Ceramic World Review India 2024 by Kairos Media Group (div. ceramics)

C eramic W orld R eview

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Indian Ceramics Asia 2024

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Year 34 Supplement to no. 155 February/March 2024 Bimonthly Review

contents

Cover picture by: Giancarlo Pradelli

Editorial

Welcome to Indian Ceramics Asia 2024!

Paola Giacomini

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World News

14 Sanitaryware

World sanitaryware exports and imports

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The big players in the sector

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22 Interview

Somany: a commitment to quality and innovation

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The innovative spirit of Prayag Clay Products

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34 Technology

Increasingly high-performance, digital and flexible slab production lines

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An integrated approach to large slab production

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Functionality and aesthetics with dry super-polishing

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New heat recovery solutions

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Circular economy: from waste to recycling

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Sustainable innovation to combat electrical energy wastage

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56 Heavyclay

Tunnel kiln for very hot countries

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58 Tableware

The new frontier of automatic dip glazing

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LATEST TECHNOLOGIES

Luca Baraldi

Paola Giacomini

Milena Bernardi

Sacmi

Rita Cagnoli

Marco Sichi

Poppi Clementino

Minerali Industriali Engineering

Gmm Group

Equipceramic

Sacmi

71 Advertisers’ List

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Hkkjrh; fljsfeDl ,f'k;k 2024 esa Lokxr gS! WELCOME TO INDIAN CERAMICS ASIA 2024! From 6 to 8 March, the Indian ceramic industry will meet again in Gandhinagar for the 18th annual edition of Indian Ceramics Asia and its concurrent show IBaRT, the India Brick and Roof Tile Expo. The show will occupy around 18,500 sqm exhibition space featuring over 200 exhibitors from India, Europe, China & other countries. More than 9,000 visitors are expected. The industry’s leading international suppliers will all be present, including the Italian machinery, equipment and material manufacturers Appel, Bocedi, Cimes, Essepienne, Interser, Keran, LB, Metco, Minerali Industriali Engineering, Sacmi and BMR, Smac, Surfaces Group, System Ceramics, Tecnocer Italia and Tecnoferrari, most of which will be exhibiting in the Italian pavilion organised by ACIMAC in cooperation with the Italian Trade Agency. Lamberti and Smaltochimica will also be present with their Indian companies, as well as the glaze manufacturers Colorobbia, Vidres and Esmalglass-Itaca. AKW, Imerys, Sibelco and Alteo will be among the exhibitors in the field of ceramic raw materials, and the IBaRT show can count on the presence of well-known European suppliers, including Equipceramic and Beralmar. Indian Ceramics Asia provides a welcome opportunity to meet up with local customers. In the last couple of years, the Indian ceramic tile industry has further strengthened its position as a global tile player and as the world’s second largest manufacturer and consumer behind China, while, according to preliminary results, in December 2023 India could have even overtaken China as the world’s first largest ceramic tile exporter. In the calendar year 2023 (January-December), India’s tile producers chalked up another astonishing success with total exports of around 590 million sqm (up around 40% on 2022), and a 33.7% growth in value to 2.8 billion USD (it was 1.9 billion in 2021 and 2.1 billion in 2022). Indian exports in volume grew by 17% in the Middle East, by 74% in Africa, by 49% in North America, by 84% in the European Union, by 166% in Extra-EU Europe, by 128% in South America, while they decreased by 6% in Asia. The 10 biggest Indian exports markets in 2023 were: the USA, UAE, Iraq, Mexico, Kuwait, Russia, Israel, Oman, South Africa and Saudi Arabia.

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23/01/24 10:11

sanitaryware

oSf'od lsfuVjhos;j vk;kr vkSj fu;kZr WORLD SANITARYWARE EXPORTS AND IMPORTS Luca Baraldi, MECS / Acimac Research Dept. (l.baraldi@mecs.org)

World ceramic sanitaryware import/export flows grew by 71.3% from 2.16 million to 3.7 million tonnes over the period 20102022, corresponding to a compound annual growth rate of 4.6%. However, the positive trend that continued for almost the entire period (with the exception of 2020, due to the pandemic) was interrupted again in 2022 with a 5.6% decline in exports compared to 2021. This negative trend was observed in practically all geographical areas of production and in the major exporting countries. Asia remained the largest world sanitaryware exporter, increasing its share of world exports to 66% despite a 3.5% fall to 2.44 million tonnes in 2022. This was a combined result of contractions in almost all the major Asian exporting countries, namely China, India, Thailand and Vietnam, with the only positive exception being Iran. Exports from the European Union, the world’s second largest exporter, also fell by 3.7% to 520,000 tonnes. The three largest exporting countries alone accounted for half of EU exports, but followed different trajectories, with Poland and Portugal maintaining their 2021 levels, while Germany’s exports declined by 4.6%. Exports from North America (NAFTA) suffered

TAB. 1 - EXPORTS OF SANITARYWARE BY AREA (TONS) 2022

% 22/21

CAGR 22/10

% on 2022 world exports

2,127,623 2,533,625

2,444,509

-3.5%

6.9%

66.0%

541,584

488,917

539,775

519,756

-3.7%

0.0%

14.0%

220,127

237,166

235,176

291,352

253,113

-13.1%

5.6%

6.8%

366,973

375,412

365,789

368,372

379,235

327,907

-13.5%

1.7%

8.9%

80,315

79,513

89,375

86,782

78,814

99,853

84,479

-15.4%

-1.4%

2.3%

84,042

71,958

65,933

66,113

75,238

64,296

79,216

73,571

-7.1%

6.2%

2.0%

902

1,084

411

583

580

315

364

867

138.2%

-6.6%

0.0%

-5.6%

4.6%

100.0%

2010

2015

2016

2017

2018

2019

Asia

1,100,506

1,697,734

1,603,571

1,756,791

1,988,977

2,220,614

European Union

522,118

569,475

583,409

570,549

585,034

Other Europe

132,132

185,960

187,805

203,077

NAFTA

268,401

340,565

368,326

South America

100,043

72,548

Africa

35,861

Oceania

1,960

TOTAL WORLD

2021

2,161,021 2,951,226 2,896,468 3,043,247 3,325,621 3,527,753 3,363,513 3,923,420 3,704,202

% var y-o-y

2.1

-1.9

Source: Mecs / Acimac Research dept. on BSRIA and ITC data

2020

CWR INDIA 2024

5.1

9.3

6.1

-4.7

16.6

-5.6

. Innovation

. Product Development

. Modelling

. Resin moulds

. Casting and handling

. Finishing

. Glazing

. Off-line Technology

. Firing

. Sorting

ENDLESS INNOVATION SINCE 1919

momic

[ ENVIRONMENT ]

[ RESEARCH ]

[ A U T O M AT I O N ]

We A R E Sanitaryware

a more severe, double-digit decline, down to 328,000 tonnes (down 13.5% on 2021), largely attributable to the -10% drop in Mexico. Exports from non-EU European countries recorded a similar contraction (-13.1% to 253,000 tonnes), with Turkey down 8.3% (187,000 tonnes). Next, again with a downward trend, came South America (84,000 tonnes, -15.4%) and Africa (73,000 tonnes, -7%). A glance at the twelve-year period as a whole provides a clear picture of how exports have evolved in each area and in particular reveals the growth of Asia, whose exports have more than doubled from 1.1 to 2.4 million tonnes (CAGR 2022/2010 +6.9%). Asia’s percentage share of global exports has risen from 51% in 2010 to the current figure of 66%, winning shares from almost all the other regions. By contrast, the EU’s exports remained unchanged at 522,000 tonnes during the period in question, with its share of world trade falling from 24.2% to 14%. The NAFTA region’s share fell from 12.4% to 8.9% despite overall 22% growth in exports since 2010. South America, which in 2010 accounted for 4.6% of world exports, saw its share drop to 2.3%, while volumes remained stable over the 12-year period. The only exceptions were non-EU European countries and Africa. Non-EU Europe saw its share of world exports rise from 6.1% to 6.8% over the 12-year period thanks to a 92% increase in export volumes, while Africa’s exports grew by 105% over the period, raising its share of global trade from 1.7% to 2%. The 2022 ranking of the top 10 exporter countries changed very little in terms of positions, with Poland rising from 6th to 5th place and Iran from 10th to 9th, switching positions with Thailand and Vietnam respectively. China remained at the top

TAB. 2 - THE TOP EXPORTING COUNTRIES (TONS) 2010

2015

2016

2017

2018

2019

2020

2021

2022

% 22/21

CAGR 22/10

% on 2022 world exports

China

901,962

1,335,212

1,238,558

1,378,951

1,532,833

1,747,579

1,698,152

1,968,003

1,917,768

-2.6%

6.5%

51.8%

Mexico

226,569

295,439

322,169

326,289

342,666

335,958

333,230

328,904

295,441

-10.2%

2.2%

8.0%

India

15,076

119,752

135,776

137,717

182,691

199,371

171,698

264,253

251,195

-4.9%

26.4%

6.8%

Turkiye

94,354

120,613

127,065

140,759

154,285

164,809

166,370

203,467

186,656

-8.3%

5.8%

5.0%

Poland

67,572

77,048

80,323

76,620

78,617

77,470

82,537

91,206

91,397

0.2%

2.5%

Thailand

57,189

79,242

81,016

86,512

96,067

92,094

87,129

111,703

88,218

-21.0%

3.7%

2.4%

Germany

63,742

65,734

79,124

75,478

81,952

80,382

75,861

88,863

84,735

-4.6%

2.4%

2.3%

Portugal

75,049

87,434

93,891

94,164

101,654

81,574

65,438

82,200

82,012

-0.2%

0.7%

2.2%

Iran

25,895

31,420

33,962

35,206

46,573

46,469

48,893

52,869

57,865

9.4%

6.9%

1.6%

Vietnam

19,590

47,892

35,034

40,457

41,292

52,982

51,986

67,565

57,669

-14.6%

9.4%

1.6%

1,546,998 2,259,786 2,226,918 2,392,153 2,658,630 2,878,688 2,781,294 3,259,033 3,112,956

