ACIMAC

HANDBOOKS
ACIMAC

HANDBOOKS

© Copyright ACIMAC, Associazione Costruttori Italiani Macchine Attrezzature per Ceramica

Via Fossa Buracchione 84 • 41126 Baggiovara (MO) • Italy • Tel. +39 059 510 336 • www.acimac.it

Edito da S.A.L.A. srl • Via Fossa Buracchione 84 • 41126 Baggiovara (MO) • Italy • Tel. +39 059 510 108

In cooperation with:

Printed in september 2011

Euro 10 - IVA assolta dall'editore

ACIMAC
HANBOOKS
Introduction
The “Acimac handbooks”, a series of
technical publications launched in
2009 with the release of the first
manual on digital decoration techno-
logies, is being further expanded
this year with two new titles: this
one devoted to “Green technolo-
gies, energy saving and cost sa-
ving in ceramics industry”, and the
second updated edition of “Digital
decoration: how to optimise cera-
Pietro Cassani
mic production”.
Both publications, produced in coo-
peration with the magazine Ceramic
World Review and presented to the
public at Cersaie 2011, are already
available on www.tiledizioni.it along
with the entire collection of techni-
cal manuals produced by Acimac
over the past decade.
The aim of the Acimac handbooks is
to promote knowledge of technologi-
cal and process aspects of the ce-
ramic industry through publications
Villa Marchetti, ACIMAC headquarter
2 . Acimac handbooks - 2011 edition
that are straightforward and easy
to read but at the same time offer
exhaustive and detailed coverage of
key issues. The ceramic technology
supplier companies have supported
us in these efforts by making their
expertise available and providing the
texts.
In recent years there has been an
enormous proliferation of technolo-
gical and plant engineering propo-
sals in the field of green technolo-
gies, along with broader solutions
for energy saving and production
cost cutting and for adding value to
ceramic products.
The topical interest of these solu-
tions also lies in the fact that opti-
mising production processes, cut-
ting energy consumption and
production costs and improving the
quality of finished products are key
factors for maintaining the competi-
tiveness of the ceramic industry and
for responding to growing envi-
Pietro Cassani
ronmental concerns amongst consu-
mers.
Acimac has also devoted two techni-
cal seminars to these issues.
The first, held on 19 May, presented
various green solutions relating to
the process phases from raw mate-
rials preparation through to firing.
The second, held on 23 June, concen-
trated on the contribution that cera-
mic finishing and end-of-line techno-
logies make in terms of increasing
the quality of ceramic products and
cutting energy consumption and pro-
duction costs in general.
The two conferences, attended by a
total of around 250 technicians from
Italian ceramic companies, provided
the material for this new Acimac
Handbook which we trust will make
an important contribution to the
knowledge of industry professionals
in Italy and abroad.
Pietro Cassani
Acimac Chairman
Green technologies, energy and cost saving
in ceramics

Contents

Preparation

Technological innovations in the grinding process

Ferdinando Cassani, Sacmi ..............................................................................................................pag. 4

Glazing & Decoration

Smaltochimica: chemistry at the service of the environment

Federico Piccinini, Lucia Guaitoli, Smaltochimica ...............................................................................pag. 8

Cutting-edge spare parts on glazing lines

Elisa Sala, FM ..............................................................................................................................pag. 12

Drying & Firing

Energy saving in drying and firing

Ferdinando Cassani, Sacmi ...........................................................................................................pag. 14

The kiln attack zone: Choice of roller

Stefano Cosmini, Keratech ............................................................................................................pag. 20

Eco-friendly solutions and reducing consumptions in drying and firing

Ruggero Casoni, Siti - B&T ...........................................................................................................pag. 24

Finishing

BMR: the added value of honing and lapping

Claudio Avanzi, Marco Cicorella, Luigi Prampolini Tirelli, BMR ............................................................pag. 32

End Of Line

4PHASESTM: the new packaging standard

Giuseppe Bandieri, Andrea Toro, System ....................................................................................... pag. 38

Processmaster and Flawmaster: Quality control of unfired and fired products

Sandro Zini, Surface Inspection .................................................................................................... pag. 42

Packaging large-format tiles: new solutions

Sandro Zini, Nuovafima .................................................................................................................. pag. 44
Acimac handbooks - 2011 edition . 3
P R E PA R AT I O N
Technological innovations
in the grinding process
by Ferdinando Cassani The grinding process in the ceramic
industry has evolved considerably
over the years, but the main steps in
the process can be outlined in terms
of a few key dates.
Prior to 1968 all ceramic bodies
consisted mainly of clays that were
dry ground using peg mills.
That year saw the introduction of
wet grinding in discontinuous mills
followed by the process of spray
drying of powders. Since then, Sacmi
has installed 5,000 mills of this kind
worldwide. In 1984 Sacmi installed
Fig. 1
the first continuous wet mill,
which marked a real technological
revolution.
And finally, 2005 saw the introduction
of the first continuous modular mill,
the latest innovation in this sector.
The discontinuous grinding process
features:
Fig. 2 • a grinding load consisting of balls
of different dimensions operating
in a single grinding chamber;
• a single type of mill lining;
• a single slip level;
• downtimes for loading and
unloading of raw materials that
reduce milling capacity.
Continuous grinding has in turn
evolved over the years and various
Fig. 3 different configurations have been
tried out.
Initially, continuous mills were
produced with a linear lining and
Fig. 4
4 . Acimac handbooks - 2011 edition
subdivided into 3 grinding chambers
(fig. 1).
The next step was the single-chamber
classifying lining (fig. 2) and finally the
2-chamber classifying lining (fig. 3),
the configuration currently in use.
The continuous modular mill (MMC)
derived from the idea of separating
the chambers of the traditional
continuous mill (MTC) with the aim of
optimising grinding in each individual
stage.
For this purpose, several
discontinuous mills have been coupled
in series and a system developed
for in-line transfer of slip from one
module to another.
In this approach (fig. 4), while
maintaining the single loading and
unloading point of conventional
continuous mills, each module is able
to operate with:
• different speeds;
• different slip levels;
• different types of grinding load;
• different types of internal lining.
These characteristics allow grinding
efficiency to be optimised in each
individual module.
Figure 5 shows installation of a
3-module continuous mill.
Figure 6 shows how the slip is
transferred from one module to
another without the use of pumps
Fig. 5
thanks to a system patented by
Sacmi. In the connection between
one module and the next it is also
possible to replenish the grinding
load without stopping the mill.
So in the light of the above, modular
mills offer the following advantages:
• Optimisation of production:
production capacity is 15%
higher than that of a traditional
continuous mill with the same
volume and installed power.
• High installation flexibility: the
third module can be installed at
a later time if and when higher
output is required.
• Gradual investment over time.
Moreover, modular mills can be used
in many different ways.
For example, they can be used to
increase the production of existing
continuous mills (acting as a refining
module downstream of an existing
continuous mill to increase its
production capacity) or for dissolving
wet clay to be sent to the grinding
stage.
Sacmi’s current range of modular
mills comprises:
• MMC074 mill consisting of two
36.8 m³ modules
• MMC092 mill consisting of two
45.6 m³ modules
• MMC111 mill consisting of three
 36.8 m³ modules
• MMC120 mill consisting of two MMC continuous modular mills
60 m³ modules
• MMC138 mill consisting of three
45.6 m³ modules
• MMC180 mill consisting of three
60 m³ modules.

All the listed machines also have

the advantage of being more easily
transportable and installable than
traditional continuous mills.
The ease of operation of the machines
remains unchanged.
Thanks to their excellent level
of automation, they have been
successfully installed in more than
Fig. 7
80 units the world over (fig. 7).

ENERGY SAVING

In a practical example that will allow
us to evaluate the benefits in terms
of electrical energy consumption
of continuous modular grinding,
we shall compare a discontinuous
grinding system with a continuous
system and a continuous modular
system for a plant producing
14,000 m²/day of glazed porcelain
tiles in a 450x450x9 mm size.
A plant set up in this way requires a
grinding capacity of 340 t/day.
This requirement can be met
by choosing one of the following
alternative solutions:
- eight 45,000 litre MTD450
discontinuous mills
- one 88,000 litre MTC088
continuous mill
- one 74,000 litre MMC074
continuous mill.
Figure 8 summarises the grinding
data for these three solutions.
Note that power consumption
decreases from 1024 kW for
discontinuous grinding to 535 kW
for continuous grinding and 425 kW
for the continuous modular solution.
Specific grinding energy drops
from 54.3 kWh/t for discontinuous
grinding to 31.5 kWh/t for
continuous grinding and 22.6 kWh/t
for the modular continuous solution.
This is equivalent to an electrical
energy saving of 42% with
continuous grinding and 51% with
modular continuous grinding.
Furthermore, due to the
complete automation of the
process, manpower requirements
decrease from 9 persons/day with
discontinuous grinding to 3 persons/
day with modular continuous
grinding.

Fig. 8

Fig. 6

Acimac handbooks - 2011 edition . 5

P R E PA R AT I O N
www.sacmi.com
Fig. 9
Sacmi, in collaboration with Industrie
Bitossi and B&B, has developed
a new composite alumina/rubber
lining for continuous modular mills
that combines the advantages of
an alumina lining (greater durability
and high grinding efficiency) with
those of the rubber lining (ease of
Fig. 10
6 . Acimac handbooks - 2011 edition
SAVINGS OF NATURAL GAS
Another advantage of continuous
grinding is that of natural gas
savings.
The continuous grinding process can
operate with a higher slip density (33%
water compared to 35%), resulting
in an approximately 2% reduction in
the quantity of water that has to be
evaporated (from 161,400 l/day to
145,800 l/day). This in turn allows
for a reduction in gas consumption
of the spray dryer (the required
evaporation capacity decreases from
7335 l/h to 6627 l/h). Furthermore,
the temperature of the slip at the
mill exit is higher (55°C compared
to 40°C), because higher milling
efficiency means that more energy
is transferred to the slip. The slip is
therefore sent to the spray drying
at a higher temperature than the
slip originating from discontinuous
THE NEW MILL LININGS
replacement and maintenance). It
consists of alumina blocks embedded
in a rubber lining bolted onto the
mill cylinder in the same way as a
conventional rubber lining (figs. 10
and 11).
The advantages are:
• About 5% higher grinding
Fig. 11
mills, which contributes to lower
gas consumption in the spray drying
process (from 791 kcal/l to 760 kcal/l
of water).
Figure 9 shows the value of energy
saving at the spray dryer. In general,
the use of continuous rather than
discontinuous grinding allows for
a reduction in spray drying gas
consumption of around 10-15%.
Summing up, the main advantages
of modular continuous grinding
compared to discontinuous grinding
are:
• 50% lower electricity
consumption
• 10-15% lower natural gas
consumption at the spray dryer
• Complete plant automation
• Reduction in number of mills
• Smaller occupied space.
efficiency, with a consequent
increase in production and
energy saving.
• Around three times longer
lifetime compared to a lining
made of just rubber.
• Comparable replacement times
to those of rubber linings.
 NOTE

Acimac handbooks - 2011 edition . 7

 GLAZING AND
by Federico Piccinini and Lucia Guaitoli
Fig. 4
8 . Acimac handbooks - 2011 edition
DECORATION
Smaltochimica: chemistry at
the service of the environment
Over the last few years the world of
industry has been showing a greater
awareness of eco-sustainability.
Attention to the environment
is now no longer limited to the
sensibilities of individual citizens but
also extends to companies, whose
eco-friendly efforts can really make
a difference.
This is also beginning to be seen in
the chemicals industry, where the
green revolution essentially involves
the application of three golden
rules:
1. the use of eco-friendly raw
materials;
2. a drastic reduction in waste in
chemicals production;
3. reduction in energy costs.
The ideas behind this increasingly
topical and concrete “green
chemistry” movement originated in
the early 1990s with the formulation
of 12 principles by Paul Anastas,
who saw in the green revolution the
possibility of successfully combining
ecology with economics.
Of Anastas’s principles, the first
would appear to be common sense:
“It is better to prevent waste than
to treat or clean up waste after it
is formed”.
Smaltochimica has embraced this
principle by developing a new series
of antibacterial additives called
Biocleaner.
These products optimise the
ceramic production process so as
to obtain tiles with an extremely
high bactericidal action which, when
used as floor or wall coverings,
allow for a drastic reduction in
the use of cleaning and sanitising
products with a high environmental
impact.
Ever attentive to environmental
issues, Smaltochimica has decided
to adopt a process of eco-
sustainable chemistry, following in
the footsteps of other important
chemicals and petrochemicals
groups.
Eco-sustainability is the principle
of controlling human activities in
accordance with environmental
principles within a framework of
sustainable development.
Eco-sustainability means
consuming resources in such a
way that we are able to pass on
to the next generation the same
quantities of resources that
we received from the previous
generation.
Campaigns promoting
environmental awareness have
contributed enormously to the
emergence of eco-sustainability in
the world of chemistry.
Smaltochimica has always devoted
a great deal of attention on
the formulation of eco-friendly
products that allow for reduced
environmental impact both during
production and when applied to
ceramic products.
Several years ago it began to study
additives with low VOCs (volatile
organic compounds) during both
application (glazing) and the firing
process (flue gases).
With the Biocleaner additives this
goal has been widened to include
a reduction in the consumption
of chemical products (cleaning
and sanitising products and
disinfectants) over the entire
lifetime of the tile.
 ANTIBACTERIAL SURFACE: THE GREEN REVOLUTION

Nanotechnology is an expanding designed to protect spaces that

science that allows for need to be totally aseptic. It is
the production and use of an additive capable of reducing
nanoparticles, as demonstrated bacterial contamination by
by the new ceramic materials from controlling microorganisms and
Smaltochimica. thereby reducing the consumption
Biocleaner is a completely natural of cleaning and disinfection
and inorganic antimicrobial product products.

