innovative technologies for the production of large ... technologies for the production of...

Innovative technologies for the production of large -formats,

decoration and firing

Andrea Morozzi – SACMI

November 27th, 2015

2Technologies for Large Formats

Large Ceramic Formats: evolution of presses

1980 1990 2000 2010

600 t 1.500 t 3.000 t 10.000 t

20x20 4u.0,16 m2

30x30 4u.0,36 m2 60x60 2u.

0,72 m2 100x200 1u. 2,00 m2


PH 10000PH 10000

Nowadays SACMI offers several different technologies

suitable for large formats


PH 10000

� Max size 120 x 180 cm� Thickness 3 ÷ 30 mm� Production up to 10.000 sqm/day

� Max size 120 x 180 cm� Thickness 3 ÷ 30 mm� Production up to 10.000 sqm/day


CONTINUA line with PH10000 press

� Max size 120 x 180 cm� Thickness 3 ÷ 30 mm� Production up to 8.000 sqm/day� Very high value products

� Max size 120 x 180 cm� Thickness 3 ÷ 30 mm� Production up to 8.000 sqm/day� Very high value products


New CONTINUA+ line

� Max size 160 x (unlimited) cm� Thickness 3 ÷ 20 mm� Production up to 14.000 sqm/day� High value products

� Max size 160 x (unlimited) cm� Thickness 3 ÷ 20 mm� Production up to 14.000 sqm/day� High value products


New CONTINUA+ line

� Introduced in 2012 (GranitiFiandre Italy)

� Presently 15 lines installed/sold (7 Italy, 8 World)

� There is NO final press, since PCR+ applies the total force by means a special steel belt

� Real thickness from 3 to 20 mm (fired)

� Max format 160 x (theoretically unlimited) cm

� Great variety of effects (even in the body and surface)

� Very high throughput (up to 14.000 sqm/day)

� Decoration with extra-large digital printers

� Structured surface with special steel belt


New CONTINUA+ line

� The Continua+ line does not require any foundation; all machines are simply placed over the ground

� The perfect compaction all over the front ensures low scraps (less 3%)

� Very low energy consumption (- 80% with respect a PH press)

� The PCR+ press is very silent

� No dust generation, no environmental pollution


� Continua+ allows easy realization of full body , multi-layer and structured effects suitable for different product destinations

� Thermal insulation (with foamed ceramic)

� Aesthetical stratifications� Savings of expensive raw materials

� Structured surfaces


New CONTINUA+ line� Heart of the Continua+

technology is the new PCR+high pressure belt compatter (SACMI’s patent)

� The high pressure roller system plus a special high resistance steel belt allows to reach definitive compacting action onto the powders

� The continuous action of PCR+ allows tremendous throughput of perfectly pressed slabs


New CONTINUA+ line� In order to produce structured

surfaces , the pressing steel belt can be covered by a special resin layer, reproducing the desired relief

� The layer, seamless, is applied by means a special process (SACMI’s patent)

� The quality of the relief, the shining of the surface are strength points of this exclusive process

� The change of the structured belt requires 30 minutes


CONTINUA+ promo video

� Official video


DDD PCR DHD

DECORATION LINE

DIGITAL POWDER APPLICATION

STRUCTURED BELT

DIGITAL WET DECORATION


APB-0Base body

DDDPowder decoration

PCR 2000Compaction

Powder application


DDD Digital Dry Decoration

FEEDING MATERIALS

SPRAY DRIED POWDERSMoisture

2,5÷5%

SPRAY DRIED GLAZESMoisture

2÷3%

GRAINS 3 mm max

FLAKES 3 mm max

Vibrating plates

Hopper

Width range: 1000÷1900 mmResolution: 100 dpiGraphic length: up to 200 m


DDD Digital Dry Decoration


STRUCTURED BELT

COATED STEEL BY UV RESIN

Width range: 1000÷1900 mmBelt length: 7500 mmRelief depth: 1mm


DHD 1808 1882 mm

DHD 1408 1390 mm

DHD High Definition Decoration

up to 8 colour bars

1200 mm

1500 or 1600 mm

resolution: 360 dpi

Large formats


DIGITAL GRAPHICS DEVELOPMENT

DDD FILE STRUCTURE FILE DHD FILE

PRODUCT DESIGN LINE Set-up


APB-0 + APB-00 (base body + second layer)


DRY DECORATION - (DDD color 1)


DRY DECORATION - (DDD color 2)


PRESSING WITH STRUCTURED BELT - ( PCR2000 )


INK-JET DECORATION - ( DHD )


FINAL PRODUCT - ( travertino )


PRODUCT EXAMPLES


TravertinoBase powder

DHD (4 barre colore)

TravertinoBase powderDDD (2 grafiche)DHD (4 barre colore)

PRODUCT EXAMPLES


Marble «Pavonazzetto»Base powderDDD (2 graphics)DHD (4 colour bars)

Travertino greyBase powderAPB-M (mix powders second layer)DHD (4 colour bars)

PRODUCT EXAMPLES


EKO kiln

RR RLW RF900 – 1250 °C500 – 899 °C30–499 °C


The EKO kiln advantage

� The firing of very large ceramic slabs represents a challenging technical issue

� Due to uneven temperature distribution inside the kiln tunnel, big slabs could suffer differential deformation, leading to distortions and, in some case, breakages

� The EKO kiln, recently introduced by SACMI, approaches the issue in a revolutionary way, changing the flow direction of the fumes inside the kiln

TILES

traditional kiln: longitudinal fumes flow

TILES

new EKO kiln: transversal fumes flow

� To realize this, the kiln is equipped with auto recuperative burners, that allows the transversal recirculation of the fumes at very high flame speed (up 100 m/s)


The EKO kiln advantage

� Every EKO burner has its own chimney that evacuates the relative fumes portion, after a high efficiency pre-heating of the combustion air.

� The selective fumes extraction allows also a more effective depuration (particularly F, Cland heavy metals).

� The transversal flow permits a better kiln regulation, even in case of product loss or delays.

� As a consequence, the EKO kiln performance in term of final product quality reaches top levels.


Conclusions

� The Continua+ technology recently introduced in the market allows tremendous throughput production of very high quality level ceramic slabs.

� Due to its exclusive pressing method, Continua+ ensures great homogeneity in the product density, determining good stability and low scraps level.

� Thanks to the particular restraint method, the pressing action is independent with respect the front width , allowing great format flexibility and different product size modules, always maximizing the productivity.

� The continuous belt pressing process ensures the maximum freedom in aesthetical effects , giving any possibility in term of dry or wet decoration, particularly with digital decorating machines.

� The very low energy consumption, joined with no pollution and no dust generation, makes the Continua+ process the best available technology in the ceramic field for the environment .

� Joining high productivity and beautiful aesthetical effect, the Continua+ is the future ceramic technology of the next decades.


Thank you for your attention

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