-4.5%

6.0%

TOTAL % on total world exports

71.6%

76.6%

76.9%

Source: Mecs / Acimac Research dept. on BSRIA and ITC data

CWR INDIA 2024

78.6%

79.9%

81.6%

82.7%

83.1%

84.0%

sanitaryware

of the ranking with exports of 1.92 million tonnes (down 2.6% on 2021), alone accounting for 78% of Asian and 52% of world exports. Mexico, the second largest exporter country with an 8% share of global exports, suffered a 10.2% fall in its exports to 295,000 tonnes. Following very strong growth in 2021, India also experienced a decline, with export volumes falling from 264,000 tonnes to 251,000 tonnes last year (-4.9%). Next came Turkey with 187,000 tonnes (-8.3%), Poland (91,000 tonnes, +0.2%), then Thailand, Germany, Portugal, Iran and Vietnam. Overall, the 10 largest sanitaryware exporter countries accounted for 84% of global exports.

TAB. 3: IMPORTS OF SANITARYWARE BY AREA (TONS) 2010

2015

2016

2017

2018

2019

2020

2021

2022

% 22/21

CAGR 22/10

% on 2022 world imports

Asia

478,338

818,090

793,850

833,259

926,612

1,023,083

942,443

1,078,614

1,114,587

3.3%

7.3%

30.1%

European Union

692,328

791,241

812,874

837,139

880,867

913,292

838,875

837,865

769,859

-8.1%

0.9%

20.8%

Other Europe

96,507

89,772

70,806

77,761

90,187

87,862

96,767

242,811

208,218

-14.2%

6.6%

5.6%

NAFTA

620,716

809,546

819,097

866,815

948,435

967,327

986,193

1,132,138

1,032,911

-8.8%

4.3%

27.9%

South America

119,957

146,436

130,758

140,950

145,579

158,296

143,521

217,373

183,171

-15.7%

3.6%

4.9%

Africa

111,952

235,655

199,740

221,986

259,390

310,834

288,084

336,648

310,262

-7.8%

8.9%

8.4%

Oceania

41,223

60,486

69,343

65,337

74,551

67,059

67,629

77,971

85,194

9.3%

6.2%

2.3%

-5.6%

4.6%

100.0%

TOTAL WORLD

2,161,021 2,951,226 2,896,468 3,043,247 3,325,621 3,527,753 3,363,513 3,923,420 3,704,202

% var y-o-y

2.1

-1.9

5.1

9.3

6.1

-4.7

16.6

-5.6

Source: Mecs / Acimac Research Dept. on BSRIA and ITC data

TAB. 4 - THE TOP IMPORTING COUNTRIES (TON) 2010

2015

2016

2017

2018

2019

2020

2021

2022

% 22/21

CAGR 22/10

% on 2022 world imports

USA

500,415

683,754

690,500

738,424

811,329

817,814

837,589

931,311

875,416

-6.0%

4.8%

23.6%

Germany

107,509

142,391

147,060

140,282

148,431

150,425

144,299

155,318

149,626

-3.7%

2.8%

4.0%

Republic of Korea

84,543

132,361

147,756

142,706

142,732

142,658

127,185

156,902

141,505

-9.8%

4.4%

3.8%

France

115,108

101,819

107,421

116,870

125,738

135,313

125,226

150,811

130,060

-13.8%

1.0%

3.5%

United Kingdom

103,815

147,323

145,992

151,904

138,454

143,344

118,906

131,784

112,302

-14.8%

0.7%

3.0%

Canada

104,680

104,119

108,442

106,137

103,682

107,464

107,013

138,487

108,422

-21.7%

0.3%

2.9%

Spain

83,634

88,245

93,758

89,036

108,096

104,981

86,835

118,467

103,707

-12.5%

1.8%

2.8%

Saudi Arabia

33,592

83,934

67,918

58,100

51,814

74,034

82,903

70,855

88,027

24.2%

8.4%

2.4%

Vietnam

3,866

7,693

12,476

20,855

32,342

55,237

68,354

75,538

84,719

12.2%

29.3%

2.3%

Philippines

25,667

39,508

41,191

39,507

49,829

55,205

49,561

71,708

81,247

13.3%

10.1%

2.2%

1,162,829 1,531,147 1,562,514 1,603,821 1,712,447 1,786,475 1,747,870 2,001,181 1,875,031

-6.3%

4.1%

TOTAL % on total world imports

53.8%

51.9%

53.9%

52.7%

51.5%

50.6%

52.0%

51.0%

50.6%

Source: Mecs / Acimac Research dept. on BSRIA and ITC data

CWR INDIA 2024

An analysis of 2022 imports to the various continents not only confirms Asia and North America as the two regions accounting for the majority of sanitaryware imports but also reveals that they are almost level in terms of imported volumes: Asia with 1.11 million tonnes (30% of global imports, +3.3% over 2021); North America with 1.03 million tonnes (27.9% of global imports, -8.8% over 2021). The European Union can also be included in this leading group, which despite a drop of 8% to 770,000 tonnes in 2022, accounts for 21% of global imports. The remaining 21% of world imports are divided between Africa, South America, non-EU European countries and Oceania. The 2022 ranking of the top 10 sanitaryware importing countries saw a number of changes in position compared to the previous year, as well as the exit of Italy and the en-

FIG. 1 - SANITARYWARE EXPORTS BY AREA (SHARES IN % - 2010 VS. 2022)

South America 4,6% South NAFTA America 12,4% 4,6%

NAFTA Other Europe 12,4% 6,1% Other Europe 6,1% European Union 24,2% European Union 24,2%

Africa 1,7%

2010

Oceania 0,1%

South America 2,3%

Oceania 0,1%

NAFTA South America 8,9% 2,3% Asia 50,9%

Asia 50,9%

2022

CWR INDIA 2024

Africa 2,0%

Other Europe NAFTA 6,8% 8,9%

Other Europe European 6,8% Union 14,0% European Union 14,0%

OceaniaFIG. 2 - SANITARYWARE IMPORTS BY AREA (SHARES IN % - 2010 VS. 2022 2022) 2010 1,9% Oceania Africa Africa 2,3% 5,2% Asia 8,4% Oceania 2022 2010 22,1% South 1,9% Oceania Africa America South America 2,3% Africa 5,6% 5,2% Asia 8,4%4,9% 22,1% South America South America 5,6% 4,9% NAFTA NAFTA 28,7% 27,9% European Union NAFTA NAFTA 32,0% Other Europe Other Europe 28,7% 27,9% European 5,6% 4,5% Union 32,0% Other Europe Other Europe 4,5% 5,6%

Africa 2,0%

Asia 66,0%

Asia 30,1%

European Union 20,8% European Union 20,8%

sanitaryware

try of Saudi Arabia. Overall, the ten largest sanitaryware importers accounted for 50.6% of global sanitaryware imports (1.86 million tonnes). In 2022, the United States was once again the world’s biggest sanitaryware importer with 875,000 tonnes (6% down on 2021). It retained a strong lead over all other importing countries with 23.6% of world imports, as well as almost all (85%) of imports to the NAFTA region. This marks the continuation of a longstanding record considering that in 2010 the USA imported more than 500,000 tonnes, 23% of world imports. Germany climbed to second place with imports of almost 150,000 tonnes (-3.7% over 2021), overtaking South Korea at 141,000 tonnes (-9.8%), followed by France (130,000 tonnes, -13.8%), the United Kingdom (112,000 tonnes, -14.8%), Canada, Spain, Saudi Arabia, Vietnam and the Philippines. Germany and Vietnam rank among both the top 10 exporters and the top 10 importers of sanitaryware, both with higher import than export volumes. One final point of interest is the analysis of the main export destinations with respect to the geographical areas of production. Four out of seven areas sell the vast majority of their exports within their own geographical regions or continents: 97% of North American exports remain in the NAFTA region; 82% of South American exports remain in Latin America; 80% of Oceania’s exports remain in Oceania; and 78% of the European Union’s exports are sold in EU markets. At the other extreme, 85% of exports from non-EU Europe are sold in other regions, particularly the EU (Turkey’s largest export market). Likewise, 82% of Africa’s exports are sold outside Africa and Asia sells 58% of its exports outside the Asian continent thanks to China’s ability to ship to almost all global regions.

◼

FIG. 3 - EXPORTS INSIDE AND OUTSIDE INTEGRATED AREAS (SAME CONTINENT OF PRODUCTION) - % SHARES 2022

100%

2,9%

90%

22,2%

18,2%

19,7%

80% 70%

58,3%

60%

81,8%

84,7%

50%

97,1%

40%

77,8%

81,8%

80,3%

30% 20%

41,7%

10% 0%

18,2%

15,3% Asia

European Union

Other Europe

Export inside integrated areas

NAFTA

South America

Africa

Oceania

Export outside integrated areas

CWR INDIA 2024

THE BIG PLAYERS IN THE SECTOR

Roca Group

Spain

n.a.