USE AND ACTION OF BIOCLEANER

Silver nanoparticles have long been
known and used for sanitisation.
Thanks to its natural properties,
silver has been used as an
antibacterial agent for more than a
thousand years.
Biocleaner is an additive based on
silver nanoparticles encapsulated in
an inert matrix.
The product is supplied as an aqueous
suspension to facilitate batching
and to avoid problems relating to the
handling of nanometric powders.
The well-known antibacterial
properties of silver make it effective
as a bactericidal agent for surfaces,
including ceramic tiles.
Silver is present in the product
as a mixture with carefully
selected chemical compounds and
elements and has a synergic action
that enormously increases the
antibacterial effect.
The size of the silver particles used,
between 1 and 100 nm, gives the
active principle a relatively large total
surface area.
This allows the contact area with
the bacteria to be increased thereby
improving the product’s antimicrobial
efficacy.
Biocleaner must be added during
grinding of the glaze used to cover
the ceramic tile (more precisely at
the end of the grinding process,
after which it must be completed for

Acimac handbooks - 2011 edition . 9

 GLAZING AND

DECORATION
www.smaltochimica.it
a further 45-60 minutes).
This ensures a uniform presence of
particles of silver throughout the
applied thickness of glaze and a
uniform distribution over the entire
surface of the tile.
This in turn guarantees long-
term antibacterial efficacy of the
treatment and also allows the tile
to undergo lapping or honing while
maintaining the surface bactericidal
properties.
The quantity of Biocleaner that has to
be added to the liquid glaze depends
on the applied weight of glaze.
Biocleaner is designed in such a way
that it does not affect the gloss or
colour characteristics of the tile
after firing. It does not require light
to be activated and therefore has
a prolonged action, night and day,
throughout the year.
Furthermore, the product’s
antibacterial effect is enhanced in
the presence of moisture, a condition
that promotes the proliferation of
bacteria.
This technology can be used in any
place or application that requires the
maximum hygiene, safety, cleanliness
and simple cleaning and maintenance
procedures. Ceramic tiles treated
with Biocleaner are particularly
suitable in healthcare facilities,
dental surgeries, laboratories,
schools, swimming pools and
sports centres, wellness centres,
kitchens and bathrooms, bars and
restaurants and food factories.
Biocleaner was developed on the basis
of microbiological tests performed
in accordance with international
standard ISO 26196:2010, which
standardises methods for measuring
antibacterial activity on plastics and
other non-porous surfaces (such as
ceramic tiles).
Smaltochimica offers the support of
specialist technicians in conducting
the initial tile treatment tests. It
also offers the services of a qualified
laboratory that performs free of
charge all the microbiological tests
necessary for preliminary product
certification and for setting up
the treatment, and which must
be validated by a second official
certification from an authorised
laboratory, at the discretion of the
user company.
The Biocleaner treatment offers
ceramic companies the opportunity
to create products with high added
value capable of increasing the
market share held by ceramic tiles.

THE ACTION OF THE ANTIBACTERIAL AGENT

Nanometric silver is a broad- basis of a process of migration but the cell count remains constant.
spectrum antibacterial agent that is releases silver ions via a mechanism If the bacteriostatic agent is
effective against both gram-positive regulated by ion exchange laws. removed or its concentration falls,
and gram-negative bacteria, including Ion exchange stops when equilibrium bacterial growth resumes.
Pseudomonas. conditions are reached, thereby The bactericidal effect of
Biocleaner does not act on the maximising the product’s efficiency Biocleaner results in the death of
and extending its the microorganism cells but does
lifetime. not cause lysis, or disintegration of
Adding an the cells.
antimicrobial agent Bactericides are normally
to a bacterial substances that bond irreversibly
culture undergoing to cellular components and are not
e x p o n e n t i a l removed with dilution.
growth can have When using a bactericide, the
three effects: total cell count remains constant
bacteriostatic, while the number of living cells falls.
bactericidal and A bacteriolytic agent has the
bacteriolytic. effect of killing the microbial cells
The bacteriostatic and causing lysis, or disintegration.
effect is that of They often act by inhibiting
inhibiting the growth synthesis of the cell wall or by
of bacterial cells damaging the cell membrane.
but without killing When using a bacteriolytic agent,
them. Bacteriostatic the total cell count falls in step
agents often act with that of the living cells.
by inhibiting protein This way the nanoparticles of
synthesis in the silver inhibit the proliferation and
target organism. growth of the bacteria that cause
When using a infections, foul odours, irritations
bacteriostatic agent, and other unpleasant effects.
10 . Acimac handbooks - 2011 edition
 ADVANTAGES OF BIOCLEANER PROTECTION

The main advantages offered by tile • Resistance to high-temperature • Technology developed in

treatment with Biocleaner are the
following:
• Effective and odourless
antibacterial action
• Stability, as it is a natural and
inorganic product
• Non-toxicity as there is no
migration of active silver
particles
firing cycles (below 1250°C)
• Compatibility with the glazes
normally used in the ceramic
process (it does not affect the
colour or surface of ceramic
tiles)
• Possibility of use in spaces
where the maximum hygiene is
required
conformity with national and
international standards:
JIT Z 2801:2000 and ISO
26196:2010
• Lasting antibacterial protection
that is not eliminated by normal
cleaning of the ceramic surface
with cleaning agents, abrasives
and high temperatures.

PROCEDURE FOR ANTIBACTERIAL CERTIFICATION

The performance of Biocleaner end user of the tiles. The tests for evaluating antibacterial
allows the required antibacterial The recognised international efficacy are performed using
efficacy to be easily achieved, even certification refers to the standard dedicated microbiological cultures
when it is as high as 99.9%. ISO 26196: 2010 based on the of Staphylococcus aureus (gram
It depends only on the percentage previous Japanese standard JIT Z positive) and Escherichia coli (gram
of Biocleaner that is added to the 2801:2000. negative), which are deposited on
ceramic glaze. The certifications must comply with the surface of the tiles and left to
Obtaining certifications is this standard which is the only one proliferate in the laboratory.
fundamentally important for applicable to ceramic materials. The antibacterial activity of a
controlling the product’s Each individual State has treated ceramic tile is expressed as
antibacterial action and laboratories and authorised bodies a percentage of bacteria eliminated
guaranteeing the stated for performing product tests and with respect to the same untreated
performance characteristics to the issuing certifications. material.

CERTIFICATION TEST

With the support of

Smaltochimica, promoting
antibacterial products is quick
and simple.
To optimise the timeframes
and costs necessary for
setting up and certifying
the treatment with
Biocleaner, Smaltochimica
offers the support of
specialist technicians and
the free performance of
microbiological tests. If the
results are positive, this
preliminary certification must
be validated by a second
official certification from any
authorised laboratory.
Acimac handbooks - 2011 edition . 11
 GLAZING AND
DECORATION
Cutting-edge spare parts
on glazing lines
by Elisa Sala The company F.M. has always
maintained a focus on technical and
technological development and on
continuous experimentation in the
Disk packs in particular make up
the company’s core business.
Based on more than thirty years
of experience in collaboration
with ceramic companies, F.M.
has developed a full range of disk
packs capable of meeting any
requirement.
This invaluable knowledge is made
available to customers through
a consulting service that helps
identify the right disk pack
according to the parameters of use
so as to achieve the best effect or
solve specific glazing problems.
As part of its constantly expanding
range, the latest disk pack line from
F.M. is Evolution, which marks a
real quantum leap forward and won
the S.T.A.R. award (Italian acronym
for Development, Technologies,
Applications & Research) as
innovative product of the year.
Evolution represents a genuine
revolution in disk glazing, differing
12 . Acimac handbooks - 2011 edition
field of new raw materials, offering its
services as a technical partner in the
design and construction of technical
items made of thermoplastic
EVOLUTION DISK PACKS
from past solutions in terms of its
new glaze application principle.
Glazing occurs by impact (the
glaze is transformed into a fluid
flow) rather than the previously
used process of nebulisation (in
which the glaze is transformed into
micro-droplets).
This brings numerous advantages,
the most important of which are
the following:
1) Total elimination of mist in
the glazing department
An improvement in
environmental conditions in
the glazing department is
one of the most important
advantages of Evolution.
The mist caused by spray
application is entirely
eliminated.
The absence of mist also
increases the durability of all
components of the line.
The quantity of used glaze
is also reduced as less is
dispersed to the environment.
2) Improved application even
on textured surfaces and in
the case of very low speeds
of rotation and application
weights
In the impact application
technique the glaze is able to
reach holes and depressions in
the surface of textured tiles
(e.g. stone effect) without the
need to increase application
weight, thereby achieving
savings in terms of quantity of
glaze used.
Furthermore, for the same
application and results a lower
speed of rotation is required
materials. For the ceramic sector
it offers a wide range of spare parts
for glazing lines that includes more
than 5,000 articles.
compared to the past.
3) Total elimination of “memory
lines”
In the past, the problem of
lines on tiles arose from the
disk configuration, which has
been entirely redesigned in the
Evolution disk pack.
4) Complete disposal and
recycling
At a time of growing
awareness of environmental
issues, Evolution is an eco-
friendly solution.
The fact that it is made from a
single thermoplastic material
produced in a single pressing
means that it can be fully
recycled.
5) Energy saving
The fact that Evolution
consists of a smaller number
of elements allows for
simplified production and
consequently energy savings.
Furthermore, due to its
lower weight with respect to
conventional disk packs (its
geometry and the material
used allow for an approximately
40% reduction in weight of the
finished product compared to
previous disk packs), Evolution
also allows for lower energy
expenditure during rotation
while achieving improved glaze
penetration and uniformity.
To help ceramic companies improve
spare parts management and
reduce warehouse stock, Evolution
has been designed in a single model
that can be adapted to all glazing
booths by means of a “configuration
kit”. Each Evolution pack contains a
cap set (closure cap, lower closure
cap, cap with Ø35, Ø30, Ø25 holes,
To achieve maximum efficiency in disk
glazing, F.M. also proposes the use
of plastic glaze supply pipes.
In addition to the lightness and
durability of plastic, these pipes offer
numerous advantages, including:
• Optimisation of disk pack
performance
They have holes of decreasing
diameter (larger at the base and
smaller at the top), allowing the
glaze to be distributed over the
entire length of the disk pack and
not just in the final section due to
the glaze injection pressure. This
results in uniform application over
the entire tile.
etc.) to allow for universal use. perfect base for modern digital www.fm.re.it
Due to the above-mentioned applications and for subsequent
characteristics, Evolution is application of the protective glaze
recommended for producing a layer.
GLAZE SUPPLY PIPES
• Different choices of
application weight
Three versions are available
distinguished by different
colours (Grey, Orange, Black)
and two different sizes
(short and long) to meter the
necessary glaze weight.
So to change application
weight it is sufficient to
change the pipe without
altering the other line
parameters.
The pipes are supplied in kits to
be adapted to any kind of booth
and can be combined with all disk
packs produced by F.M.
NOTE
Acimac handbooks - 2011 edition . 13
 DRYING &

FIRING
by Ferdinando Cassani The reduced availability of energy
sources and the consequently higher
costs makes it essential for the
purposes of strategic development
for companies to optimise both the
production process and the use of
Energy saving
in drying and firing
energy resources.
To meet this growing need, Sacmi
has set up H.E.R.O. (High Efficiency
Resource Optimizer), a research
laboratory devoted to developing
innovative technologies and achieving
the greatest possible savings in
resources at every stage of the
production process. In addition to
clear economic benefits, it also
allows for a significant reduction in
emissions of CO2 and pollutants.

