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

3Technologies for Large Formats

PH 10000PH 10000

Nowadays SACMI offers several different technologies

suitable for large formats

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

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

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

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

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

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

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

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

12Technologies for Large Formats

CONTINUA+ promo video

� Official video

13Technologies for Large Formats

14Technologies for Large Formats

DDD PCR DHD

DECORATION LINE

DIGITAL POWDER APPLICATION

STRUCTURED BELT

DIGITAL WET DECORATION

15Technologies for Large Formats

APB-0Base body

DDDPowder decoration

PCR 2000Compaction

Powder application

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

17Technologies for Large Formats

DDD Digital Dry Decoration

18Technologies for Large Formats

STRUCTURED BELT

COATED STEEL BY UV RESIN

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

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

20Technologies for Large Formats

DIGITAL GRAPHICS DEVELOPMENT

DDD FILE STRUCTURE FILE DHD FILE

PRODUCT DESIGN LINE Set-up

21Technologies for Large Formats

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

22Technologies for Large Formats

DRY DECORATION - (DDD color 1)

23Technologies for Large Formats

DRY DECORATION - (DDD color 2)

24Technologies for Large Formats

PRESSING WITH STRUCTURED BELT - ( PCR2000 )

25Technologies for Large Formats

INK-JET DECORATION - ( DHD )

26Technologies for Large Formats

FINAL PRODUCT - ( travertino )

27Technologies for Large Formats

PRODUCT EXAMPLES

28Technologies for Large Formats

TravertinoBase powder

DHD (4 barre colore)

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

PRODUCT EXAMPLES

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

30Technologies for Large Formats

EKO kiln

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

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)

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.

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.

34Technologies for Large Formats

Thank you for your attention