Kohler Group

USA

25.0*

Geberit Group

Switzerland

TOTO Ltd

Corona

2022 Exports %

Country

Sensowash D-Neo by Duravit

Production 2022 (mill. Pcs.)

Group

Capacity in 2022 (mill. Pcs.)

To round off the international trade figures for the sanitaryware sector, we are presenting the key figures for the big players updated to 31 December 2022. Where available we also provide the figures for turnover generated purely from sales of sanitaryware. This allows for a more uniform comparison between large groups which often operate in multiple segments. To provide a more complete picture of group size, we also include total or consolidated turnover. The figures were supplied directly by the companies themselves or in some cases were based on estimates or obtained from public sources.

2022 Total Group turnover (mill. €)

Sanitaryware plants / Location

Main Brands / Companies

28.0

2,092.0 (sanitaryware, and other businesses)

76 (total group) in Spain (9), rest of Europe, America, North Africa, Asia

Roca, Laufen, Celite, Incepa, Parryware, Jika, Ying

19.0*

n.a.

15 in USA, Mexico, Brazil, Morocco, Thailand, India, China, Indonesia

Kohler, Jacob Delafon, Sterling, Ann Sacks

14.5*

11.5*

n.a.

3,463.9 (3,392 mill. CHF) of which 1,054.9 Bathroom

Sanitaryware plants in Finland, Sweden, Poland, Germany, Switzerland, France, Portugal, Italy, Ukraine

Geberit

Japan

n.a.

11.6

n.a.

5,547.1 (bathroom, tiles, other)

4 in Japan + 12 in China, Taiwan, Indonesia, India, Vietnam, Thailand, USA, Mexico

TOTO

Colombia

13.5

10.6

n.a.

779.1 (303.1 sanitaryware, 161.6 tiles, 314.5 other activities)

2 in Colombia + 3 in Mexico, 1 in Guatemala, 1 in Nicaragua, 1 in USA

Corona, Mansfield, American Standard, Vortens, Incesa Standard, Ecoline, Ambiance

Lixil Corporation

Japan

10-12*

9.0*

n.a.

10,372 (sanitaryware & other businesses)

10 in Japan, China, Vietnam, Indonesia, Thailand

American Standard, Lixil, Inax, Grohe, Jaxson

Huida Sanitaryware

China

10.0*

7.0*

n.a.

458.9

2 in China

Huida, Dofiny

Cersanit

Poland

7.5*

n.a.

432.7 (sanitaryware, tiles)

1 in Poland, 1 in Ukraine

Cersanit, Mito

Ideal Standard

Belgium

7.0*

6.5*

n.a.

737.0

1 in Czech Rep., 1 in Bulgaria, 1 in UK, 1 in Egypt

On 18 September 2023, Villeroy & Boch announced the acquisition of Ideal Standard, which will be completed in early 2024

Arrow

China

8.7*

6.5*

n.a.

1,003.8 (471 sanitaryware)

Eczacibasi VitrA

Turkey

5.7

n.a.

Dexco

Brazil

11.3

5.6

1,572 (169 sanitaryware, 212 tiles, 1190 other activities)

Lecico

Egypt

6.7

5.1

RAK Ceramics

UAE

5.0

4.8

Duravit

Germany

4.5

4.1

*estimates - Source: MECS / Acimac

CWR INDIA 2024

Ideal Standard, Porcher, Armitage Shanks

5 in China

Arrow, Faenza, Annwa

1 in Turkey, 1 in Russia

VitrA

4 in Brazil

Deca

123.7 (75.7 sanitaryware, 40.9 tiles, 7.1 other)

4 in Egypt (incl. Tiles), 1 in Lebanon

Lecico

883.0 (138 sanitaryware, 545 tiles, 200 other activities)

2 in UAE, 3 in India and Bangladesh

RAK Ceramics, Eliesaab

n.a.

715.8

3 in Germany, 1 in France, 2 in Egypt, 3 in China, 1 in Tunisia, 1 in India

Duravit

Group

Country

Capacity in 2022 (mill. Pcs.)

Production 2022 (mill. Pcs.)

2022 Exports %

sanitaryware

2022 Total Group turnover (mill. €)

Turkuaz Seramik

Turkey

3.6

n.a.

Cisa SA

Ecuador

4.5

3.3

n.a.

105.1 (70.2 sanitaryware, 4.6 tiles, 30.3 other activities)

Hindware Limited

India

4.2*

3.0*

n.a.

Cera Sanitaryware

India

3.3*

3.0*

Villeroy & Boch

Germany

3.0*

Sanitaryware plants / Location

Main Brands / Companies

2 in Turkey

Turkuaz Seramik, Cerastyle

2 in Ecuador, 1 in Chile

Edesa, Briggs, Fanaloza

n.a.

2 in India

Hindware, Queo, Hindware Italian Collection

n.a.

201,7

1 in India

Cera

n.a.

994.5 (662 bathroom & wellness, 329 dining)

13 (total group). 5 sanitaryware plants in Germany, France, Hungary, Romania, Thailand

Villeroy & Boch, Gustavsberg/Vatette, Alföldi, Mondial

On 18 September 2023, Villeroy & Boch announced the acquisition of Ideal Standard, which will be completed in early 2024

Canakcilar Seramik

Turkey

2.6

n.a.

Saudi Ceramics

Saudi Arabia

3.6

2.5*

n.a.

371.3 (tiles, sanitaryware, bricks, other)

Siam Sanitary Ware

Thailand

2.6

2.4

Ferrum

Argentina

n.a.

2.4*

Ceramica Cleopatra

Egypt

2.5*

ECE Holding

Turkey

Ceramic Industries

2 in Turkey

Creavit

2 in Saudi Arabia

Saudi Ceramics

101 (sanitaryware)

2 in Thailand

COTTO

n.a.

164.9 (sanitaryware)

2 in Argentina

Ferrum

2.4*

n.a.

2 in Egypt

Cleopatra, Eldorado

2.4

2.0

n.a.

2 in Turkey

ISVEA, Ece

South Africa

2.3

1.9

12.5

249.0 (49 sanitaryware, 203 tiles)

2 in South Africa

Betta, Bettabath

Trebol

Peru

2.6

1.9

6.2

50.7 (34.8 sanitaryware, 15.9 other activities)

1 in Peru

Trebol

Viglacera

Vietnam

2.2

1.9

565 (tiles, sanitaryware, other)

4 in Vietnam, 1 in Cuba

Viglacera, Viglacera Platinum, Sanfi, SanVig

321.5 (21.1 sanitaryware, 288.6 tiles, 11.9 other activities)

1 in Turkey

Kale Banyo, IDA

Kale Group

Turkey

1.6*

1.0

CWR INDIA 2024

lksekuh% xq.koÙkk vkSj ubZ [kkst ds fy, çfrc)rk SOMANY: A COMMITMENT TO QUALITY AND INNOVATION Paola Giacomini (p.giacomini@kairosmediagroup.it)

Somany Ceramics, India’s second-largest ceramics group, closed the first half of fiscal year 2024 (on 30/9/2023) with a 5.6% yearon-year increase of consolidated revenues (Rs. 12.4 billion, or US $146.7 million) and a stronger improvement of EBITDA (+31.6% y-o-y), thanks, above all, to the decrease of fuel and energy costs respect to the extraordinary levels of FY 2023. Tile sales in volume were up 7% year-on-year to 32.3 million sq.m. These results came after a very challenging FY 2023, which ended (on 31/3/2023) with an 18% year-on-year increase of revenues (Rs. 24.8 billion, or US $303 million,) and a 20% increase of costs primarily energy prices -, exerting considerable pressure on margins. Even in that situation, the group proved to remain resilient and managed to navigate through the uncertainties thanks to the strategies adopted to support its growth. We spoke to CEO Abhishek Somany and Amit Bhatnagar (AVP and Head of International Business & Strategy). CWR: How do you judge your last year performances? ABHISHEK SOMANY: As you can easily understand, the sharp rise in natural gas prices during FY 2023 has put pressure on our margins, but our commitment to quality and innovation has allowed us to achieve satisfactory results and we have been able to limit our price increases to partially covering the rise in input cost. In recent years, we have witnessed both challenges and opportunities within the tile segment. As you can remember, between 2021 and 2023 we have added around 25% capacity to increase our access to capacity to ~80 million square metres. In accordance with changing market dynamics and consumer preferenc-