SELF-RECOVERY SYSTEMS ON KILN

An analysis of the energy system pre-heats the air in the

consumption of the ceramic
production cycle shows that the
kiln is the thermal machine with the
biggest share of consumption.
The energy balance of conventional
kilns is such that some 23% of the
energy introduced into the kiln is
lost with combustion gases and a
further 55% is lost to the cooling
Fig. 1 air flue (Fig. 1).
To improve this energy balance,
Sacmi has concentrated its efforts
on the combustion air supplied to
the burners.
The first step was to introduce
a heat exchanger into the fast
cooling stage to cool the products
inside the kiln and to pre-heat the
combustion air sent to the burners
to approximately 100°C (Fig. 2).
This application brings fuel savings
of up to 5%.
The next step was the MDR system,
which collects the air evacuated
from the cooling flue at an average
temperature of approximately
120°C.
Fig. 2
Following suitable filtration, the
heat exchanger and sends it to the
burners in the form of combustion air
at a temperature of around 160°C
(Fig. 3). With this application the fuel
saving relative to a conventional kiln
may be as high as 10%.
Another interesting recovery system,
called SPR, is similar to the previous
one but splits the cooling flue into
two flues, the first of which collects
cooling air at a higher temperature
and the second expels air at a lower
temperature.
This means that only the hot air
emitted at the first flue (super-
heated air) is collected and conveyed
to the heat exchanger, allowing
the burners to be supplied with
combustion air at a temperature of
around 210°C (Fig. 4).
With this application the fuel saving
relative to a conventional kiln may be
as high as 15%.
Another higher-level recovery system
called XTR represents a variant of
the SPR with the sole difference
that the temperature of the air

Fig. 3 Fig. 4

14 . Acimac handbooks - 2011 edition

taken from the first cooling flue is
higher, supplying the burners with
combustion air at a temperature of
around 300°C after being filtered and
passing through the heat exchanger
(Fig. 5).
The combustion air pipes must be
RECOVERY FROM KILN TO DRYER
The hot air reused as combustion
air inside the kiln normally accounts
for only a portion of the air sent to
the flue, so the rest can be used for
recovering heat in the horizontal or
vertical dryers.
The heat recovered from the
multi-level horizontal dryers is
significant only if high-temperature
air originating from the hotter kiln
cooling flue is used.
This is because these machines
perform drying with short cycles at
a high temperature.
In these conditions the amount
of heat recovered may be as high
as 50% of consumption depending
on the operating conditions of
the machine and the quantity and
temperature of the hot air available.
On vertical dryers, energy savings
are achieved by recovering hot
air used for replenishment and as
combustion air.
The average quantity of air that can
be recovered on each dryer in the
EVA series is equal to:
• 3,100 Nm3/h with a max.
temperature of 200°C for EVA
912 – 993,
• 4,100 Nm3/h with a max.
temperature of 200°C for
larger EVA models.
The air is supplied by means of a
double pipe that connects to the
dryer’s side panel and a pipe that
supplies the burner fans.
Figures 6 and 7 show the hot air
pipe that connects to the tower
and the EVA dryer burners.
In this case fans capable of treating
high-temperature air must be
mounted on the burners.
The amount of heat that can
mounted outside the structural
framework to allow for adequate heat
insulation and to avoid overheating
the equipment on board the machine.
With this application the fuel saving
relative to a conventional kiln may be
as high as 15% or more.
be recovered depends on the
temperature of the hot air available Fig. 5
at the dryer but may be as high as
45%.
As it consists of hot air free of
pollutants, no kind of purification
is required. In the event of a dryer
stoppage, the air can be released
directly to the atmosphere.
As an example, we shall consider
recovery on four EVA 983 dryers
with the following design data,
using hot air both for replenishment
and as combustion air:
• Max. flowrate of hot air that
can be recovered for each
EVA983 = 4,100 Nm3/h
• Temperature of hot air entering
EVA983 = 180°C Fig. 6
• Ambient temperature = 25°C
• Natural gas (LHV) = 8,480
kcal/Stm³.
In this case we obtain a thermal
energy saving of 197,000 Kcal/h for
each EVA 983. This is equivalent
to 23.2 Stm³/h of gas, with a total
saving of 92.8 Stm³/h.
Considering 18 h work/day for 280
days/year, this allows for an annual
saving of 467,700 Stm³/year.
Calculating a gas cost of 0.3 €/Stm³
this results in economic savings of
140,300 €/year.
Fig. 7
Sacmi has created a kit consisting
of a burner with pilot flame available It brings significant energy savings,
for all EVA series vertical dryers. especially when frequent product
This simple device allows the changes are performed.
burner to be shut down completely The advantages of this type of plant
depending on the amount of hot air are:
supplied or in the event of temporary • expected return on investment
stoppage of the line (e.g. product/ within about 2 years;
size change), and subsequently • total absence of additional
restarted automatically. maintenance.
Acimac handbooks - 2011 edition . 15
 DRYING &
FIRING
www.sacmi.com
AUTOMATIC CONTROL OF FLOWRATE TO VERTICAL DRYER FLUE
To improve the thermal efficiency of
the dryers in the various operating
conditions, Sacmi has developed an
automatic system for adjusting the
flue door by means of an inverter
coupled with a humidity control
system. In order to optimise operation
EVA983 – Savings in replenishment air with difference
between T flue and T external air of 100°C E
Savings with respect to open flue (kcal/h)
Press output (kg/h)
Sacmi has designed a new and
completely innovative kiln called
EKO which represents a genuine
Fig. 10 technological revolution.
In a conventional kiln, the combustion
16 . Acimac handbooks - 2011 edition
of the dryer, the combustion gas
flowrate to the flue must be as low
as possible to reduce consumption
while achieving an appropriate value
of humidity in the dryer, maintaining
a suitable dryer internal pressure
and preventing the release
of hot air.
As shown in figure 8,
automatic control of the
combustion gas flowrate
is achieved by fitting a
hygrometer on the flue
as well as two pressure
switches and an inverter to
control the combustion gas
expulsion fan.
The dryer PLC is pre-
designed to manage these
devices and therefore to
automatically regulate the
Replenishment air (Nm3/h)
set humidity.
If the flue flowrate is set
correctly, the heat released
with combustion gases is
normally no greater than
25% of the heat supplied.
But if the characteristics
or quantities of the product
to be dried are changed
and the flue flowrate is not
consequently adjusted, this
value may rise to as much as
37%, reducing the machine’s
thermal efficiency.
As an example, we shall
consider an EVA 983 model
dryer with the following
production data:
NEW EKO SERIES KILNS
gases generated during firing flow
towards the kiln entrance in the
opposite direction to the ceramic
Fig. 11 undergoing firing (fig. 9).
products
As they do this, the combustion
• Incoming humidity: 5.5%
• Outgoing humidity: 0.3%
• Flue gas temperature: 125°C
• Production 1: PH 8000 kg/h
• Replenishing air: 2000 Nm³/h
• Savings compared to completely
open flue: 45,000 kcal/h
• Production 2: PH 7000 kg/h
• Replenishing air: 1430 Nm³/h
• Savings compared to production
1: 62,500-45,000=17,500
kcal/h.
The graph shows the necessary
replenishing air flowrate (right) and
the energy savings compared to the
fully open flue (left) according to the
hourly production (x-axis).
It is clear that considerable energy
savings can be made by suitably
regulating the flue gases according to
production performed in the various
stages of the cycle. This operation
can be considerably simplified by
using an inverter and a hygrometer
to manage the flue fan and brings the
following advantages:
• Energy savings of around
15% compared to operation with
open flue.
• Optimisation of the flue flowrate
at every stage of dryer operation
(shut-down, pause, start-up)
according to the set humidity
value.
• Possibility of managing internal air
humidity according to the type of
body.
gases entrain new volumes of air and
exchange thermal energy with these
air volumes and the products, which
lowers their average temperature.
At the kiln entrance, the combustion
Fig. 8
gases are evacuated at an
average temperature of between
450°C and 500°C.
By contrast, in the EKO kiln the
combustion gases generated
in each thermal zone exchange
heat directly with the products
(fig. 10). The combustion gases
are evacuated in the same area,
giving up part of their residual
heat energy to the ceramic heat
exchanger located inside the self-
recovering burner.
The temperature of the evacuated
combustion gases is between
200°C and 250°C.
This lower combustion gas
temperature corresponds to a
more efficient heat exchange
SELF-RECOVERING BURNERS
Fig. 12
NEW EKO KILNS
Fig. 9
process, which in turn leads
to lower energy requirements.
This and the use of special self-
recovering burners allows for an
NEW EKO KILNS
energy saving of at least 20%.
Figure 11 shows the different
routes followed by the combustion
gases in the 2 kilns.
At the heart of the new kiln lie
the self-recovering burners (fig.
12), which allow the combustion
air to be pre-heated due to the
counterflow movement of the
combustion gases evacuated
from the kiln. Figure 13
illustrates the operating principle
of the self-recovering burner.
The combustion air, collected at
ambient temperature, is pre-
Fig. 10
NEW EKO KILNS
Fig. 11
Acimac handbooks - 2011 edition . 17
 DRYING &
FIRING
www.sacmi.com
heated by the combustion gases
that leave the kiln and flow against
the chamber used to carry air to the
SELF-RECOVERING BURNERS
gas mixing and combustion stages.
The EKO kiln essentially offers the
following advantages:
• Optimisation of combustion gas/
product heat exchange.
• At least 20% reduction in
consumption.
• Optimisation of temperature
curve profile.
• Positive and stable pressure
throughout the kiln.
• Stable temperature and pressure
as the production volume
Fig. 13 changes.
NOTE
18 . Acimac handbooks - 2011 edition
• Possibility of selecting the
combustion gases and purifying
them or, if requested, using them
as they are.
• Simplified machine operation.
• Fewer upper and lower limits to
the kiln length.
• In the event of a fall in production,
the possibility of redesigning the
thermal profile over a smaller
number of thermal zones,
deactivating those that are
unnecessary. In theory, it is like
having a variable length kiln. This
makes it possible to keep specific
consumption constant in spite
of a reduction in production
volumes, resulting in lower fuel
consumption.
Acimac handbooks - 2011 edition . 19
 DRYING &

by Stefano Cosmini
Sample A
Sample B
Fig. 1 - Samples of rollers A and B
20 . Acimac handbooks - 2011 edition
FIRING
Ceramic rollers must have two main
characteristics:
1. They must have a high elastic
modulus and therefore a low
tendency to bend under load, to
ensure that the material moves
forward correctly in the kiln.
2. They must have the longest
possible lifetime.
This is ensured by an effective
choice of the type of roller
to be used in the various kiln
zones.
The kiln attack zone:
choice of roller
Chemical attack is the phenomenon special importance is given to the
that has the greatest impact use of zircon.
on the average lifetime of a roller The use of this raw material gives
inside the kiln. the product superior mechanical
It normally occurs in a zone between characteristics, increases
800°C and 1000°C but in modern thermal shock resistance and also
kilns the airflows involved and the considerably influences chemical
ever faster cycles required by resistance.
the market may also lead to roller
attack issues in the firing zone. Two identical mixtures were
In this short article we shall attempt prepared and zircon added to one
to explain the mechanisms that lie of them.
behind chemical attack and the The final compositions of the two
characteristics that rollers must samples were as follows:
have to overcome these problems.
SAMPLE 1 SAMPLE 2
Firstly, a roller intended for use in Alumina 57.7% Alumina 72.7%
a particularly aggressive zone must
have low porosity. Mullite 19.3% Mullite 24.3%
Clearly, a less porous material offers
Zirconia 20% Zirconia ---
fewer potential entrance routes
for aggressive agents, so it is Clay 3% Clay 3%
important to reduce the porosity of
the roller both percentagewise and The two prepared samples were fired
in terms of the physical dimensions at 1620°C with a sinter time of 3
of the pores. hours. The results obtained from the
There are various ways to achieve density and porosity tests revealed
this, either using special raw the essential role played by the
materials with given characteristics presence of zircon.
or using different particle sizes.
For example, the use of a raw
SAMPLE 1 SAMPLE 2
material with finer particle size
and therefore a larger specific d=2,90 Kg/dm3 d=2,70 Kg/dm3
surface area will also have a higher
reactivity. P=17.9% P=23.8%
This will influence the degree of
sintering, allowing a product with As regards resistance to alkaline
lower porosity to be obtained. attack, the function of zirconia is
not limited to reducing porosity but
This is fairly intuitive and can be also has a fundamental influence on
observed in the image in Fig. 1, chemical behaviour.
which shows two rollers composed Here too we can look at a practical
of exactly the same mixture where example.
only the particle size of the reactive
raw materials has been changed. The test involved casting a cubically
Density and porosity were shaped refractory block with l =
measured using the standard water 75 mm and a central hole of depth
immersion method and the following 25 mm, produced with the same
values were obtained: composition and with the same firing
Sample A: d=2.80 kg/dm3 P=18% parameters as SAMPLE 1 above.
Sample B: d=2.95 kg/dm3 P=14%
So simply by making these changes SAMPLE 1
a reduction in porosity of more than
Alumina 57.7%
20% was obtained.
Mullite 19.3%
Significant results can be obtained
simply by adding special raw Zirconia 20%
materials.
Clay 3%
In the production of ceramic rollers,
The central hole was filled with a at 1370°C for 72 hours. and of 5 interface zones a distance
standard sodium-calcium-silica At the end of this period, a chemical 0.5 mm apart.
glass screened to 600 micron. analysis was made of the vitreous The results are shown in the
The sample was then left to stand phase, of the refractory material following table and in fig. 2:

