contribution to the overall graphic and aesthetic quality of the tile, opening the way to previously unexplored creative and design solutions. ✕ Macchina digitale per decorazioni a SECCO + EFFETTI
DDG DIGITAL DRY DECORATION
Sincronizzazione del processo di decorazione digitale
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technology
Vkby ,saM LVkby esa u, fljsfed VªsaM~l ij /;ku Focus on new ceramic trends at TILE&STYLE
In October and November, Fritta opened the doors to its headquarters in Onda (Castellón) for the traditional Tile&Style open house event, where it presented its new ceramic collections in its large showroom. This year’s event saw less minimalism and a greater emphasis on the application of effect on natural materials, a choice dictated by the Spanish glaze and colour producer’s desire to cater more for the aesthetic tastes of this year’s most dynamic markets – North and South America and North Africa – rather than the more sluggish European markets, held back amongst other things by the uncertainty surrounding Brexit. The event saw a strong focus on large surfaces, a product type that is now being used in the widest range of applications including floors, walls, facades, bathroom and kitchen countertops and furniture, and to 20 mm thick tiles for outdoor areas and urban design. With these products in mind, Fritta has developed materials with specific technical characteristics including glazes with high scratch and impact resistance, non-slip characteristics and at the same time soft-touch and easy-to-clean surfaces. Fritta has expanded its range of digital effect inks to cater for millennials, a generation who are keen to customise spaces with their own personal style. Along with glossy matt effects, these include a series of collections with microreliefs, from the opal series for applications on white backgrounds to digital glue for grit applications. At Tile&Style, Fritta also presented a new high-performance metallic ink suitable for various firing processes with traditional ceramic materials. The most innovative effects include: • Chisel Ink, capable of creating a wide range of textures and microreliefs synchronised with the graphic designs, also available in Chisel Mate and Chisel Brillo versions; • Opal Ink, an ink with a high whiteness index and unique colour rendering, available in a range that includes the new Opal
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Soft and Opal White HT versions for polished porcelain; • Glue Ink, the digital glue that fixes grits selectively and, combined with the matt or gloss effects, enhances volumes by creating outlines synchronised with the design; • Metallic Ink, a metallic effect for porcelain that performs well on glaze-engobe or matt with suitable application weights for today’s printheads. Given that digital technology is already capable of performing selective grit application for synchronisation with the graphic design or for creating high-definition reliefs, Fritta presented a new range of wet or dry decoration grits, including coloured grits and products with a “sugar” or metallic effect. The latest product trends include polished, lapped and crest-polished surfaces, for which Fritta mainly proposes the use of glazes and grits in the form of a gel. As already mentioned, current trends are turning away from minimalist zen environments in favour of lively and intense colours with a predominance of blue, green, reddish, ochre and violet tones. Here too, the use of metallic effects on marble, stone, concrete and wood look surfaces creates unique and highly distinctive details. Along with large size white and black veined marble, Tile&Style also showcased marbles with blue, green, ochre and reddish tones and gloss and matt finishes. The displayed projects also included terrazzo and concrete effect surfaces with natural textures created using metallic effects and grits in the Hurley, Slater, Shire and Dotstone collections. For wood effect surfaces, the featured solutions concentrated on neutral, metallic and matt tones in the Preston, Marwood and Scarle collections. And naturally there were also fabric and wallpaper effects proposed in the Penza, Lambra, Hypatia, Leak and Hand collections, created through the application of grits and digital effects. Last but not least, a variety of surfaces with reliefs created in-press were presented, including Strata, Folds and Rutendock. ✕
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HITO TECHNICAL INDUSTRIES
HIGH DENSITY ALUMINA BALLS AND LINING BRICKS ALUMINA NANOBEADS ZH
HITO TECHNICAL INDUSTRIES, S.L.
• Narcís Monturiol, 26 · 08187 Santa Eulàlia R. (Barcelona) · Spain · Phon. +34 938 449 982 · Fax +34 938 449 269 • Cantabria, s/n · Pol. Ind. El Colador · 12200 Onda (Castellón) · Spain · E-mail: hito@hito.es • Paseo de la Castellana, 141 · Edificio Cuzco IV, planta 5 · 28046 Madrid · Spain Phon. +34 915 726 529 · Fax +34 915 726 621 · E-mail: international@hito.es
HITO GRINDING MEDIA, S.L.
•Avenida de Aragón, 30 · Edificio Europa, planta 8 · 46021 Valencia · Spain Phon. +34 960 468 643 · Fax +34 960 468 601 · E-mail: ceramica@hito.es
HITO POLSKA Sp. z o.o.
• ul. Tadeusza Kosciuszki 34 · 81-702 Sopot · Poland · Phon. +48 58 355 10 08 · E-mail: hitopolska@hitopolska.pl
Poppi Clementino
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第34届广州陶瓷工业展 Ceramics China 2020 May 26-29,2020 广州·广交会展馆A区一楼全馆 China Import and Export Fair Complex · Guangzhou
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We give more to ceramics to make better ceramics
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