CWR INDIA 2024

interview

Talking to, from left... Abhishek Somany and Amit Bhatnagar

es, we have mainly increased our production of GVT (glazed vitrified tiles) followed by ceramics and PVT (polished vitrified tiles). Within PVT we are selling more technical ceramics and industrial tiles of higher thickness. CWR: And what about the first six months of fiscal year 2024? A. SOMANY: To be honest, the first two quarters of fiscal year 2024 have not been much brilliant, as we grew only by about 6% in sales value and 7% in volumes, but EBITDA saw a double-digit growth, thanks to two factors: on one hand, fuel and energy costs have decreased to acceptable levels, and on the other hand, the new capacity installed has started slowly and steadily to show up in higher value-added product sales. Hopefully this trend will continue. CWR: In October 2023 you completed your expansion project for the new Somany Max factory. When did it start production? A. SOMANY: The new Somany Max plant in Morbi started commercial production of COVERSTONE 15 on 29th January 2024. The factory has a capacity of ~4 million sq.m/year, representing a significant investment in pursuit of our commitment to innovation, aimed to increase not only volumes but also value. In the first stage of production, we will focus on sizes between 800x1800, 800x2400, 800x2600 and 800x3000mm in 15 mm thickness. Somany Max Coverstone 15 is powered by our Frittage Compact slabs (FCS technology) which helps in achieving outstanding surface properties through a meticulous process involving exposure to high temperatures, reconfiguring the atomic structure for a dense, tough, brighter, homogeneous and non-porous, non-abrasive surface. Coverstone 15 will be available in three broad ranges, Technical Porcelain, Contemporary Surfaces and Luxury Polish. They are intricately crafted to replicate natural textures of marble, stone, wood and fabrics. They ignite creativity with maximum colours, maximum sizes, maximum finishes and create maximum possibilities. Many of these surface finishes are produced for the first time in India and we are hopeful for a positive affirmation from the market. CWR: What are your expectations for the current year? A. SOMANY: We are optimistic. The lower cost of gas has reduced our production and freight costs, making our ceramic tiles more competitive in the market. This is crucial for sustaining our market share, especially in the context of competition landscape of the market. As seen, the cost savCWR INDIA 2024

interview

ings has opened up opportunities for us to invest in capacity expansion, technology upgrades and innovative product development. It is true that the Indian market remained sluggish throughout the first half of the fiscal year 2024 but there are positive signs of improvement in the second half. For example, our tile capacity utilization grew from 70% in the first quarter to around 85% in October, while in the sanitaryware factory we should reach around 75% in the second half of the year from 52% in the first semester. Other good news is related to our distribution network as in the first half of the year we added 130 new dealers and 22 new showrooms. We are now very confident that we will be able to achieve a good single-digit growth at the end of FY 2024 as for both value and volumes. CWR: Somany Ceramics is not an export-oriented company, but a leader in the domestic market. What’s your analysis of the Indian market? A. SOMANY: Despite fluctuations in demand in recent times, our long-term outlook for ceramic consumption in India remains positive. As we have seen, the local market has remained tepid in the last months, but forecasts point to a significant increase in real estate activity as early as next year, which will push up demand for tiles. There are several factors that will drive strong growth in the coming years, particularly urbanisation as a growing number of people move to the cities in search of better opportunities. The demand for housing, both affordable and premium, will remain strong. Additionally, renovation and refurbishment activities will further boost demand for ceramic tiles. Government initiatives such as Housing for All and Smart City projects aimed at providing quality housing and infrastructure in urban and semi-urban areas are also expected to drive demand for construction materials. So while short-term challenges may impact the industry, the long-term growth drivers remain intact. Moreover, alongside the growth in market demand, the industry is demonstrating a remarkable ability to innovate, adapt and offer a diverse range of products to cater to evolving consumer demands. CWR: So the Indian ceramic tile industry has a bright future. A. SOMANY: It is a well-known fact that the Indian ceramic tile industry has undergone significant evolution and growth over the past decade. The market has become more organised, with new players entering the industry and existing ones adapting to changing consumer preferences. The industry’s growth has been driven by government initiatives, rising disposable incomes and increased demand for modern and aesthetically pleasing living spaces. The Indian economy is doing well. Although the fall in demand over the last year has led to an excess in capacity and factory stock (or unutilized capacity mostly in the export-oriented Morbi district), I believe this will be absorbed this year thanks to the very strong increase in

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Quality manufacturing by Cuccolini srl / Virto Group.

INTER SER exclusive dealer for several countries.

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exports, which is estimated to reach 40-45% of India’s entire production as early as the current fiscal year 2023-2024. Morbi tile exports in value could easily reach the 20000 Crores figure this year, and further increase to 24-25000 Crores from next year. Moreover, the Indian ceramic tile industry has become more structured and many small, unorganised companies have exited the market. Based on these considerations, I firmly believe that the Indian ceramic tile industry still has substantial growth potential (it may even double volumes over the next five years), as well as the ability to cater to an increasingly demanding market. CWR: Are your exports also growing? AMIT BHATNAGAR: As you correctly pointed out, our business strategy has always centred on the domestic market, but the International business division has made remarkable progress with the aim of establishing Somany as a global brand. Our products are currently exported to over 80 countries across six continents, a success that derives from our ability to understand and meet customers’ needs with products that exceed international standards in quality, thereby cultivating a strong global brand reputation. Looking ahead, the prospects are promising, given the positive trend in tile exports from India. We distinguish ourselves from India’s unorganized sector through our strategic positioning based on unwavering quality, constant innovation, trust and customer service. Our global recognition as a dependable, trustworthy and excellent provider gives us a competitive edge. This is a result of our continuous investment in technology, exceptional pre- and post-sales service and a diversified product range. Our portfolio boasts the latest international quality certifications and includes cutting-edge offerings such as the VC Shield range (PEI 50000 Revolution Approved), Temperature Shield Tile, anti-bacterial solutions, hydrophobic innovations and R11 Anti-Slip technology and recently introduced COVERSTONE 15. CWR: Could you tell us about your operations in the sanitaryware and bathroom furniture sector? A. SOMANY: Here too we have introduced advanced technologies and designs in terms of aesthetics and functionality, such as the Somany Signature series and the French Collection. As for market results, we have seen a sharp uptick in sales to the hospitality sector, which is finally recovering after the pandemic. In general, our growth plans in the sanitaryware and bathroom accessories segment prioritise quality and innovation in order to maintain the same top-level reputation that we have achieved in the tile market. We will pursue effective marketing strategies aimed at building a strong brand and will invest in expanding our manufacturing capabilities, including both brownfield and greenfield expansion projects. To be more precise, as we do not see any need now to further increase our capacity in the tile sector after the opening of the Somany Max plant, in the sanitaryware sector we should make an expansion in the next 12 to 18 months.

◼

CWR INDIA 2024

应该是最优质的氧化铝陶瓷研磨球和衬砖

Room 319, No. 12A DongHai West Road, Shinan District, 266071 Qingdao Room 2123, Sino-Ocean Tower Phase II, No. 618 East Yan’an Road , 200001 Shanghai

ç;kx Dys çksMDV~l dh vuks[kh Hkkouk THE INNOVATIVE SPIRIT OF PRAYAG CLAY PRODUCTS Milena Bernardi (m.bernardi@kairosmediagroup.it)

Founded in 1937 in the city of Varanasi in the state of Uttar Pradesh, Prayag Clay Product (PCP) is one of India’s top three structural clay product manufacturers in terms of volume, quality and the breadth of its product range. The company has always played a key role in the country’s architectural development by supplying products for the construction of public works, housing and historic building renovation. Due to its ability to offer highly customised, tailor-made solutions, it also enjoys an excellent reputation outside India and exports 60% of its output. Prayag is highly investment and innovation oriented and has become the first company in northern India to introduce energy-efficient interlocking lightweight blocks, an innovative product that will help the Indian building industry achieve its latest goals in terms of sustainable construction. The government is aiming to stimulate the sector through financial incentives and by adopting specific measures such as the National Buildings Code of India (NBCI) and the Energy Conservation Building Code (ECBC) to ensure compliance with international building standards. We spoke to Dishaant Badlani and Petros Avgoustidis, respectively managing director and chief operating officer of Prayag Clay Products. CWR: How has Prayag evolved since 1937? DISHAANT BADLANI, PETROS AVGOUSTIDIS: The com-

Die performing extrusion

CWR INDIA 2024

TFI die model

interview

Talking to, from left... Dishaant Badlani and Petros Avgoustidis

pany started out by producing handmade bricks, then began making soft mud bricks back in the 1990s. This was followed by roof tiles, then extruded bricks in 2018, brick slips and pavers, and finally thermally insulating interlocking blocks in 2022. It has taken at least four generations, decades of R&D and investments, but today we are proud to offer a full range of structural clay products. We have 150 employees and five production lines and in the near future aim to reach an output of 800 tonnes per day compared to the current level of 300 tonnes. CWR: Did your 2022 economic and financial performance come up to your expectations? D. BADLANI, P. AVGOUSTIDIS: Absolutely. Product diverCWR INDIA 2024

sification coupled with our ability to establish a successful export business has enabled us to maintain an important growth trend during the difficult pandemic years. We posted a 28% increase in revenue compared to 2021 and are expecting further growth of more than 25% in the current year, partly due to the production of new energy-efficient blocks. CWR: You recently became the first company in northern India to introduce this type of block. Could you tell us about the project? D. BADLANI, P. AVGOUSTIDIS: Going forward, we wanted to find a way to give our business a real boost while helping to combat climate change. As well as saving energy and cutting CO2 emissions, our vertically interlocking blocks of various heights and thicknesses reduce the weight of masonry walls by more than 60% and allow for savings in mortar and plaster of 50% and 70% respectively. The green building sector is growing rapidly in India as it is seen as the only effective response to the alarming levels of pollution, so it’s important to offer the market appropriate solutions while at the same time promoting a change in mentality. The fact that only about 5% of all buildings in India currently have green certification gives an idea of the market’s enormous growth potential. CWR: Tecnofiliere has worked with you to find the best solution for ensuring high production performance. Are you satisfied with the equipment supplied? D. BADLANI, P. AVGOUSTIDIS: Tecnofiliere’s technical team provided constant and highly professional support in the design and construction of customised dies and carefully assessed the specific handling needs in our factory. They provided us not only with their own technological resources such as drawings, simulations and flow and insulation calculations but also the knowledge they had acquired over many years of business. The results exceeded our expectations and we are now ready to respond to India’s growing demand for new brick solutions with modern and efficient equipment. CWR: Did you have to make any other technology investments to produce the new blocks? D. BADLANI, P. AVGOUSTIDIS: A couple of years ago, we made some upgrades to our production lines in anticipation of a future shift towards less conventional, non-standard products for the Indian market and installed clay preparation machines, a dryer and automated handling lines. Once the project was completEco_block ed, we were ready to start. All that was