GLASS 1 2 3 4 5 REFRACTORY
Na2O 8.7 6.6 5.3 4.5 4.8 4.0 0.4
Al2O3 24.4 43.2 49.7 53.2 50.9 52.2 67.6
SiO2 59.2 30.2 26.4 24.1 27.2 24.2 18.6
K2O 0.5 0.2 0.3 0.3 0.4 0.2 0.2
CaO 7.2 5.7 2.7 1.5 0.9 0.6 0.1
ZrO2 - 14.0 15.6 16.4 16.0 18.7 13.1

As can be seen from the analyses
and the photo in fig. 2, zirconia is
not present at the interface when
the glass begins to penetrate
inside the pores, and the small
particles of alumina distributed
randomly around the vitreous phase
are absorbed into this phase.
During penetration of the vitreous
phase, acicular alumina crystals
(with random orientations) are
formed as the particles of alumina
diffuse through the vitreous phase.
In this phase the acicular alumina
crystals have a length of between
10 and 30 µm.
The particles of zirconia dispersed
uniformly around the vitreous phase
prevent it from penetrating inside
the pores.
In this zone, the alumina reaches
its maximum solubility in a phase
with a high silica-calcium content
at a distance of about 500 µm from
the initial vitreous phase. In this
phase the crystals grow to a length
of around 65µm.
From the refractory zone, the
primary particles of alumina that
dissolve and enter the vitreous
phase precipitate in the form of
even longer crystals, reaching a
length of 150µm.
However, the particles of alumina
located along a zirconia-rich path
tend to maintain their initial shape
and their growth is limited by the
presence of zirconia (see fig. 3).
In this zone, the zirconia acts as a
barrier that obstructs the progress
of the vitreous phase.
Fig. 2
It can therefore be argued that the
degree of corrosion of an alumina-
mullite-zirconia based material
(such as a ceramic roller) placed at
a high temperature in the presence
of alkalis is governed by a vitreous
phase zirconia transport system
and the consequent decomposition
of the crystals.
The analyses show that the increase
in alumina and zirconia concentration
is inversely proportional to that of
silica and alkalis.

Fig. 3
CORROSION OF MULLITE

Ceramic rollers used in kilns are
normally mullite based.
The use of this material raises
the melting point of ceramic and
gives it good resistance to creep
deformations, a low coefficient
of thermal expansion and good
characteristics of thermal shock
resistance.
Here too we can look at a practical 1200°C.
example to investigate the behaviour Fig. 4 shows the results of the X-ray
of mullite when subjected to an refractometry.
alkaline type chemical attack.
In this specific case, sodium chloride In these conditions, sodium
(NaCl) was used. penetrates to a depth of about 10-
Mullite based samples were left 20 µm from the surface.
exposed to the attack for 4h and The main corrosion reaction that
24h at temperatures of 1000°C and occurs can be summed up by the
Acimac handbooks - 2011 edition . 21
 DRYING &

FIRING
www.keratech.net
following formula:

2Al6Si2O13(s) + 8NaCl(l) + O2(g) → 4NaAlSiO4(s) + 4Al2O3(s) + 2Na2O(s) + 4Cl2(g)

This is the reaction that occurs in rollers in normal operating conditions. Due to the stack
effect generated by the rollers, alkalis are able to penetrate inside the porosity of the
rollers and condense when they encounter a lower temperature (towards the kiln walls),
consequently altering the chemical structure of these areas. In these areas the internal
surface of the roller will have a different chemical and mineralogical composition to the
external surface and hence different characteristics and properties (fig. 5).

Fig. 4 Fig. 5

In this case the parameter of
greatest interest is the different
dilatometric behaviour of the phases
in question (internal and external).
The dilatometric behaviour of an
attacked roller may vary by as much
as 20% due to the different chemical
and mineralogical compositions that
are created.
If the roller is subjected to rapid
cooling (e.g. removing the roller from
the kiln for cleaning), an excessively
large difference in thermal expansion
between the two surfaces (which
have become chemically different)
will generate tensile stress (and we
know that the tensile strength of
ceramic is 6-7 times lower than its
compressive strength), resulting
in the formation of a longitudinal
crack along its entire length and
consequently breakage.
This kind of breakage has now
become fairly common and tends
to be incorrectly attributed to
thermal shock experienced by the
roller, whereas in reality it is a
classic example of damage caused
by chemical attack.

THE IMPORTANCE OF THE VITREOUS PHASE IN AN “ATTACK ZONE” ROLLER

Due to the raw materials used
and the firing temperature, each
individual type of roller has its own
mineralogical composition that
varies according to the intended
use.
For example, a roller that has to
withstand high loads and is intended
for use in the firing zone should
have a very low vitreous phase in
Fig. 10
its composition (lower than 1%) to
prevent bending caused by creep
22 . Acimac handbooks - 2011 edition
phenomena and to guarantee as
uniform support as possible for
the transported material, which
displays maximum pyroplasticity in
this zone.
Conversely, at lower temperatures
where the rollers do not require any
special characteristics, products
with a certain percentage of vitreous
phase can be used to achieve
Fig. 11
superior mechanical properties
even in low-cost products.
It is essential for rollers intended
for use in the attack zone to have
a certain percentage of vitreous
phase, because when the roller is
fired (at temperatures of between
1400°C and 1600°C or more)
around one third of the zirconium
dioxide present in the mixture
dissolves inside the roller’s vitreous
phase, giving rise during operation
to the processes described above.
We shall give a practical example of
this.
Two sample sections of roller were
taken, with the characteristics
shown in the table:
ROLLER ROLLER
A B
Density (Kg/dm3) 2.7 2.8
Porosity (%) 19 17
E (GPa) 85 105
Vitreous phase (%) 3.5 <2
From the values of elastic modulus
and vitreous phase percentage, it
is clear that roller A is much more
suitable for use in an attack zone,
whereas roller B is suitable for use in
the firing zone.
Both samples were placed in a closed
box made of refractory material in
the presence of NaOH and KOH and
CONCLUSIONS
The examples given clearly show how
important it is to use high-quality
rollers, which amongst other things
bring cost benefits.
Suffice it to think how much kilns
have changed in recent years.
They now have 3 metre wide entrances
and high chamber pressures and are
used to fire ceramic bodies containing
recycled washing water with all kinds
of impurities.
And given that concentrations of
aggressive vapours inside the kiln
have increased exponentially whereas
their condensation temperatures
have remained unchanged, rollers are
required to operate in truly extreme
conditions.
These are the issues that Keratech
left for 60 h at a temperature of
1250°C.
The cross-section of both rollers was
subsequently analysed with a SEM to
verify the degree of attack (figs. 6a
and 6b).
In figs. 6a and 6b, the mapping of K2O
is shown in green and that of Na2O
in red.
At first glance it can be noted that
in roller A the attacked region was
limited to the surface zone, whereas
in roller B it extended to a greater
Roller A
depth.
The following results were recorded: Fig. 6A
ROLLER ROLLER
A B
K2O (%) 1.24 2.29
Na2O (%) 0.88 0.96
has been focusing on in its research
efforts. In particular, the company’s
high-quality, cutting-edge products Roller B
that satisfy market requirements
Fig. 6B
are a source of great satisfaction.
The decision to double production
(the new production line was officially
opened a few weeks ago) has also
proved successful in a period in which
markets have not entirely emerged
from the crisis.
We wish to thank Sacmi Imola and
Sacmi Forni for their collaboration,
which led to the creation of a work
group focusing exclusively on roller-
related issues which is at our
customers’ disposal at all times for
queries of a technical nature.
NOTE
Acimac handbooks - 2011 edition . 23
 DRYING &
FIRING
Eco-friendly solutions and
reducing consumptions in
drying and firing
by Ruggero Casoni In the ceramic tile production
process, the firing stage is the
cycle with the highest energy
requirements alongside spray
drying.
KILN: SPECIFIC CONSUMPTION
To gain a better understanding of
energy consumption issues, we
shall take a look at the specific
consumption (Kcal/h per kg of
product) of a ceramic tile kiln.
4 terms contribute to specific
consumption:
1) Energy necessary to make the
endothermic reactions take place
2) Energy necessary to heat
the product to the firing
temperature
3) Energy lost through the kiln walls
4) Energy lost via fumes.
Let’s evaluate the 4 terms in detail.
1) Energy necessary to make the
endothermic reactions take
place.
The precise value of this term
depends on the chemical
composition of the tile body.
In normal operation this value can
be estimated as
q1s =Kre = 50 Kcal/Kg
2) Energy necessary to heat
the product to the firing
temperature.
Assuming:
- cpp the value of the tile’s
specific heat
- Tc the tile’s firing temperature
- Ti the tile’s incoming
temperature.
We can define:
q2s = cpp(Tc-Ti)
3) Energy lost through the kiln
walls.
Starting out from the
consideration that about 2/3 of
the length of a kiln is devoted to
the process of supplying energy
to the product, considering:
24 . Acimac handbooks - 2011 edition
Most kilns currently in operation
generate heat through the
combustion of a gaseous fuel, either
natural gas or liquefied propane gas.
The steady increase in purchasing
- Lf the kiln length
- Lb the width of the kiln
entrance
- Hc the height of the
combustion chamber
- k coefficient related to the
overall thermal exchange
coefficient through the kiln
walls
- Tamb ambient temperature.
We can define:
P = 2/3 Lf 2(Lb+Hc) k (Tc-Tamb) (1)
Defining Gp as the kiln’s production
value in terms of kg/h of tiles, if we
divide (1) by this value we obtain the
expression for the specific energy
losses through the kiln walls:
q3s = 2/3 Lf 2(Lb+Hc) k (Tc-Tamb) /
Gp (2)
4) Energy lost via fumes.
The fumes give up energy to heat
the products and give up further
energy in the form of losses
through the kiln walls.
The rest is lost to the
atmosphere.
a. a. Energy lost through the
flue.
Assuming :
- gfp the ratio between the
fume flowrate and the
product flowrate
(kg fumes/kg product)
- cp specific heat of the fumes
- Tuf fume exit temperature.
We can define:
q’4s = gfp cp (Tuf -Tamb)
b. b. Energy lost through the kiln
walls.
Assuming:
gfd the portion of the fume
flowrate, compared to the
costs over the years and a green
vision of energy consumption and
environmental emissions have led
to the development of systems for
cutting consumption.
product flowrate, equivalent
to the thermal power lost
through the walls. As a
formula it can be written as,
Pdpar= gfd cp (Tc –Tuf)
from (2) we can write:
2/3 Lf 2(Lb+Hc) k (Tc-Tamb) / Gp = gfd
cp (Tc –Tuf)
from which we obtain:
gfd = 2/3 Lf 2(Lb+Hc) k (Tc-Tamb) /
[ Gp cp (Tc –Tuf)]
The thermal energy lost to
the environment due to this
fume flowrate can therefore be
expressed as follows
q”4s = gfp cp (Tuf -Tamb)= 4/3 Lf
(Lb+Hc) k cp (Tuf -Tamb)(Tc-Tamb) /
[ Gp cp (Tc –Tuf)]
We can therefore define the total
specific consumption of fired
product as the sum of the values
of qi:
Cs= q1s + q2s + q3s + q’4s
+ q”4s (3)
Reworking (3) we obtain a
simplified expression:
Cs = 50 +0,25 (Tc-Ti)+693 Lf
(Lb+Hc)/Gp+(Tuf -Tamb) {0,24 gfp
+ 693 Lf (Lb+Hc)/ [Gp (Tc-Tuf)]}
which, for the same kiln
dimensions, type of insulation
and products, clearly shows
that specific consumption is
dependent on the fume outflow
temperature.
Where it is not possible to reduce
 the contribution of Tuf for content of the fume flow rate
technological reasons, it is that would otherwise be lost to
clearly worth recovering the heat the environment.

