Innovative technologies for the production of large ... technologies for the production of...
Transcript of Innovative technologies for the production of large ... technologies for the production of...
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Innovative technologies for the production of large -formats,
decoration and firing
Andrea Morozzi – SACMI
November 27th, 2015
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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
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3Technologies for Large Formats
PH 10000PH 10000
Nowadays SACMI offers several different technologies
suitable for large formats
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4Technologies 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
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5Technologies for Large Formats
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
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6Technologies for Large Formats
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
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7Technologies for Large Formats
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
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8Technologies for Large Formats
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
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9Technologies for Large Formats
� 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
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10Technologies for Large Formats
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
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11Technologies for Large Formats
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
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12Technologies for Large Formats
CONTINUA+ promo video
� Official video
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13Technologies for Large Formats
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14Technologies for Large Formats
DDD PCR DHD
DECORATION LINE
DIGITAL POWDER APPLICATION
STRUCTURED BELT
DIGITAL WET DECORATION
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15Technologies for Large Formats
APB-0Base body
DDDPowder decoration
PCR 2000Compaction
Powder application
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16Technologies for Large Formats
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
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17Technologies for Large Formats
DDD Digital Dry Decoration
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18Technologies for Large Formats
STRUCTURED BELT
COATED STEEL BY UV RESIN
Width range: 1000÷1900 mmBelt length: 7500 mmRelief depth: 1mm
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19Technologies for Large Formats
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
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20Technologies for Large Formats
DIGITAL GRAPHICS DEVELOPMENT
DDD FILE STRUCTURE FILE DHD FILE
PRODUCT DESIGN LINE Set-up
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21Technologies for Large Formats
APB-0 + APB-00 (base body + second layer)
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22Technologies for Large Formats
DRY DECORATION - (DDD color 1)
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23Technologies for Large Formats
DRY DECORATION - (DDD color 2)
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24Technologies for Large Formats
PRESSING WITH STRUCTURED BELT - ( PCR2000 )
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25Technologies for Large Formats
INK-JET DECORATION - ( DHD )
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26Technologies for Large Formats
FINAL PRODUCT - ( travertino )
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27Technologies for Large Formats
PRODUCT EXAMPLES
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28Technologies for Large Formats
TravertinoBase powder
DHD (4 barre colore)
TravertinoBase powderDDD (2 grafiche)DHD (4 barre colore)
PRODUCT EXAMPLES
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29Technologies for Large Formats
Marble «Pavonazzetto»Base powderDDD (2 graphics)DHD (4 colour bars)
Travertino greyBase powderAPB-M (mix powders second layer)DHD (4 colour bars)
PRODUCT EXAMPLES
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30Technologies for Large Formats
EKO kiln
RR RLW RF900 – 1250 °C500 – 899 °C30–499 °C
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31Technologies for Large Formats
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)
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32Technologies for Large Formats
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.
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33Technologies for Large Formats
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.
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34Technologies for Large Formats
Thank you for your attention