CWR INDIA 2024

interview

Oranje Castle

missing was the right extrusion equipment for our products, and this was supplied by Tecnofiliere. CWR: What is the current level of automation of your production processes? D. BADLANI, P. AVGOUSTIDIS: Everything is fully automated, from clay preparation through to the drying system. Improving production processes is now part of our development plans and we intend to continue to invest in this area in order to pursue innovation. CWR: In terms of technology, the brick and roof tile industry has not developed as much in India as in other countries. Why is this? D. BADLANI, P. AVGOUSTIDIS: Historically, India is renowned for handmade bricks made by highly skilled local craftsmen. Unlike in other countries, finding skilled workers has never been a problem for us and even today supply often exceeds demand. In addition, our unique climate allows products to be dried naturally in the sun without the need for any special technology. But of course these manual processes reduce productivity, so the biggest manufacturers have been adopting more technological solutions. Small local companies will gradually follow their example spurred by strong demand, especially in the residential and social housing sectors. CWR: The Indian residential market is seeing double-digit growth. According to Magicbricks’ PropIndex report, housing demand grew by 19% in Q4 2022 compared to 2021. What are your expectations for 2023? CWR INDIA 2024

D. BADLANI, P. AVGOUSTIDIS: We expect demand to continue to grow in the current year at a similar pace to Q4 2022, again driven by the severe housing deficit. CWR: Let’s talk about foreign markets. What kinds of products do you export and where? D. BADLANI, P. AVGOUSTIDIS: Our main overseas markets are the UK, Ireland and Australia, where we sell brick slips, paving products and traditional handmade bricks, which are popular because they are more rustic and have a strong design appeal.

CWR INDIA 2024

interview CWR: One of the recent building projects carried out using your bricks is the Oranje Castle in Lucknow. Could you tell us a little more about it? D. BADLANI, P. AVGOUSTIDIS: It is an upscale residential mega-project completed in 2022, consisting of 437 homes in an area of more than 131,000 square metres. Built entirely of brick, it replicates the structure of a European-style castle where the residential units are arranged in a ring around a large courtyard. For the construction of the complex, Prayag supplied 8.000 tonnes of extruded facing bricks from its Country Blend Facing Brick series. CWR: What are your short-term investment plans? D. BADLANI, P. AVGOUSTIDIS: We are about to install a new-generation natural gas-fired tunnel kiln with a fully automated loading/unloading system. The investment will enable us to reach a production capacity of 800 tonnes/day and continue our strategy of functional and qualitative improvement. We aim to be a market leader in India today and worldwide tomorrow.

◼

High-capacity Italian-made extrusion dies For the new Prayag’s project Tecnofiliere supplied the TFI model dies equipped with a tapered direct mounting plate with oversized cross-section capable of withstanding high pressures. The internal braking system uses independently adjustable Hardox elements on each clay infeed section. The Hardox core holder and special steel self-centring supports with anti-rotation system for the cores ensure high levels of stability and precision, avoiding variations in the thickness of the inner walls of the bricks which would result in cracks and other defects in the finished product. The dies are also fitted with highly abrasion-resistant special metal cores and liners for durability and constant brick weight, as well as optimal flow and reduced energy consumption of the extruder. 90% of the dies were manufactured using electrical discharge machines to ensure a very high level of precision, while the core holders were fabricated using special welding robot platforms. To successfully complete the launch of the new product range, the order also included a new differential taper pressure head made of wear-resistant metal and equipped with all-round reinforcements. For all its production requirements, Prayag Clay Products Limited, will be able to make use of Tecnofiliere’s remote technical support system, which was expanded and improved during the pandemic and now provides an outstanding after-sales service.

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CWR INDIA 2024

yxkrkj csgrj çn'kZu] fMftVy vkSj yphyh LySc mRiknu iafä;ka INCREASINGLY HIGH-PERFORMANCE, DIGITAL AND FLEXIBLE SLAB PRODUCTION LINES Sacmi Group (Imola, Italy)

Sacmi’s slab production line covers everything from Continua+ shaping technologies through to digitally coordinated application of glues, grits, glazes and effects and the Maestro kiln, designed to combine lower energy consumption with the highest levels of finished product quality. Renowned for its power, performance and versatility, the line has evolved over the years in keeping with the latest market trends towards sustainability, attention to aesthetic details, and the convergence of digital and material. LIMITLESS SHAPING WITH CONTINUA+ The Continua+ range is the market benchmark for the production of slabs and sub-sizes and currently consists of four solutions. In the past two years in particular, Sacmi has developed the new PCR2180, the fastest line of its kind on the market, and the smart PCR2120 version which immediately proved popular due to its ability to handle different sizes, small batches and composite orders with the utmost flexibility and efficiency and a small footprint. To date more than 150 Continua+ lines have been sold worldwide for applications that go well beyond the conventional concept of large decorated slabs. They are particularly popular for coordinated indoor and outdoor product lines due to their highly flexible management in terms of speed of changeover and variability of sizes and textures. Sacmi is also catering for the high-value furniture segment with its new systems for creating through-body veins coordinated with dry and wet digital applications. Advances in the control and feedback systems are among the most important innovations of the new Continua+ generation of machines. The MDX and OPTIMA systems represent a revolution in process control thanks to automatic load profile correction and the ability to deal effectively with any variability in incoming raw materials (an important fac-

CWR INDIA 2024

technology

tor considering the problems in some of the traditional supply channels and the consequent need for diversification). Further advantages include the lowest levels of energy consumption during compaction of any solution on the market (0.05 kWh/ sqm), the absence of foundations, and up to 90% less oil consumption than a conventional or discontinuous press. DIGITAL AND MATERIAL: THE DEEP DIGITAL R-EVOLUTION Sacmi’s exclusive technologies allow producers to focus on creating surfaces with entirely new characteristics in terms of textures and three-dimensional effects, a capability that is further enhanced thanks to digital coordination between the various machines on the Deep Digital line. Application of glues, glazes, materials and other dry and wet effects on ceramic surfaces create unique textural effects that are further enhanced by the possibility of coordinating the digital application both upstream (controlled powder storage, textured belt) and downstream with the new-generation Sacmi DHD wet applications. It is also possible to create a wide range of through-depth effects to cater for the renewed interest in natural stone aesthetics, especially in the European and North American markets. A MAESTRO IN TERMS OF QUALITY AND CONSUMPTION Sacmi kilns have evolved in two different directions to cater for the needs of slab firing. The first is the development of a new generation of modulated air-gas machines (FMA Maestro) with significantly higher levels of efficiency, now also available in the new digital (FMD) version. The second relates specifically to large slab firing and has involved completely redesigning the system to minimise the issues typically encountered when firing large sizes (stresses, black core, etc.). The cooling area in particular has been redesigned with the inCWR INDIA 2024

technology

troduction of piped burners to avoid generating stresses in the fired product. The kiln entrances and the rotational tolerance of the rollers are also key parameters, especially for the correct treatment of smaller thicknesses. With the new digital setups, it is also possible to call up the firing parameters directly into the recipe and adjust them in real time as required, thereby optimising synergies with Continua+. THE ADDED VALUE OF SACMI TILES LAB The Sacmi Tiles Laboratory is equipped with all the advanced instrumentation needed to offer a full range of consulting services, from raw materials analysis to the development of complete technological expertise on formulations and the process. Assistance, problem solving and on-site training are the further benefits provided by the Laboratory, which works alongside customers at all stages from product development through to proper plant management. This significantly speeds up the new product development and plant start-up stages and guarantees improved quality and results as early as the pre-production stage. The Laboratory is equipped to carry out complete slab prototyping on the pilot line in sizes up to 1200x2400 mm, from body formulation through to decoration. Specialised consulting in raw materials, formulations and body recipes has proved to be a particularly important service during the last year as it allows the most suitable solutions to be found in the event of variations in supplies. The Laboratory’s database contains analyses of more than 30,000 raw materials (clays, kaolins, feldspars, sands, etc.) from all over the world, on the basis of which more than 20,000 ceramic body compositions have been formulated and verified to date.