COMBUSTION

Fig. 1-2: Siti B&T axial burner with

high-speed combustion head
Combustion reactions are always therefore the greatest efficiency. combustion air by the HV65 head
oxidation reactions in which fuel However, to avoid the formation results in optimal air-fuel mixing in
is oxidised in the presence of a of unburned products a condition the combustion chamber.
combustion agent or oxidising gas, of excess air is generally adopted Together with the combustion
generally oxygen. (apart from rare cases in which chamber geometry, this guarantees
The combustion mechanism a reduction process is required a high fume velocity and therefore
consists of 4 separate phases: according to the specific type of an excellent temperature
product being fired). distribution across the width of the
a. mixing kiln chamber.
b. pre-combustion For this purpose, Siti B&T has
c. combustion developed and optimised a high- The use of radial burners, which
d. post-flame reactions. velocity burner with special are normally positioned above and
attention to the mixing unit. below the rollers in the last stage
The mixing phase serves to promote
Gaseous fuel and combustion air of firing, is able to offset the
intimate and uniformly distributed
enter the burner separately and small temperature discrepancy
contact between the particles
are then mixed in the combustion between the central section of
or molecules of fuel and the
chamber, immediately below the the kiln and the walls, thereby
combustion air.
HV65 combustion head (detail 4 in eliminating calibre variations.
The construction geometry of the
fig. 1). Simply replacing the mixing
burner is crucially important in this
head on old-generation Siti-B&T
stage.
The swirl motion imparted to the machines (HV61 head and SITI
The pre-combustion phase, which
occurs between 400°C and 600°C,
generates unstable and extremely Fig. 2
reactive species (free radicals or
atoms) that are responsible for the
speed of the subsequent oxidation
reactions.
In the combustion phase, the free
radicals combine with oxygen and
with fuel molecules in a complex and
rapid sequence of chain reactions,
generating incomplete oxidation
products (CO, H2, …), complete
oxidation products (CO2, H2O,…)
Fig. 3: Firing channel temperature
and other free radicals. Fig. 3 Firing channel temperature
In the post-flame reactions, a
portion of the combustion heat
is conveyed externally by the
combustion products (fumes),
Temperature [°C]

thereby lowering the temperature

inside the flame. The chemical
species making up the combustion
products (dissociated or partially
oxidised species) are recombined to
form the final combustion products.
The combustion process in Position of temperature measurement thermocouple in
stoichiometric conditions has the channel section
highest flame temperatures and
Acimac handbooks - 2011 edition . 25
 DRYING &
FIRING
www.siti-bt.com
flat head) allows combustion to be
optimised, bringing fuel savings of
around 3-5% in the case of the
HV61 head and up to 10% on Siti
machines, without introducing
plant engineering complications.
For the above-mentioned reasons,
the use of pre-heated combustion
SYSTEMS FOR HEAT RECOVERY FROM COOLING AIR
Pre-heating
Thermal energy supplied
Pre-firing
to product
Firing
Fast cooling Thermal energy removed
Slow cooling from product
Final cooling
Fig.4: Systems for heat
recovery from cooling air
Fig.5: Kiln without hot air recovery
LHR HOT AIR RECOVERY AT 120°C: GENERAL CHARACTERISTICS
This system exploits the air
extracted from the slow and final
cooling zones, which at the flue
have a temperature of around
120°C.
The necessary quantity of this air
26 . Acimac handbooks - 2011 edition
air effectively introduces energy
to the combustion reaction and
therefore allows for fuel savings.
Regardless of the specific use,
the quantity of thermal energy
(and therefore fuel) expended to
heat a certain airflow is directly
proportional to the temperature
Besides the possibility of exploiting
the heat content of fumes, an
aspect of even greater interest
is the availability of hot air from
cooling (rapid, slow and final).
This volume of air has the
characteristic of being nominally
clean in that it is involved in a part
of the firing process in which the
tile is chemically and structurally
inert and can therefore be used
without the need for filtration.
Figure 5 shows a schematic diagram
is sent to the combustion air fan
and is used by the burners, while
the rest is evacuated or can be
used on other thermal machines.
Fig. 11
While this is the most basic,
simple and consequently also the
differential.
So if waste hot airflows are used
to raise the starting temperature
of the air and thereby reduce the
temperature differential, it is
possible to obtain direct benefits
in terms of fuel consumption.
of the air circuit for a standard kiln.
Only the main fans involved in hot
air recovery applications are shown.
Siti – B&T offers various solutions
for heat recovery.
Along with energy recovery systems
on the kilns themselves, these
include various solutions involving
the other thermal machines in the
ceramic production process.
There characteristics are discussed
in greater detail below.
cheapest system, it also has the
lowest performance in terms
of energy saving. In standard
conditions it allows specific
consumption during firing to be
reduced by around 4-4.5%.
When installed on existing kilns,
the performance of the system
obviously depends on the machine’s
operating conditions.
MHR HOT AIR RECOVERY AT 230°C + 80°C WITH SPLIT EXTRACTION:
GENERAL CHARACTERISTICS
This type of solution involves split
collection of cooling air using two
separate fans.
About 2/5 of the normally
collected flow is extracted from
the hottest zones of slow cooling
and start of final cooling, at a
temperature of approximately
230°C-270°C, while the remaining
3/5 is extracted from the second
part of the final cooling zone at
around 80°C.
The quantity of air at 230°C
required for use as combustion
In the event of modifications on SITI
kilns, the operating temperatures
may be higher than 120°C and may
even reach 160°C.
air is sent to the burners,
while the remaining part, if any,
can be remixed with the 80°C
portion to obtain an intermediate
temperature flow that can be
evacuated or used on other
thermal machines.
Although this recovery system
is more complicated in terms
of plant engineering than the
previous solution, it is more
effective in terms of energy with
a standard reduction in specific
This is due to a different type of
kiln management which makes a
greater quantity of heat available
to the cooling flue.
Fig.6: LHR hot air recovery at 120°C
consumption of 8-10%.
However, it can only be used on
kilns with a minimum length of
100-110 metres, a necessary
requirement for splitting of
extraction from the slow and final
cooling zones to be effective.
The more complex engineering
involved with installing two
extraction fans in the cooling
zone is amply compensated by
the absence of a heat exchanger
in the rapid cooling zone.
Fig.7: MHR hot air recovery
at 230°C + 80°C with split extraction
Acimac handbooks - 2011 edition . 27
 DRYING &

FIRING
www.siti-bt.com

HHR HOT AIR RECOVERY AT 300°C WITH SPLIT EXTRACTION:

GENERAL CHARACTERISTICS

The plant architecture builds on
the recovery concept of MHR
at 230°C, maximising its energy
performance and fully exploiting
the advantages offered by the air
circuit configuration and by the
control system for Siti-B&T kilns.
In particular, the cooling extraction
splitting system is modified so
that only the air from the initial
slow cooling modules is used for
combustion.
This makes it possible to operate
with higher temperatures, 300°C
or above.
With this type of recovery solution
savings in the region of 12-14%
can be obtained.

Fig.8: HHR hot air recovery at

300°C with split extraction

XHR RAPID COOLING BOOSTER KIT: GENERAL CHARACTERISTICS

Energy saving performance increasing the air temperature

can be considerably improved
by extracting an additional air
fraction from the end of the
rapid cooling zone. This is done by
generating a pressure drop along
the combustion air circuit which
allows high-temperature air to be
extracted.
This booster system can be
applied both to recovery at 120°C,
to 200°C or more, and to
recovery at 230°C, reaching as
high a temperature as 300°C.
Naturally these results depend
on the product and the operating
conditions of the kiln.
It is a very interesting solution for
application on existing installations
with low-performance recovery
systems.

Fig.9: XHR rapid cooling booster kit

250°C FUME HEAT RECOVERY SYSTEMS

These solutions involve using
fumes exiting from the first 2-3
kiln modules at a temperature of
around 230-250°C.
28 . Acimac handbooks - 2011 edition
Although they are potentially due to:
highly advantageous applications,
the characteristics of the fumes • the presence of dangerous and
create considerable complications highly corrosive contaminants
 such as fluorine, sulphur and gnificant corrosive effects on cessary to adopt special mate-
chlorine, which generate the machine parts; rials for filtering.
corresponding acids in the pre- • low oxygen content; In view of these considerations, the
sence of water; these have si- • high temperature, making it ne- possible uses are described below.

USE OF FUMES DIRECTLY IN THE SPRAY DRYER: GENERAL CHARACTERISTICS

In order to recover the kiln fumes of up to 30-35%, net of losses

directly in the spray dryer, the
extracted fumes are sent to a
special high-temperature filter
and subsequently transferred
to the spray dryer where they
are supplemented with air
with a high oxygen content and
further heated by a special post-
combustor.
This system brings energy savings
along the connecting pipes. The
presence of chlorine, fluorine and
sulphur based pollutants in the
fumes means that meticulous
filter maintenance is required
in order to guarantee maximum
efficiency of abatement as well
as appropriate management of
the recovery system and spray
dryer to avoid acid condensates.

Fig.10: Use of fumes for the spray dryer

HEATING OF CLEAN AIR VIA A HEAT EXCHANGER: GENERAL CHARACTERISTICS

In this case the fumes pass
through a heat exchanger before
being sent to the flue.
This enables them to heat a flow
of ambient air that can be used
as combustion air or as process
air for other thermal machines.
This solves the problem
associated with direct use of
fumes in the machines as they
never come into direct contact
with the air and the pollutants
remain isolated.
The application is advantageous
in countries that do not have
restrictive laws on emissions or
in the presence of plants where
filtering must be preceded by
an exchanger to lower the fume
temperature.
Unfortunately the effectiveness
of the heat exchanger is limited
by the necessity to prevent the
fumes from falling below the dew
point as this would result in the
formation of acids that would
rapidly corrode the pipes.