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CWR INDIA 2024

INTO THE FUTURE Data

flows,

technology

remains

www.bmr.it

fo'kky LySc ds mRiknu ds çfr lexz –f"Vdks.k AN INTEGRATED APPROACH TO LARGE SLAB PRODUCTION Rita Cagnoli, System Ceramics (Fiorano Modenese, Italy)

With their unique blend of functionality and aesthetics, porcelain slabs have pushed back the traditional boundaries of ceramic tiles as a floor and wall covering material. System Ceramics, a company owned by Coesia Group, is one of the leading players in the industry and has made a vital contribution to the success of these large-format surfaces by developing a pioneering process solution for the production of through-vein slabs. The company’s cutting-edge technologies are uniquely interconnected, ensuring a highly competitive end result in terms of functionality and aesthetics. The finished slabs now deliver far higher levels of through-body definition, strength, durability and versatility, making them suitable for use in the furniture and design sectors. As part of its longstanding commitment to technological innovation, System Ceramics has incorporated factors such as sustainability and energy saving into its philosophy. This approach has led to the development of extremely high-performance decorating and pressing solutions that make a key contribution to the effectiveness of the complete slab production line. With the recent presentation of Genesis at Tecna 2022, System Ceramics has taken this industrial philosophy a step further and once again revolutionised the ceramic industry in terms of fields of application, aesthetics and above all synergy between the various processing stages. The futuristic vision that has always guided System Ceramics in the design of individual machines has prompted the company to focus on an all-round plant engineering concept that brings advantages in terms of both the finished product and the process as a whole.

CWR INDIA 2024

CWR 151/2023

technology

THE INTEGRATED HI-TECH LINE FROM SYSTEM CERAMICS System Ceramics’ response to this need for transformation is exemplified by its ceramic slab production line. The sequence of technologies consisting of Genesis, Superfast, Eye-tron and Creadigit Infinity represents the cutting edge of innovation in the industry. Genesis is an innovative three-dimensional fullbody decoration system based on fully digital and integrable process management and is the ideal solution for today’s slab production requirements. Genesis replicates every aspect of the natural material. Deposition of the full-body spray-dried powder is the first step towards the creation of a ceramic product that emulates natural material to an astonishing degree. In terms of its dimensions and characteristics, Genesis integrates perfectly with the Superfast mouldless press, which stands out for its high production flexibility based on the zero-waste mouldless process and has the lowest energy consumption levels of its category. Given the compatibility between Superfast and Genesis, the latter can be considered a hybrid between a pressing machine and a digital printer in accordance with a new plant engineering approach aimed at upgrading the production process. Superfast mouldless pressing technology not only focuses on the visible surface but also redefines the back of the tiles. The press is capable of creating a three-dimensional, customised design, taking the idea of a ceramic surface to an entirely new level in terms of customisation and originality. CWR INDIA 2024

Superfast is also closely interconnected with the drying stage, for which purpose System Ceramics is proposing the first Fastdry horizontal multi-channel dryer ready to accept recovered heat flows. These machines are also synchronised with decoration systems and in particular with Creadigit Infinity, the digital printer with unprecedented computing power which now incorporates water-based inks, resulting in between 40% and 50% lower emissions. Creadigit Infinity represents the next step forward in high-resolution digital printing. Not only can it be positioned anywhere on the line, it also has an astonishing degree of flexibility, with configurations of up to 12 colours and different families of inks and materials, offering unprecedented control over the creation of ceramic surfaces. This in turn is integrated with the new Eye-tron, which dialogues with the digital printer in real time to ensure perfect synchronisation between the surface designs and the through-body effects. Eyetron is a three-dimensional vision system that ensures unparalleled precision in creating the through-vein effect. Eye-tron scans and accurately detects the position of the through vein obtained with Genesis, making it a key component in ensuring a flawless end result. System Ceramics is investing heavily in this overall vision in the knowledge that an advanced, dynamic approach is essential to ensuring the highest level of competitiveness for its customers and the industry as a whole given that product quality is intrinsically linked to improved productivity. But what are the advantages? Above all, consistent and lasting results. As well as delivering

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high-quality products with outstanding aesthetic value and unlimited creative potential for both full-body and decorated surfaces, System Ceramics also guarantees long-term reliability, further aided by its membership of the Coesia Group. SUSTAINABLE GROWTH The second goal is sustainable growth. Superfast, Creadigit Infinity and all the other technologies have a shared focus on saving energy resources and raw materials, and on ensuring the utmost respect for the environment and human beings. Another key contribution is made by Hypermate powered by Prime, the software services platform designed to organise the information flows of entire factories with a high level of integration and connectivity. The platform’s data driven vision allows it to offer considerable advantages in terms of reduction in energy and raw material wastage. A system-based design approach creates a collective mindset and ensures that a shared language is used throughout the process. In other words it establishes an optimal connection, resulting in improved functionality, the ability to finetune processes and consequently higher levels of production performance and aesthetic quality. ALL-ROUND CUSTOMER SERVICE Customer service is another important aspect of this integrated approach. An all-round vision that includes technical support and technology upgrades on all machines guarantees a consistent plant set-up. This brings advantages in terms of overall performance and enables technicians to make overall assessments and fine-tune the production process to ensure a longer machine lifetime and higher process efficiency. SHALL WE STILL TALK ABOUT “CERAMIC SURFACE”? As we have seen, from conventional ceramic tiles to the latest through-vein slabs, System Ceramics’ production line transforms ceramic surfaces into a highly competitive and sustainable asset for manufacturers. System Ceramics has established itself as a pioneer within the dynamic landscape of the ceramic industry, responding to the growing need for materials with added value. The key to this revolution lies in reinterpreting the traditional role of ceramic tiles, elevating them from mere floor or wall coverings to prestigious interior design elements. This radical transformation has centred around the use of advanced technology and a production line specialising in throughvein ceramic slabs. System Ceramics has expanded the field of application of ceramic tiles by moving beyond the limited definition of a surface and introducing a broader and higher value concept. The advent of through-vein technology has acted as the catalyst for this change. The use of Genesis technology to create products with remarkable aesthetic depth has made it possible to replicate natural materials almost to perfection. This change has made the traditional concept of “ceramic surface” obsolete, paving the way for new potential applications and market opportunities.

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'kq"d lqij&i‚fyÇ'kx ds lkFk dk;Z'khyrk vkSj lkSna ;Z'kkL= FUNCTIONALITY AND AESTHETICS WITH DRY SUPER-POLISHING Marco Sichi, BMR (Scandiano, Italy)

Driven by the need to improve the productivity and efficiency of new technologies, BMR has made further investments in R&D with the aim of developing a new finishing solution capable of guaranteeing an adequate, constant and high-performance workflow. These needs are largely met by SuperShine, the hi-tech surface treatment machine that is transforming the ceramic surface and slab finishing process. SuperShine is effectively the first dry super-polisher. The process is based on a mechanical and physical interaction between the tool, the surface and the applied chemical product and is designed to enhance the digital graphics of the tile and give the surface a high level of gloss and protection.

Fig. 2: Untreated ceramic slab and slab treated with SuperShine

Fig. 3: Reduction in roughness of the treated surface The reduction in roughness makes the glaze extremely transparent with more reflected than refracted light

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technology Fig. 1: The lapping process

Lapping is the first processing step and involves removing a portion of the surface from glazed and/or porcelain products (photo 1). Its aim is to achieve the desired finish, giving the surface a high gloss level and an appearance of greater reflectivity and depth thanks to the considerable reduction in roughness (photos 2 and 3). The lapping phase is followed by finishing and then treatment. In this stage, SuperShine alters the morphology of the surface by filling the pores that typically occur in the material, giving the finished product very specific technical characteristics such as high abrasion and acid resistance. A lapped product generally arrives at the super-polishing stage with a Gloss value of 55/60 and roughness Ra 0.060 mm, whereas after treatment the Gloss level is 95/100 and average roughness Ra 0.020 mm. With this final roughness value the tile has a good level of resistance to soiling and staining. Photo 4 shows an electron microscope image of a surface treated with supergloss applied by a BMR SuperShine lapping and treatment line. For a correct understanding of the images, it is important to note that the colour scale is inversely proportional to the density. Higher density elements therefore appear whiter, while the voids (corresponding to an absence of density) appear blacker the deeper the pore. In the photo showing a specimen of treated material, the light and uniform colour of the pores indicates a high degree of penetration of the treatment (the lighter the colour, the denser the treatment). Conversely, we can see that the colour of the glaze around the pores has remained unchanged, indicating that it has not been coated with any material. On enlarging the images (photos 5 and 6), we can see that not only the colour but also the appearance of the pores has changed. The green and blue boxes show the points where a qualitative analysis of the chemical elements present was carried out. The resultant spectra are shown below.

UNTREATED

TREATED

Fig. 4: Electron microscope analysis of treated and untreated surfaces

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UNTREATED MATERIAL (FIG. 7) The compositional analyses show that the elements present in the pore of the untreated material are the same as those found in the area surrounding the pore, namely: Si, O, Ca, Zn, Na and K. In box 3 relating to the empty pore, note the background noise represented by the values of between 0 and 2. This is because the surface is more difficult for electron beams to reach due to the cavity. MATERIAL TREATED WITH SUPERSHINE (FIG. 8) Comparing the values for the empty pore with the subsequent spectra (filled pores) for the treated material, it is evident that the elements inside the pore have changed whereas those in the area surrounding the pore have remained the same. This is due to saturation of the porosity following the treatment and underscores the fact that the surface portion of the glaze has not been coated. Si, O, Ca, Zn, Na and K are again found in the area surrounding the pore, whereas almost solely Si and O are found inside. It can also be seen that the quantity of C (carbon) is very low and practically the same in all the samples, demonstrating the inorganic nature of the treatments. Conversely, the Au (gold) peak is attributable to metallisation, a technique necessary to prepare the samples for scanning. As can be seen from the above analysis, the post lapping process using SuperShine improves both protec-

Fig. 5: Untreated sample (empty pores are dark coloured)

Fig. 6: Treated sample (pores filled by the treatment are light coloured)

Fig. 7: Spectra of untreated material

Fig. 8: Spectra of treated material

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TAB 1. ROUGHNESS ANALYSIS Untreated

Treated with SuperShine

Measurement

0.053

1.613

0.156

0.046

0.443

0.066

0.046

1.513

0.112

0.045

0.861

0.089

1.171

4.797

0.527

0.052

1.585

0.137

0.196

4.858

0.578

0.048

0.971

0.089

0.086

3.031

0.249

0.037

0.567

0.063

0.144

3.797

0.395

0.081

1.241

0.169

0.063

1.191

0.124

0.132

1.190

0.210

0.100

3.460

0.328

0.079

1.091

0.144

0.199

5.589

0.595

0.098

1.198

0.208

0.108

3.773

0.333

0.094

1.955

0.247

AVERAGE

0.053

3.364

0.340

0.071

1.110

0.142

tion and the surface finish. Following the lapping process, the average roughness value Ra was further reduced by approximately 40% (Table 1). CONCLUSIONS The tests carried out show that the SuperShine process has a dual function: aesthetic polishing performed by the mechanical action of the tools, and a protective treatment that involves closing the surface porosity. These results are demonstrated both by the increase in gloss level (from 73/76 at the entrance to 89/92 at the exit from SuperShine) and by the lower degree of roughness, which is reduced by a further 40% after lapping. The compositional analyses also show that no material from the treatment is found on the glaze and that the treatment inside the pores is inorganic. Furthermore, the polishing process carried out with SuperShine allows the line to be upgraded in terms of finish. The process has a proven track record of improving aesthetic quality due to its ability to remove finishing defects such as stains, movement marks and tiny scratches. This increases the productivity of the line by reducing fixed production costs and significantly improves the quality of the slab.

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Fig. 9: Acid resistance

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Fig. 10: Foot traffic resistance

Your ambition, our colours

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u;k rki iquçkZfIr lekèkku NEW HEAT RECOVERY SOLUTIONS Poppi Clementino (Reggio Emilia, Italy)

In today’s highly uncertain and critical energy market, optimising the energy sources that are already present on site is a strategic choice that can be delayed no longer. In particular, flue gases originating from ceramic kilns are an important resource that must not be wasted regardless of their level of contamination. This is why many ceramic companies around the world are opting for the solutions supplied by Poppi Clementino, especially the latest generation of P-Rex© Series heat exchangers. ENGINEERING The P-Rex© series plate-shaped heat exchangers were designed as an upgrade to the previous range of machines, which enjoyed considerable market success with dozens of units installed in the factories of leading world ceramic groups. Poppi Clementino’s efforts to continuously improve its range has led to the development of the P-Rex© series, which stands out for the improved design of the contact surfaces as well as an increasingly meticulous choice of materials. This series of machines represents the new technological frontier of heat exchange as it can achieve lower flue gas temperatures at the heat exchanger exit and consequently recover a greater quantity of heat. Latest-generation analysis software was used to study the paths and fluid-dynamic flows inside the heat exchanger, thereby determining the most critical areas for the exchange surfaces. Advanced modelling software allowed the machine’s internal design to be improved, achieving a level of thermal efficiency that is unmatched in the ceramic industry.

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ENERGY SAVINGS P-Rex© heat exchangers are an ideal solution for energy-saving systems, especially for recovering the heat potential of the flue gases produced inside the kiln during the ceramic firing process. This new series of heat exchangers is a key component of the latest high-performance systems designed by Poppi Clementino, but they can also be easily integrated into existing systems. To further improve its performance, P-Rex© can be used in conjunction with advanced energy recovery systems such as cogeneration plants and new technologies for pre-heating slurry upstream of spray dryers (EnerGX© technology).

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pØh; vFkZO;oLFkk % vif'k"V ls iqupZØ.k rd CIRCULAR ECONOMY: FROM WASTE TO RECYCLING Minerali Industriali Engineering (Novara, Italy)

Recent sociopolitical events have forced the entire business world to rethink production processes, and the ceramic industry is no exception. While innovation remains the main driver, there is an increasing focus on sustainability in terms of raw materials procurement and energy consumption. The aim is to improve the efficiency of all processes while maintaining the industry’s excellent results and reducing costs and consumption, for the wellbeing of humans and the planet. Minerali Industriali Engineering - MIE supplies state-of-theart technologies for the preparation of raw materials for ceramic bodies and has a forward-looking vision aimed at optimising efficiency and sustainability. Thanks to its more than a century of experience in raw materials processing combined with continuous R&D efforts, the group is renowned for its extensive expertise covering various fields of application. SOLUTION REC The Solution REC series from MIE meets the need for great-

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technology

er efficiency and sustainability. It consists of a range of extremely versatile “End of Waste” processes for recycling waste from various industrial sectors including ceramics, glass and stone agglomerates and for grinding industrial minerals in general. The ground materials can subsequently be reused in companies’ production cycles, ensuring a significant long-term reduction in disposal costs. All REC solutions can be customised according to the available layout and specific customer requirements. Using a closed-loop model, all waste can be mixed with a smaller quantity of high-quality infeed material, a solution that brings considerable financial savings in terms of raw material purchases and energy and logistical costs, as well as a lower environmental impact by avoiding landfill. Solution REC can also use the patented Fusion® technology, the cutting-edge dry raw materials preparation technology which almost completely eliminates water consumption while maintaining the same quality standards as ceramic body produced using wet technology. Along with water savings, additional advantages for the entire industrial process include lower energy consumption and the reduction of pollutants. Fusion® also guarantees a high degree of production flexibility and in the case of Solution REC operates effectively even with smaller quantities of raw materials while maintaining the excellence of this Italian-made technology.

WASTE type Green body waste

WASTE typ Green body waste

SOLUTIONS

Ceramic tile manufactur

SOLUTIONS for

GREE GREEN BOD RECYCLING

Ceramic tile manufacturers

RECYCLING

Rec Green Body is an innovative system that allows the recovery of materials at a lower cost than the known traditional techniques.

This process takes place through several stages,

BODY

including: Rec Green Body is an innovative system that 1. humidifying stage; allows the recovery of materials at a lower cost 2. compacting stage; than the known traditional techniques. 3. grinding stage.

This process takes place through several stages, Thanks to these phases, the recovered materials including: can be reused as new raw materials. 1. humidifying stage; The use of Rec Green Body helps to reduce the 2. compacting stage; environmental impact of waste and to preserve 3. grinding stage. natural resources, thus contributing to a greater sustainability of our planet. Thanks to these phases, the recovered materials can be reused as new raw materials.

The use of Rec Green Body helps to reduce the environmental impact of waste and to preserve natural resources, thus contributing to a greater sustainability of our planet.

To optimise the various processes, MIE has developed different ranges of Solution REC: • REC MUD and REC GREEN BODY, for recycling unfired wastes, mainly in the tile, sanitaryware, engineering stone and limestone sectors; • REC Ti and REC Pi for fired tile and sanitaryware waste; • REC GLASS for recycling glass. THE REC GREEN BODY SOLUTION The REC GREEN BODY range was developed for recycling unfired waste, from the cutting and squaring process of large panels. The waste, which has a moisture content of 3%, is humified and subsequently compacted, ground and sieved. This process improves the final granulate’s homogeneity, flowability and density, resulting in a high level of stability during the pressing, drying and firing phases.

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CWR INDIA 2024

fo|qr&ÅtkZ dh gkfu jksdus ds fy, fVdkÅ vkfo"dkj SUSTAINABLE INNOVATION TO COMBAT ELECTRICAL ENERGY WASTAGE Gmm Group (Fiorano Modenese, Italy)

Improving the energy efficiency of industrial processes is now a real necessity for ceramic companies given the current energy crisis and the increasingly urgent need for more environmentally sustainable production activities. The Gmm Group, a Global Industrial Partner for the ceramic industry, leverages the expertise and synergies offered by its subsidiaries Gmm, Bbm and E. Malaguti and works in partnership with leading industrial automation brands to offer solutions capable of reducing companies’ electricity consumption across all factory departments. IMPROVING THE EFFICIENCY OF COMPRESSED AIR SYSTEMS Among its various partnerships, the Gmm Group is an official service provider for Festo, a leading company in the pneumatics and automation sector. Pneumatic industrial automation is responsible for significant energy costs, but also has plenty of room for efficiency gains. In a production process that makes intensive use of compressed air, the pneumatic systems are subject to frequent leaks, which unfortunately are also difficult to detect. For decades, the industry resorted to the use of ever larger compressors rather than carrying out extensive maintenance, but with today’s high electricity costs, this is no longer feasible. For example, a leak with an average diameter of 2.0 mm at a service pressure of 7 bar results in a financial loss of approximately €2,886 per year. In response to the need for solutions capable of reducing consumption and improving plant efficiency, the Gmm Group offers an innovative service aimed at detecting and remediating air leaks. This state-of-the-art solution reduces costly energy losses. The key strength of the service lies in its perfect combination of technological and human factors. Using ultrasound instrumentation and exploiting the expertise of in-house maintenance technicians and product specialists, the Gmm Group is able to provide all-round consulting based on an energy audit that identifies leaks and quantifies their cost. The client company benefits from a customised service that includes a wide range of solutions, from the replacement and restocking of damaged components to the possibility of revamping or modifying existing applications. This brings an overall improvement in energy efficiency that is consistent with the principles of the circular economy.