Fig.11: Heating of clean air by means of a

heat exchanger for spray dryer process air

Acimac handbooks - 2011 edition . 29

 DRYING &
FIRING
www.siti-bt.com
HEAT RECOVERY ON OTHER THERMAL MACHINES
As previously described, the
flowrate of hot air originating
from cooling can be exploited on
various thermal machines.
Below we briefly outline some
potential uses on devices other
than kilns.
Pre-kiln dryer
On this machine the hot
air is used to replenish the
recirculation flow in place of
ambient air.
Given the low specific
consumption of the pre-kiln
dryer and the limited flowrates
involved, this application is rarely
used as the low performance
does not justify the installation
cost.
The saving that can be achieved
on pre-kiln consumption is at
most 25-30%.
Horizontal dryer
Here too the hot air is introduced
in place of the replenishing air
in the recirculation circuit, in
a quantity that depends on
the number of modules and
layers and on the drying curve
in terms of relative humidity and
NOTE
30 . Acimac handbooks - 2011 edition
recirculation air content, which
in turn is strictly dependent on
the product characteristics.
It is also possible to use the
hot air as combustion air.
This solution is independent
of the technological aspects
(relative humidity and drying air
content), but does require the
use of burners equipped with
combustion air fans suitable for
use with hot air.
Given the greater heat
requirements compared to
the pre-kiln, application on
horizontal dryers is more cost-
effective, although performance
is not particularly high.
The saving that can be achieved
on horizontal dryer consumption
is at most 20-25%.
Vertical dryer
As with horizontal dryers,
the hot air replaces the
replenishment air.
Modifying the burner fans allows
it to be used as combustion air.
A maximum saving of 15-20%
can be obtained.
Simultaneous recovery on a costs for the plant.
number of machines
Although it is cost-effective to
recover the greatest quantity
of heat possible, it is preferable
to avoid excessively complicated
configurations in which a
large number of machines are
connected to the hot air pipe.
Each additional user device not
only brings further technical
complications in the form of
valves, sensors, branches and
the pressure head that must
be provided by means of the
fan, but above all represents an
additional parameter that has
to be taken account of in the
management of the system,
especially transients.
For this reason, it is preferable
to perform recovery on a small
number of machines with as
consistent operation as possible,
typically the kiln and spray dryer.
Given that the quantity of thermal
energy available is constant, the
quantity of saved fuel will always
be the same. Optimising the
number of machines on which
this recovery is performed
directly minimises the additional
Acimac handbooks - 2011 edition . 31
 FINISHING
BMR: the added value
of honing and lapping
by Claudio Avanzi and Marco Cicorella Honing is a machining operation
performed on porcelain tiles to bring
out the colour of the body and to
make the surface perfectly flat and
homogeneous.
It involves remove a surface layer
1 - Calibration - tile thickness.
Percentage of material removed: 80%
So the first step consists of
calibration, which is the operation
that removes the largest quantity of
material.
Next comes smoothing, which
flattens out the crests generated by
the diamond tools of the calibrator.
The last stage consists of polishing,
during which the quantity of
material removed is small or totally
insignificant.
The following diagram shows the
various stages in the honing process.
The ordinate shows the tool grit
TOOL SCALE
HONING LINE WORK POINTS
32 . Acimac handbooks - 2011 edition
from the tile down to a depth of
between 0.6 mm and 1 mm.
However, greater depths can be
removed depending on the colours of
the body and the tile geometry after
firing.
2 - Smoothing. Percentage of material removed: 15%
3 - Polishing. Percentage of material removed: 5%
(tool operation represented by the
blue line) while the abscissa shows
the number of work points (or the
approximate number of heads).
The red line represents the quantity
of material removed.
It will be clear from the diagram
that after the first 6-8 heads, the
amount of material removed falls off
rapidly, eventually dropping to zero.
This means that it is the first 8 work
points that determine the quality,
intensity, tools and forces required
for the subsequent steps.
The green line shows the gloss level.
HONING
Honing consists of three basic steps:
1- calibrating the tile thickness
2- smoothing
3- polishing.
It can be seen that the gloss level
increases significantly up to a value
of 50-55 Gloss, after which it takes
almost the same number of work
points to reach 62-65 Gloss as to
go from 25 to 50.
Above all, this means that the tool
sequence must be gradual and is
directly proportional to the achievable
gloss level. Short lines may therefore
have high tool management costs,
whereas long lines allow wear to be
optimised.
Tool scale
Removal quantity
Gloss
 TRANSLATING ROLLER TECHNOLOGY
Calibration is the first and certainly
the most important stage of the
honing process.
Its function is to prepare the surface
of the tile so that it is as flat as
possible and free from depressions
and scratches that might affect the
subsequent step in the process.
During this operation, material is
removed to a depth of between 0.6
mm and 1.2 mm.
Of course, the greater the quantity
of material removed, the higher the
cost of the calibration process will
be.
The traditional calibration process
uses fixed diamond rollers alternating
with satellite or radial heads.
The rollers have a high capacity for
removing material, but because of
their aggressive nature they leave
deep longitudinal grooves in the tile
surface.
It is the satellite and/or radial heads
that then have the job of levelling out
the surface after the fixed rollers,
compared to which they have a
much lower capacity for removal of
material.
Furthermore, due to their diameter
and highly sophisticated mechanics
(in the case of radial heads), this
kind of head requires continuous
maintenance.
As a result, it is frequent to observe
heads stopped for maintenance on
production lines.
Add to this the fact that little
importance has previously been
attached to the calibration operation,
limited to just a few points of
contact, and it is clear why so many
honing lines are so inefficient.
With this in mind, BMR has launched
a new generation of translating roller
calibrators onto the market.
This new technology uses existing
diamond rollers which are capable of
removing a large quantity of material,
but introduces an innovative
translational movement that
practically eliminates the negative
effects of grooves created by the
traditional fixed position of the roller.
The new translating roller system
performs a zigzag movement on the
tile surface, which if necessary can
be further smoothed out by a single
satellite head mounted prior to the
last two fine grit final rollers.
The function of this head is to
clean the edges of the tile from
irregularities deriving from the action
of the previous rollers.
Due to their mechanical simplicity,
the translating roller calibrators are
very simple and cheap to maintain
and allow the line to operate with
maximum efficiency and with reduced
total management costs.
Due to its modular nature, the BMR
translating roller system can also
be installed on existing calibrators,
thereby increasing their efficiency.
In this case, it is advisable to modify
the final section of the existing
calibrator by installing one or more
translating spindles in the final
positions to allow the tile to enter
the smoothing stage with an optimal
surface.
So although honing is a simple
process, it requires delicacy and
precision given the forces involved
and the meticulous finish that is
required.
The machine frames therefore
have adequate dimensions and
construction quality to withstand
strenuous operating conditions for
long periods of time.
Traditional calibration
Translating roller calibration
Acimac handbooks - 2011 edition . 33
 FINISHING

www.bmr.it

LAPPING AND SATIN FINISHING

Lapping is a mechanical finishing
process performed on the tile
surface that involves polishing the
glaze after firing.
It is generally performed on glazed
porcelain tile, but it is also possible
to lap single fired and monoporosa
tiles.
This operation is performed solely
in the final stage of the honing
process but with greater variability
in terms of the use of tools.
One last process is that of satin
finishing, a light lapping process
that gives the surface a satin matt
finish and soft touch.
Neither lapping nor satin finishing
involves removal of glaze.
The following table sums up the
types of lapping:

Lapped porcelain tile

TILE SURFACE TOOL GRIT GLOSS PROCESS EFFECT
Tile surface matt and soft to the touch.
SATIN FINISH Glazed 200/500 25/40
Often used for exterior products.

Tile surface slightly rough with lighter

and darker areas produced by the
Metallic glazed 400/1500 45/80 machine tools. The gloss value is
generally high due to light reflected by
the grooves produced by lapping

Tile surface with reflecting zones as

the lapping process smoothes out
only the crests of the vitreous grains,
creating small flat areas with a high
gloss level.
LAPPED
The part of the vitreous glaze in low
relief can be left matt or brushed
Glazed and large grain
100/1500/LUX 45/70 without becoming glossy.
vitreous glaze
Tile surface glossy and flat: application
usually devoted to monoporosa.
The thickness of the vitreous glaze
in large grains gives a depth of field
effect to the screen printing design
below.
Glazed and fine grain Tile surface not flat and entirely
400/1500/LUX 45/70
vitreous glaze glossy.

Due to the characteristic effect that
must be attained, the satin finishing
machine can have a small number of
work points (from 8 to 12 heads) and
can therefore be relatively short.
But because the lapping machine
requires gradual operation in the
same way as the honing tools, it
must have a minimum number of
heads, almost always from 16 to 20.
The lapping tools require an oscillating
movement of the head support.
Based on its experience in the sector,
BMR adopts a double support at the
mid point of the machine to provide
two oscillating speeds according to
the gradual sequence of tool grits.
To optimise use of the tools, the
34 . Acimac handbooks - 2011 edition
ideal solution would be to divide the
machine into two modules with 90°
rotation of the tile between the first
and second module.
Lapping is a machining process that
requires a machine base with the
same ruggedness and rigidity as that
of the honing machine. By contrast,
the upper section must be dynamic
and flexible so as to be able to
distribute significant moving masses
if and where they are required.
For this reason, they have flexible
oscillating movements and lightened
aluminium alloy heads.
The amply proven gear components
remain unchanged, but overall the
moving masses have been lightened
and balanced more effectively with
respect to the finishing process.
Considering that honed unglazed
porcelain tile and glazed single firing
have two different degrees of surface
hardness, the diagram (next page)
provides a comparison between
the lapping and honing processes.
Comparing the purple line with the
other lines shows that the lapping
process is lighter and more effective
than honing.
Starting out from a very low gloss
value, it rapidly attains the same level
as that reached with honing and goes
on to achieve superior final results.
 POLISHED/LAPPED
TOOL SCALE

Tool scale

Removal quantity

Honed gloss level

Lapped gloss level

LAPPING HEADS 20/FROM POSITION 20/40

DRY SQUARING

Squaring is a finishing process that
adds value to products.
Squadra®, created in 1995, is the
first machine designed specifically for
squaring porcelain tile and featuring
different construction solutions
from machines used in the stone and
marble sector.
After many years of experience with
outstanding results, BMR decided
to complement its traditional
calibration/honing/squaring lines
with Cut Crush, a system for score-
and-snap cutting of porcelain and
monoporosa tiles.
This system features dry operation
and is therefore eco-friendly as it
does not require the use of water.
This avoids the need to dry tiles,
eliminating the dryer and the
consequent fuel consumption from
the process.The Cut Crush system
is designed for industrial volumes and
large format tiles with dimensions up
to 1.2x2.4 m.
25% to 50% of the necessary volume
of porcelain tile or monoporosa, with
a removal capacity of between 0.5
mm and 2 mm per grinding wheel on
all materials. When the front grinding
wheel has to remove large quantities
of porcelain tile, it grinds the tile by
removing the edges in small pieces.
The operating principle of high
removal volume front grinding wheels
reduces the lateral thrust on the
tile and allows for a reduction in
vertical pressure and corresponding
component wear.
The machined tile edge will therefore
exhibit a light vertical line due to by Claudio Avanzi and
the aggressive nature of the tools. Luigi Prampolini Tirelli
The tile edge will then be delicately
ground by means of the final spindle
with a resinoid grinding wheel and at
the end of the line will be smooth and
uniform.
The second step consists of double
floating chamfering. There are two
types of chamfering: mechanical,
with spring balancing; and pneumatic,
with manometer-controlled air
pressure balancing. The floating
chamfer is particularly suitable for
tiles with a textured surface.

The first step in the operation involves

the use of front grinding wheels,
which in the initial attack remove Squadra Front grinding wheels

Porcelain re- Monoporosa

Diameter Diamond width r.p.m. Peripheral speed
moval removal
FRONT 300-345 mm 12/30 mm 2.800 42 m/sec 0.5/2 mm 0.5/2 mm
Acimac handbooks - 2011 edition . 35
 FINISHING

www.bmr.it
Details of squaring/pushing device, which allows for a precisely squared product

No. of wheels Pressure on tile with pressing Contact cm2 of the 2 upper
Pressure Max. pressure
SIZE in contact wheels in new condition belts of width 38 mm
1 bar 4 bar
with strip (1 wheel = 12 kg) on each tile
10x60 38+38 cm2 76 kg 304 kg
2
15x60 2+2 48 kg 57+57 cm 104 kg 416 kg
20x60 3+3 72 kg 76+76 cm2 152 kg 608 kg
2
20x120 3+3 72 kg (on 30 side) 76+76 cm 152 kg 608 kg
30x120 4+4 96 kg (on 30 side) 114+114 cm2 228 kg 912 kg

The central stage, between the 1st and precision. The tile is pushed between to the grinding spindle bench) which
2nd module, has a squaring/pushing the pressing belts by the two arms of have a higher translational speed than
device that ensures perpendicularity the pusher (perpendicular with respect the lower belt.

SQUADRA® DRY

Squadra Dry

Squadra® Dry is the new squaring
machine for monoporosa and double-
fired tiles. This machine uses both
metallic and resinoid bond grinding
wheels. Considering a machine with
8 motors, the first four spindle
positions (1, 2, 3, 4) have metallic
bond wheels with a special diamond
coating for dry operation and a
bond with high thermal conductivity.
Grinding wheels with dry operation
must have a softer bond than wet
wheels to allow the diamond to be
dressed. Positions 5, 6, 7 and 8 will
use resinoid grinding wheels with a
coarse, coarse, medium and fine grit
sequence and with a suitable bond for
glazes and crystalline.

Grinding wheel diameter r.p.m Removal quantity Peripheral speed

Metallic bond: 300 mm 2800 1/1.2 mm 44 m/s
Resinoid bond: 300 mm 2800 0.2/0.5 mm 44 m/s
36 . Acimac handbooks - 2011 edition
Details grinding wheels

Squadra Dry

WET SQUADRA DRY SQUADRA: monoporosa

Foundations and water channelling

Installation engineering No foundations
to the ground

Reduction in line length

due to absence of dryer:
Water recycling system: value 100
- 30 m for horizontal dryer
- 15 m for vertical dryer

Dryer: value of investment and more than

0
150,000 euro/year in fuel
Water consumption 100 0
Electricity consumption 100 40
Finished product
PRODUCTIVITY 100 100
Material removal principle Crushing into small fragments Pulverisation by abrasion
Consistency of machine structure 100 100
GRINDING WHEEL WEAR 100 120
Metallic grinding wheel wear 100 100
Resinoid grinding wheel wear 100 130
Grinding wheel wear for porcelain tile/monoporosa 100 110
Tool price 100 100
Parts that must be changed after No maintenance of normal wear parts
Belts, pulleys, belt guides
12 months of operation performed or imminent
DUST: 10 big bags/day Recyclable Recyclable

NOTE

Acimac handbooks - 2011 edition . 37

 END OF
LINE
4PHASESTM:
the new packaging standard
by Giuseppe Bandieri and Andrea Toro How to cut production costs and
reduce waste in the packaging
process?
The solution is 4PHASESTM, a new
packaging system that creates
Fig. 1
cartons directly in the machine.
It also prints logos and trademarks
in a four-colour process and allows
a complete batch of tiles to be
produced at the end of the line,
bypassing all stages of carton
procurement and production.
“This new system will solve packaging
problems for many companies,”
Fig. 1B
The machine’s name derives from the
Fig. 2
4 strategic phases that make up the
production process:
1) a simple sheet of flat neutral
cardboard,
2) cutting to size and gluing of
the cardboard panels with total
elimination of waste,
3) creation of side walls,
4) carton closure.
The entire system is focused on
Fig. 3
a rapid time to market, allowing
companies to produce small batches
with different brands or sizes.
This is because the carton is formed
around the product directly in the
machine.
This completely revolutionary system
solves warehouse management
problems caused by the need to
create a different carton for each
type of product.
For this reason, companies have
until now had to manage large
38 . Acimac handbooks - 2011 edition
explains System’s founder and
chairman Franco Stefani.
“It is a small plant that uses normal
sheets of flat white corrugated
cardboard to package any kind of
product and at the same time is
capable of printing the company logo
and other required text.
It marks a major step forward for
the industry as it allows for space
savings and eliminates a stage in the
production chain. This machine allows
everything to be done in-house at the
press of a button.”
THE PRODUCTION PROCESS
quantities of cardboard that often
ends up being unused and occupies
enormous space in the warehouse,
resulting in indirect management
costs and large amounts of tied-up
capital.
Ceramic tile companies that have
adopted the system have reported
savings of about 200,000 euro per
year for each 4PHASESTM along with
higher productivity and efficiency.
The procurement process for
4PHASESTM simply involves
purchasing sheets of neutral flat
cardboard which are fed into the
system. The cardboard magazine,
with cardboard sheets of size 1200
x 1200 mm, is the starting point for
the process (Photo 2).
Each sheet is picked up from the
warehouse and introduced to the
machine after setting the required
dimensions.
The cardboard is then cut to size
longitudinally to create the 4 sides
Ever since the development in 1976 of
the first Wrap Around system, which
subsequently became a standard for
the end-of-line stage, System has
led the innovation process in the field
of packaging.
At a time when flexibility appears
to be the only way forward for the
Italian ceramic industry, System has
developed a system that is able to
cope with the fragmentary nature of
orders and the multitude of requests
that companies have to respond to
continuously.
of the carton. The longitudinal cut
serves to create the panels that will
form the four sides of the carton with
adjustable folds. The panels are cut
automatically once the dimensions
have been entered.
If so required by the dimensions,
one panel can be glued and joined
to the next by means of hot glue to
create a hypothetically infinite strip
of cardboard (Photo 3).
Again inside the machine, the panels
that will be used to form the side
walls are printed in multiple colours
with logos, trademarks, instructions,
sizes and other necessary
information.
Once the cutting and printing stage
has been completed, the side walls
are composed by joining and gluing
the 4 panels.
This has the enormous advantage
of saving the entire internal portion
of cardboard, which is no longer
required.
The movement is performed by
shifting the internal axes of the
machine, which travel parallel and
perpendicular, and positioning the
panels as required.
The 4 panels of cardboard are joined
by applying hot glue at the overlap
points and subsequently applying
pressure to the surface and the four
sides (Photo 4A, 4B).
Once the side walls have been
completed, the stack of tiles is
transported centred inside in the
Fig. 5
The advantages offered by
4PHASESTM make it a new standard
in the world of packaging, a radical
new solution that meets the
emerging market needs of reliability,
efficiency and above all savings and
flexibility, while also being attentive
to the environment.
1. SAVINGS: The 4PHASESTM
system allows for savings of up
to 80% of cardboard with large
tile sizes given that only the side
Average cost of
Size
a tray
cm 45 x 45 € 0.135
cm 60 x 60 € 0.135
cm 60 x 120 € 0.36
carton; this is followed by coupling
of the cartons at the packaging
machine exit in preparation for the
subsequent stages of strapping and
palletisation (Photo 5).
In this system the products
experience minimal movement and
are much less exposed to the risk of
damage. The entire system operates
autonomously, leaving the stack
stationary and wrapping it only in the
final stage of the process (Photos
6A, 6B).
Fig. 6A
ADVANTAGES
walls are created.
The most significant savings are
made in terms of procurement
and warehouse management
because graphic designs and
trademarks are printed directly in
the machine.
It is not necessary to obtain
cardboard blanks or trays printed
differently for each product.
A single supply of cardboard in
the form of neutral white sheets
in a 1200x1200 mm size is
Equivalent cost Minimum saving
with 4PHASESTM (*) per pack
€ 0.06 - 0.07 € 0,065
€ 0.076 - 0.086 € 0,104
€ 0.13 - 0.14 € 0,220
(*) depending on the length of the panel
Fig. 4A Fig. 4B
Fig. 6B
sufficient. This also eliminates
the need for warehouse stock
and frees up spaces currently
used for storing cardboard,
which can amount to thousands
of square metres.
Another source of saving is
that of manpower because the
machine operates independently
for 8 to 12 hours.
The operating parameters can be
set from a console without the
need for continuous monitoring.
Annual savings (based on a production of 6,000 sq.m/
day for 330 days/year, totalling 1,980,000 sq.m/year
1 tray = 5 tiles = 1.01 sq.m
No. of cartons: 1,980,000 x €0.065 =
SAVINGS: € 128,700
1 tray = 3 tiles = 1.08 sq.m
No. of cartons: 1,833,000 x € 0.104 =
SAVINGS: € 190.600
1 tray = 2 tiles = 1.44 sq.m
No. of cartons: 1,333,333 x € 0.22 =
SAVINGS: € 302,500
Acimac handbooks - 2011 edition . 39
 END OF
LINE
www.system-ceramics.it
Reducing the quantity of
Fig. 7 cardboard present within the
factory also reduces expenses
for safety and the costs of fire
insurance because fire prevention
risk is directly proportional to the
quantity of flammable material in
storage (Photo 7).
The table on page 39 gives some
examples of economic savings
calculated over a production of
6,000 sq.m/day (for 330 days/
year) to a total of 1,980,000
sq.m/year in 3 different sizes.
Fig. 8 2. FLEXIBILITY: 4PHASESTM is
able to cater for all dimensional
variations of products.
Because it uses neutral
cardboard it is able to instantly
create cartons with custom
logos and trademarks.
This system offers enormous
advantages because it allows
ceramic companies to make
cartons in-house without the
need to commission an external
carton supplier. For producers
Fig. 9
with different brands and
different sizes, the process
solves all packaging supply
problems and eliminates time
wastage associated with the
graphic design of the blanks.
4PHASESTM is the only system
capable of guaranteeing a rapid
MIN
MAX
Max wrapping size
Min wrapping size
40 . Acimac handbooks - 2011 edition
time to market with a number of
different brand names.
By creating and customising the
packaging in the machine, it can
respond very quickly to requests
for even small batches, for similar
products with different sizes, or
for the same product but with
different brands.
3. SPEED: Size changeover inside
the machine takes less than a
minute, from the smallest to the
largest possible size.
All machine adjustment times
for the new size are entirely
eliminated as the first carton for
the new size is already perfectly
formed.
4. EFFICIENCY: Companies that
have already adopted the system
have reported an increase in
productivity from 20% with
smaller sizes to 30% with larger
sizes.
5. AUTONOMY OF OPERATION:
4PHASESTM is able to operate
autonomously for a period ranging
from 8 hours in the case of thin
undulating cardboard to 12 hours
with micro-undulated sheets.
Operating duration depends on
the neutral cardboard magazine,
which can be filled at intervals by
TECHINCAL DATA
SMALL MEDIUM
FORMATS (mm)
200 X 300 200 X 300
600 X 1,200 1,200 X 1,200
Product height
155 mm 155 mm
6 mm 6 mm
Cardboard sheet carton
mm 1,200 x 1,200
Warehouse capacity
800 mm 800 mm
an operator.
6. CARE FOR THE ENVIRONMENT:
4PHASESTM is able to reduce the
quantity of cardboard used by up
to 80%, as well as saving energy
for the industrial production of
blanks that end up not being
used. 4PHASESTM eliminates
warehouse obsolescence and
there is no wastage of raw
materials.
Due to the innovative characteristics
of 4PHASESTM and its patent, on 14
April the system won the technology
category of the Packaging Oscar,
an Italian award sponsored by the
Italian Packaging Institute, the
Italian Packaging Consortium CONAI,
the exhibition Ipackima and the IULM
University and open to packaging
sector companies that have excelled
for specific projects and products.
The system offers interesting
opportunities not only for tile
producers but also for many other
sectors that have to package flat
products or in any case products
that can be packaged in a carton
with 4 corners.
The machine consists of:
• two automatic magazines for
sheets of flat neutral cardboard,
LARGE
200 X 300
1,200 X 1,500
155 mm
6 mm
800 mm
• COPILOT console (System system, system,
product) as operator interface, • cardboard cutting system, • gluing system with specific glues,
• automatic cardboard loading • multicolour inkjet printing • stack transport system.

NOTE

Acimac handbooks - 2011 edition . 41

 END OF

LINE
Processmaster and
Flawmaster: quality control of
unfired and fired products
by Sandro Zini For more than 20 years Surface
Inspection has been designing
and developing vision systems for
automatic tile inspection.
Its product range includes:
• Flawmaster 5G for final tile
inspection up to a 630x1200
mm size
• Flawmaster 5GX for final
inspection of large formats up to
1250x1550 mm
• Processmaster 5G for tile
inspection prior to firing.
Processmaster 5G marks the
evolution of a concept that Surface
Inspection has been developing for
the last 10 years.
Its main application is inspection
prior to firing of ceramic tiles.
Processmaster 5G is specially
designed for installation at the end
of the glazing line and occupies
very little space (0.4 m). It has an
IP65 protection rating enabling it
to withstand the tough conditions
present on the glazing line.
The machine is installed on the
existing transport line and uses a
colour video camera and symmetric
LED lighting to guarantee superior
intensity, stability and durability.
It is capable of inspecting tiles up to
660 mm in width and 1200 mm in
length.
The continuous inspection performed
by Processmaster can provide the
operator with useful information for
rapid problem solving. It detects
abnormalities falling into two
categories:
• Mechanical defects
• Decoration defects.
The system can report this
information in various ways: via
alarms, production reports or
remote videos.

THE ADVANTAGES OF PROCESSMASTER 5G

Immediate and accurate detection Systems currently in use have

of defects means that they can
be rectified as soon as they
arise, allowing for the production
of a higher first quality class
percentage.
PM5G also allows for the reuse of
tiles rejected prior to firing.
shown an increase in production
quality of between 3% and 5%.
On the basis of our experience,
this is a gradual process that
takes from 3 to 6 months to be
achieved.

INSPECTION OF FINISHED PRODUCTS

Flawmaster 5G and Flawmaster These are:

5GX allow for repeatable and
constant sorting operations that
are independent of the work shift.
They analyse tiles from a number
Processmaster 5G of different viewpoints and detect
various defects at the same time.
• Surface defects
• Mechanical defects: edges,
corners
• Decoration and reflection defects
• Contamination
as well as Tone and Shade.

Technical Characteristics

Flawmaster 5G Flawmaster 5GX

from 100x100 mm to from 200x200 mm to
Tile size
630x1200 mm 1250x1550 mm
Height adjustment for tile
from 3 to 40 mm from 3 to 40 mm
thickness
Lighting LED LED

Linear velocity 60 m/min. 80 m/min.

Production 750 m2/hour 1000 2/hour

42 . Acimac handbooks - 2011 edition

THE ADVANTAGES OF FLAWMASTER
Final automatic inspection allows
for higher productivity and yield
and brings a number of advantages:
• High inspection speed
• Optimised tile flow
• Reduction in stoppages
• Quality benefits
• Uniform inspection
• Fig.
Fewer
4C complaints
• Continuous monitoring of
production defects
Key strengths include twenty
years of experience and hundreds
of systems sold and installed
worldwide, the compactness of the
devices, the use of LED lighting
and simplicity of adjustments and
settings.
Software options include real-
time production monitoring, alarm
generation and production reports.
A wide range of defects can also be
detected, concerning:
• Decoration
• Irregular edges
• Thin lines.
The area to be inspected is
illuminated using LED technology
lamps, which are now replacing
incandescence and fluorescence
lamps in many applications due to
their advantages of energy saving
and lamp lifetime.
The use of this technology enables
Flawmaster to achieve optimal
lighting and therefore better image
quality.
Settings cover a full range of
colours, from the lightest to the
darkest, with greater precision in
colour tone control.
Thanks to Surface Inspection’s
team which works continuously to
develop new solutions catering for
inspection needs in a constantly
evolving market, important results
www.nuovafima.it
have been attained in terms of
software capacity (algorithms) and
ease of use.
In particular, a number of automatic
user settings have been implemented.
Complete standard recipes are also
available for each product type and
defect and can be customised for any
requirement.
At the same time, colour perception
has been continuously improved and
the already wide range of defects
detectable by the system has been
further expanded.
In particular, the system detects
mechanical defects for perimeter,
corners, edges and cracks.
Decoration defects that can
be detected include absence of
decoration, black dot, white dot,
spotting, drips, thin lines, banding
and uniformity.
The following reflection defects are
inspected: texture, holes, lumps,
dimples, glaze bands, cracks, and
gloss/matt effect.
The combination of these hardware
and software solutions allows the
devices to be used in a wide range of
applications:
• Product inspection before and
Flawmaster 5G
after firing
• Inspection of all types of
decoration: uniform background;
fixed, rotary, random and inkjet
decoration, etc.; and all types
of tiles: floor and wall tiles with
irregular edges and with relief,
porcelain tile, rectified and
polished tiles, etc.
• Inspection of sizes from 100x100
mm to 1250x1550 mm.
With these advantages, automatic
inspection is an important tool
for raising production efficiency
and for improving the image of the
producer, who is able to supply ever
higher quality products to the end
consumer.
Flawmaster 5GX
Acimac handbooks - 2011 edition . 43
 END OF

LINE
Packaging large-format tiles:
new solutions
by Sandro Zini To cater for a constantly and rapidly evolving market developed outstanding solutions for:
that requires flexible systems capable of handling • Dimensional control
medium and large sizes as well as strips of various • Sorting
sizes and thicknesses while at the same time saving • Packaging
energy, space and production costs, NuovaFima has • Palletisation.