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GREEN POWER Motors Ceramica Valsecchia and Rettifica GMC are two of the companies that have successfully adopted the Gmm Group’s service, which since the beginning of 2022 has been seeing an increasing number of requests and a sharp increase in post-research revamping projects.

SUSTAINABILITY AND INNOVATION

NEW HIGH-PERFORMANCE ELECTRIC MOTORS As part of its ongoing commitment to research and development of innovative products and services aimed at improving the energy efficiency of ceramic production facilities, Bbm has teamed up with Siemens to launch the first electric motor specifically designed for industrial ventilation systems used in ceramic kilns. Called Green Power Motor by Siemens, it can be easily identified by the Gmm Group’s trademark green colour. One of the main technical characteristics of the new motors is their total electrical insulation, which significantly improves their energy efficiency while also preserving their durability and resistance to mechanical failure. This characteristic is crucial for solving a problem that often occurs when an electrically-driven system is started up and modulated by the variable speed drives typically used on inverters. Due to the rapidly rising voltage pulses and high switching frequencies, these drives can induce eddy currents in the motor shaft which are then discharged onto the internal bearing raceways, causing premature deterioration. The special insulation adopted on Green Power motors interrupts the current arc generated between the rotor and stator, thereby protecting the bearing and ensuring better operation of the entire motor. CWR INDIA 2024

technology

Another key feature of these motors is their high energy efficiency, which is IE4 on all models. For the same output as IE3 standard models, these motors have lower electricity consumption and atmospheric CO2 emissions, resulting in greater environmental sustainability, a significant reduction in costs and a short ROI compared to the investment needed to replace the old motors. Other key technical features that contribute to improved motor performance include the presence of grease nipples and PTC thermistors as standard on all sizes. When used in conjunction with automatic lubrication devices such as the Bbm Performa Lube systems, grease nipples can significantly extend the motor’s service life as they ensure correct and regular lubrication of the bearings, thereby keeping them in perfect operating condition. A CIRCULAR ECONOMY APPROACH BASED ON COMPONENT RECONDITIONING AND RECOVERY Another way to improve the sustainability of industrial processes is to adopt good circular economy practices aimed at reducing resource consumption through recycling. E. Malaguti, now part of the Gmm Group, has been operating in this field for over 30 years. The company specialises in electromechanical recovery and reconditioning of critical components such as electric motors, power reducers and grinding line spindles, which are subsequently reintroduced into production systems with a significant improvement in terms of performance and lifetime. In the ceramic production process, surface finishing operations (such as lapping and grinding) play a major role in terms of both overall production efficiency and the essential contribution they make to the technical and aesthetic quality of the finished product. Over the years, E. Malaguti has undertaken a process of specialisation culminating in the acquisition of “SKF Certified Partner” certification for the reconditioning of grinding spindles, the components subject to the highest mechanical stress and therefore requiring continuous and specific maintenance. The most sustainable solution developed by E. Malaguti and certified by SKF involves completely reconditioning the spindle and restoring it to the same level of production efficiency as a new component. In all its spindle reconditioning operations, E. Malaguti replaces the internal mechanical components (shaft, seals, bearings) with original SKF components. In addition, it uses special greases for the first internal lubrication in order to reduce the operating temperature of the spindle, thereby extending its service life and postponing replacement. To guarantee continuous and efficient production and eliminate waiting times, E. Malaguti also offers its Gemini on-site replacement service which involves collecting non-functioning spindles directly at the factory and at the same time supplying reconditioned, tested and certified components.

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cgqr xeZ ns'kksa ds fy, Vuy Hkëh TUNNEL KILN FOR VERY HOT COUNTRIES Equipceramic (Vilanova del Camì, Spain)

Equipceramic has developed this project for countries where extremely high temperatures are reached. The aim is that working temperature in a factory, in this case a brickwork, does not exceed 50 ºC, which is the temperature determined by numerous countries as the limit temperature in working environments. Among all types of equipment installed in a factory producing bricks or roof tiles, the kiln is the major source of heat because of two main reasons: the high interior temperatures (set around 1000 ºC) and the large radiation surface due to its enormous surface. That is why it is necessary to bring a special attention to the design and insulation system of the kiln, if the aim is to preserve moderate temperatures inside the factory. This case required the development of a new project to keep the external walls of the kiln at 50 ºC, despite an ambient temperature reaching 45 ºC, which means that the difference between ambient temperature and external walls temperature was only 5 ºC. Moreover, a reduction of energy consumption with respect to the traditional kiln has been achieved too. In terms of lowering the temperature of the external walls of the kiln, the addition of wall insulation is not enough, because it implies an exaggerated increase of the thickness of the walls and enormously high execution costs. Therefore, for this new project, after the required calculations for insulation and heat transfer, the choice was made to increase the thickness of the insulation and to introduce an air-cooling circuit for the external walls of the kiln, thus ensuring the wished reduction of temperatures. Air used for cooling walls is collected by means of some manifolds and then it is injected in the kiln by the air to burners circuit, which allows for significant savings on the energy consumption of the kiln. A similar solution has been applied for cooling the ceiling of the kiln where a powerful cooling circuit has been installed below the roof deck. In this case, cooling air is routed to the dryer. HIGHLY VENTILATED DRYER The dryer represents another relevant radiation source, but in this case the solution applied is different. On the one hand, wall and ceiling insulation has been increased by applying sandwich and spray foam-type construction solutions and, on the other hand, the change in the philosophy of ventilation turns to be the most interesting aspect. It is a semi continuous dryer equipped of cone-shaped air-recirculation fans.

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heavyclay

This dryer shows the following variations compared to the traditional semi continuous dryer: • 40% reduction in width of dryer cars. • 40% increase of the number of air-recirculation fans, and • 40% increase of airflow rate. The introduction of these three measures allows the air to better penetrate the products to be dried, the reduction of drying cycles and, mainly, the possibility to operate at lower temperatures inside the dryer. The decrease of working temperatures in the dryer results in an automatic reduction of temperatures of the interior walls. Moreover, if the insulation of external walls is increased, we succeed to obtain a difference between ambient temperature and external walls temperature below 5 ºC.

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ADVERTISING

INNOVATION CREATIVITY FLEXIBILITY SERVICE

Y OUR S UPPLIER & B USINESS P ARTNER www.equipceramic.com

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IN INDIA

Lopkfyr fMi XysÇt+x dh uÃ lhek THE NEW FRONTIER OF AUTOMATIC DIP GLAZING Sacmi Tableware Division (Imola, Italy)

MONO 10T Evolution is the new solution for automatic dip glazing of cups, mugs and bowls. It is the successor to Sacmi-Sama’s well-established MONO 10T, which for over two decades has been the industry standard for automatic glazing of these types of articles. The new solution adopts a single highly automated and efficient process. The first advantage of the new machine is its modular design, which allows for maximum flexibility in the choice of configurations, resulting in greater scope for customisation and shorter delivery times. This plug&play solution simplifies both the shipping and the assembly and testing stages, allowing the customer to take an incremental approach to the investment and integrate new features over time. Equipped with 10 glaze pots, the MONO 10T Evolution stands out for its rapid glaze-colour changeover, its reduced maintenance requirements and a series of new features specially designed to minimise set-up times and increase plant uptime. Machine movements are controlled by servo-assisted motors to ensure maximum precision of operations. All the set-

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tableware

tings can be made in a simple and intuitive manner thanks to a PLC interface. Improved accessibility to the machine helps the operator perform routine cleaning and maintenance operations (for example, the glaze tank can be easily installed or removed from the machine using guides and wheels, allowing for rapid glaze changeover). In the Evolution version, the glazing arm rotation mechanism has also been redesigned so as to optimise the angle at which the pieces are dipped into the glaze and minimise contact between the glaze and the supports, thereby further reducing cleaning times and needs. The cup is rotated while being dipped into and removed from the glaze to avoid the formation of drops and residues on the surface, thereby guaranteeing perfect quality of the glazed piece. Additional features have been introduced to increase machine uptime. For example, if a piece falls into the glaze tank, the MONO 10T Evolution has a safety valve to hold the rest of the pieces safe on the supports while the machine stops automatically and removes the article from the glaze. This is a particularly important feature in the case of single firing production processes. A further innovation concerns the pick-up system, which is specially configured to allow for dip-glazing of wash foot articles. These products are increasingly in demand as they have a small incision on the bottom of the cup to help water flow out during a normal washing cycle. MONO 10T Evolution is the only solution on the market capable of performing automatic glazing of this type of product.

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Syneco

Inco

Digital application 02

Engobes

Body 01

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Glaze 04

Digital decoration 05

Final protection 06

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Efi Cretaprint

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inkjet decoration robust, reliable and performing inkjet printers EFI Cretaprint has been in the global tile industry for 25 years with digital decoration solutions that include a wide range of inkjet printers, inks, and color management software. It is an innovative ecosystem delivering reliability and high image quality.

www.efi.com · cretaprintsales@efi.com

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Rimini Expo Centre - Italy 24 - 27 SEPTEMBER 2024

The international exhibition of technologies and supplies for surfaces tecnaexpo.com

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ENDLESS INNOVATION SINCE 1919