DIMENSIONAL CONTROL: ADVANCHECK

Fig. 1
Advancheck is a fully automatic
machine for checking calibre and
dimensional defects in ceramic tiles.
The industrial PC user interface is
based on a Windows® operating
system. A “frame grabber” card
is mounted on the industrial PC
to process signals from the video
camera, which takes samples every
tenth of a millimetre.
The ability to detect geometric/
dimensional defects and connect
the device in a network with
supervision systems makes it
possible to perform real-time
analyses and potentially provide
feedback into the production
process to correct for errors,
thereby improving quality and
achieving energy savings.
The characteristics of the control
system are:
• calculation of the calibre
class and downgrading due to
difference, parallelism, side
curvature and rectangularity
(measurement of diagonals);
• setting of six calibres and three
thresholds for each type of
defect;
• acquisition of the areas of the
four corners and measurements
at the midpoints of the sides;
• interfaceability with the
Synthesis/Genusis sorting
line and with other NuovaFima
equipment;
• possibility of connecting the PC
in a network for management
of data collection, sorting
statistics and configuration
programming.

SORTING, PACKAGING AND PALLETISATION SYSTEMS

The technological requirements
dictated by the need to handle
both large-format tiles and strips
Fig. 2 - Advancheck produced from them on a given
line posed major challenges to
the production process, making
it necessary to adapt the devices
necessary for the production of
these varied tile sizes. As part of
its ongoing investments in research
and development, Nuovafima has
upgraded Synthesis/Genusis, CPK
S7, CPK EVERY, CPK T120/T150 and
Extrapack to meet the needs of an
increasingly demanding and selective
clientele.
By using the various systems in
combination it is now possible to
handle sizes with lengths from 100
mm to 1500 mm and widths from
100 mm to 1200 mm.

SORTING: SYNTHESIS/GENUSIS, SOLUTIONS FOR LARGE FORMATS

Fig. 3 - Genusis

One of the most interesting
features of Synthesis/Genusis is
the ejection mechanism.
The mechanism for transferring
the tiles from the transport
belt to the stacker is based on a
system with four pistons controlled
independently according to
operating speed.
The tiles are transferred towards
the stack below by means of a rapid
inclined movement.
Assisted by lateral rubber rollers,
44 . Acimac handbooks - 2011 edition
this guarantees the best possible
treatment of the moving tiles and
improves overall quiet running of the
system.
The stackers form stacks of tiles that
are aligned from the outset, thereby
reducing the need for adjustments
prior to packaging.
This synergy of movements reduces
impacts and friction and helps
to avoid the risk of damaging the
ceramic tiles during the delicate
stacking stage.
Another characteristic of the
system is the double chain stacker.
The double stacker is able to handle
a continuous flow of material without
saturating the sorting stage.
Programming and functional checking
during production is simpler as one
quality class is assigned to each
stacker.
The line also has smaller dimensions,
allowing for space savings.
Figure 5 shows the operation of the
double-chain stacker.
When the stack (2) is completed,
another pair of fins (3) become
available and are capable
evacuating the material originating
from sorting (4).
The complete stacks deposited on
the transfer device (1) are then
transported towards the packaging
machine, allowing the waiting stacks
(2) to be deposited in position (1).
Advantages
The Synthesis/Genusis system offers
numerous advantages. We shall look
at a few.
A) Flexibility
• The stackers can accept all
sizes within the working range
without the need to change
mechanical parts.
• The operator can perform an
automatic size change simply
by entering instructions from
the computer keyboard.
The computer also has an
archive of configurations that
are easy to call up.
The NuovaFima packaging machines
(CPK T 120/150, CPK S7, CPK
EVERY, CPK T120/T150) are fully
Fig. 6 - CPK T120/150
B) Reliability
• The machine’s structure is
simplified through the use
of of stepper motors for all
mechanical movements.
The stackers are managed by
the control drivers via two
synchronised electric shaft
motors, which ensure precise
and repeatable movements and
avoid the need for encoders,
mechanical transmissions or
position or speed detectors.
• The drivers optimise motor
control so as to achieve
the correct power delivery
according to the weight of
the products and the required
transport speed, allowing for
a considerable reduction in
energy consumption.
C) Ease of use
• The entire machine is
controlled by an industrial
computer with an intuitive and
familiar operator interfaced
based on a Windows® platform.
• Along with the normal
management functions, the
PACKAGING LARGE-FORMAT TILES
automatic machines designed and
built for packaging ceramic tiles with
cover and non-cover type cartons.
The pack closure system normally
involves the application of 4 hot glue
dots.
Fig. 7 - CPK EVERY
computer system also provides
useful production statistics
and allows the machine to be
controlled remotely (Ethernet
networks, etc.).
• The connections to all the
digital inputs and outputs are
based on a fieldbus.
This simplifies maintenance
of the electrical system and
future expansions.
D) Precision, reliability and lower Fig. 4 - Synthesis/Genusis expulsion
maintenance mechanism
• The tiles move towards the
stacker with an inclined
movement, which improves
positioning precision and
reduces wear on the main
belt, thereby cutting
maintenance costs.
• The use of stepper motors
cuts down on the number
of mechanical parts and
consequently reduces
maintenance requirements.
• Ease of diagnostics: I/O
states available at the
terminal and possibility of
remote connection.
Fig. 5 - Example of operation of
double-chain stacker
In particular the CPK T 120/150
was specifically designed to handle
products up to a maximum size of
1200x1500 mm and is capable of
managing up to 10 packs per minute
(according to sizes).
Fig. 8 - CPK S7
Acimac handbooks - 2011 edition . 45
 END OF
LINE
www.nuovafima.it
Fig. 9 - Extrapack
Extrapack is a portal type palletiser
designed and manufactured in
accordance with the most advanced
electrical and mechanical standards.
It has an independently managed
4-axis controller, an extremely rigid
structure and powerful motors
Fig.10 - Palletisation
The axes can be arranged in any way on the right or left sides of the pick-up point and parallel or
orthogonal to the feeding line, provided no pallet coincides with the pick-up point.
Extrapack allows the various pallets
to be organised independently.
Each individual pallet can be
programmed according to product
code and configuration.
Extrapack can load up to a maximum
of 20 pallets and can also pick up 2
packs simultaneously by selecting
an optional double pick-up unit.
It can be equipped with an
automatic empty pallet pick-up unit
and with a suction cup unit to pick
up interleafs.
46 . Acimac handbooks - 2011 edition
PALLETISATION
which bring significant benefits for
tile manufacturers.
These include:
• high degree of reliability and
repeatability of positioning,
• high operating speed,
PALLET ORGANISATION
It can also be programmed to
handle various sizes originating
from different lines.
The main advantages of the
NuovaFima portal palletiser are the
following:
• High operating speed to handle
demanding work loads,
• Smaller width (from 3500 mm to
2800 mm),
• Plant layout flexibility (it
• the ability to handle the toughest
work loads.
It combines a high loading capacity
(up to 250 kg according to
configurations) and high versatility of
set-up, configuration and use.
1. car x axis
2. carriage y axis
3. column z axis
4. pick-up device j axis
Pick-up point
can be fed from four sides
independently),
• Ruggedness and stability,
• High loading capacity (up to
250 kg depending on the
configurations),
• High versatility for set-up,
configuration and use,
• User-friendly interface (the user
can check the functions via an
intuitive interface),
• Complete and rapid diagnostic
check of machine.
 NOTE

Acimac handbooks - 2011 edition . 47

 • 536 pages/pagine
• English and Italian text/Testo italiano e inglese
• Price/Prezzo: 60 euro + shipping charges/spese di spedizione
“The end-of-line system and complementary activities - Sorting
& Packaging, Handling, Finishing, Special Pieces & Third
Firing, Energy & Environment” completes the series of ACIMAC’s
technical handbooks which are extremely popular amongst ceramic companies
in Italy and abroad, being the only effective publications available for training
technical personnel in the ceramic sector.
The manual covers all the stages of the production process from the kiln exit
to palletisation and storage, together with the complementary activities of
finishing, polishing, cutting and accessory operations. A part is devoted to the
production of trim pieces, accessories and third-fire decorations and a final
section refers to controlling the environmental impact of the processes.
Like the previous titles, the new manual provides detailed coverage of the
topics in terms of theory and practical application.

“Il fine linea e le attività complementari - Scelta e

Confezionamento, Handling, Finitura, Pezzi Speciali & Terzo
Fuoco, Energia & Ambiente” completa la collana di manualistica
tecnica realizzata da ACIMAC dal 2000 ad oggi; una collana di testi che
hanno riscosso grande successo tra i tecnici delle aziende ceramiche in Italia
e all’estero, rappresentando l’unica valida produzione editoriale mirata alla
formazione del personale. Il volume tratta tutte le fasi del processo produttivo
dall’uscita forno alla pallettizzazione e stoccaggio del materiale, alle attività
complementari di finitura, levigatura, taglio e le lavorazioni accessorie.
Una parte è dedicata al processo produttivo di pezzi speciali, corredi e
terzo fuoco, mentre chiude il volume una sezione sul controllo dell’impatto
ambientale dei processi. Anche il nuovo volume offre una dettagliata
trattazione teorica, pratica e applicativa degli argomenti.

CONTENTS - INDICE
Le pubblicazioni tecniche di S.A.L.A.
A colori, in italiano e inglese - Full colour pages, in English and Italian

Technical handbooks by S.A.L.A.

Glazing and decoration of ceramic tiles year 2000 - 360 pages
Smaltatura e decorazione di piastrelle ceramiche 20 Euro*

Colour, pigments and colouring in ceramics year 2003 - 300 pages

Colore, pigmenti e colorazione in ceramica 45 Euro*

Raw material preparation and forming of ceramic tiles year 2004 - 520 pages
Preparazione materie prime e formatura di piastrelle 55 Euro*

Drying and firing of ceramic tiles year 2005 - 448 pages

Essiccazione e cottura di piastrelle ceramiche 60 Euro*

Rheology applied to Ceramics year 2006 - 480 pages

Reologia applicata alla ceramica 60 Euro*

The end-of-line system and complementary activities year 2007 - 536 pages
Il fine linea e le attività complementari 60 Euro*
-20 %manuals
more
or mi
for 2 p i ù volu
* + shipping charges - + spese di spedizione o
per 2

Order form - Modulo d’ordine

Please send via fax to +39 059 512 157 - Inviare via fax a 059 512 157
I would like to buy - Desidero acquistare
❏ Glazing and decoration of ceramic tiles - Smaltatura e decorazione di piastrelle ceramiche
❏ Colour, pigments and colouring in ceramics - Colore, pigmenti e colorazione in ceramica
❏ Raw material preparation and forming of ceramic tiles - Preparazione materie prime e formatura di piastrelle ceramiche
❏ Drying and firing of ceramic tiles - Essiccazione e cottura di piastrelle ceramiche
❏ Rheology applied to Ceramics - Reologia applicata alla ceramica
❏ The end-of-line system and complementary activities - Il fine linea e le attività complementari
I would like to receive the book/s at my Company - Desidero ricevere il/i volume/i in azienda
❏ Please inform me about the shipping rates with UPS to (please quote your country):
❏ Comunicatemi la somma dovuta per le spese di spedizione con corriere espresso a (città o nazione):

Please fill in all sections of the form - Compilare in ogni sua parte
Company name/ Rag. sociale: Address/ Via:

ZIP code/Cap: City/Città:

Country/Prov.: VAT number/P.IVA-C.F.:

Tel.: Fax: Email:

Buyer’s name/Nome acquirente: Tot Euro/Euro totali:

Per Informazioni - For Information

Publisher - Editore
S.A.L.A. srl • Via Fossa Buracchione 84 • 41100 Baggiovara (MO) • Italy • tel. +39 059 512 103 • fax +39 059 512 157 • m.bernardi@tiledizioni.it
 Euro 10
IVA assolta dall'editore