M&S PRESENT THEIR NEW DRYTECH PROCESS FOR PORCELAIN STONEWARE IN BRAZIL
|
At St. Gertrudes (San Paolo) in Brazil, the 2ND Ceramic Industrial Wall & Floor tile Conference took place from 22nd to 26th October 2007 at the headquarters of ASPACER. The event was organized together with ABRACOLOR.
The Conference was hosted by ASPACER (Associaçao Paulista das Ceramicas de Rivestimento) and organized by Prof. Anselmo Boschi from the Ceramic University of Sao Carlos. The 5 days were full of intense debates where various speakers were listened to by a large audience and participants.
M&S took advantage of this occasion to present to the Brazilian Ceramic World the latest technology that was conceived in their own Technological Laboratory in Sassuolo “DRYTECH PROCESS FOR PORCELAIN STONEWARE”.
The report was presented by the Commercial Director, Mr. Arlindo Voltolini, from Manfredini & Schianchi Do Brasil Ltda, whose lecture lasted for more than one and a half hours with interesting interventions and questions from the public present in the room.
The report illustrated how Manfredini & Schianchi have been active in their research for winning solutions for the production of porcelain stoneware since 2002 with laboratory tests, industrial trials and optimization of their dry preparation plants.
Results were illustrated of an important productive unit situated in Italy who successfully utilizes this Drytech Technology for Porcelain stoneware.
The public present were able to touch and examine some samples of Porcelain stoneware tiles and were able to verify the astonishing technical data, such as: Absorption, mechanical resistance, surface hardness, abrasive, frost and stain-proof resistance. All the data clearly demonstrate how products obtained through DRY-TECH PROCESS FOR PORCELAIN STONEWARE are practically the same as those obtained through the traditional wet method, but with the great advantage that with the dry technology the industrial process costs of transformation are reduced by 70%.
In a World where energetic costs are constantly increasing, this information should be reflected upon and it is of fundamental importance for the future development of the Brazilian & Worldwide Ceramic Industry. |
|
MANFREDINI & SCHIANCHI PRESENT THE NEW MOLOMAX 4/230 MILL
|
|
Manfredini & Schianchi, during the occasion of the ceramic Exhibition CERSAIE 2007 and taking advantage of the vast presence of their valued Customers, officially presented the New MOLOMAX Pendular Mill 4/230 at their headquarters in Sassuolo.
The MOLOMAX 4/230, one of the latest developments in M&S regarding pendular mills, was designed to be able to operate with a remarkable quantity of clays and raw materials with an medium-high hardness such as ceramic mixtures for single-firing, Porcelain Stoneware, Feldspar & Dolomite, and with high humidity values (up to 20%) such as in the ceramic compositions for roof tiles and facing bricks.
One of the main characteristics of the MOLOMAX 4/230 is that of being able to offer a high production output (up to 55 t/h with primary grinding by means of Hammer Mills type PIG-MAXI) at extremely reduced costs of thermal consumption (400 kcal/lt) and electrical consumption (8 kW/ton).
Technically, in the MOLOMAX 4/230, the newly conformed grinding pendulums emerge, and, together with the new rotating track, confer higher pressure on the material allowing a grinding that is able to obtain particle sizes down to 30 microns. The extensive use of Alubit (alumina) should be remarked upon as it is applied in various parts of the machine with the objective of guaranteeing a correct functioning of the MOLOMAX 4/230 with contained maintenance costs.
The MOLOMAX Pendular Mill, thanks to this conception, is perfectly able to grind components suitable to obtain a perfect mixture for the production of Porcelain Stoneware via the “dry method”, therefore allowing a final product to be obtained of high technical quality with considerable energetic savings in respect to Porcelain Stoneware obtained via the “wet method”.
With this latest innovation, Manfredini & Schianchi are confirmed as being the leader in DRY GRINDING for the ceramic and heavy clay sectors with more than 150 plants installed Worldwide that respectively produce almost 1 billion m2 per year of tiles and more than 4 million tons of heavy clay and similar products.
|
MANFREDINI & SCHIANCHI CONTINUE TO GROW IN COAL GRINDING
|
Manfredini & Schianchi have recently started up two types of plants in two different parts of the World, suitable for grinding into fine powder different types of coal.
With the classic costs of energetic supplies continually growing, the whole World is revaluing energy sources once deemed outdated but when adequately prepared can be both economic with little pollution, namely Coal.
The first M&S raw coal Grinding plant was installed in Brazil, at Mineraçao Caravaggio, situated only a few kilometres from Criciuma in the state of St. Catarina.
This plant is essentially equipped with a MOLOMAX Pendular Mill type MS 3/120-AIR, inner drying system with process filter. The plant operates on raw coal with an initial humidity of 10% and has a production rate of 5,5 t/h and with a separation cut of 90% below 40 microns.
The same plant philosophy was adopted in Portugal at Fabricas Jeronimo Pereira Campos Filho situated in Alvaraes. It deals with a grinding unit composed with Pendular Mills type MOLOMAX 3/120-AIR, equipped with inner drying system and process filters.
The plant treats carbon coke and has a total production capacity of 9 t/h, with a separation cut of 98% below 90 microns. |
|
HIDRACOR BELIEVES IN M&S TECHNOLOGY
|
|
Manfredini & Schianchi, as well as coal grinding, are developing important experiences in sectors in which the Market requires a technology that can produce materials with particle sizes around 50-40 microns, like in the building industry sector
This is the case of Tintas Hidracor S/A, important Company of the J. Macedo Group, located near Fortaleza (Brazil) and National leader in the production of plasters, chalks, paints, varnishes and colours for the building sector, and who have decided to rely on M&S to improve the productive quality of their range of products.
Manfredini & Schianchi have in fact recently commissioned and started up 2 productive units both equipped with MOLOMAX Pendular Mills type MS/6/190-Cyclone.
These mills are equipped with centrifugal classifiers with fins to optimize the percentage of fine material after grinding and both are equipped with 2 large dimensioned Cyclones, which are activated by a highly powered fan, and directly unload the material ready to be bagged and transported to destination.
Thanks to the automatic control of the internal depression, the MOLOMAX separates the silica particles from the raw materials which are rejected and automatically collected at the bottom of the mill itself.
The first Mill grinds Dolomite with a production of 3,5 t/h with a separation cut of 99,8% under 40 microns. The second Mill grinds Hydrated Lime with a production of 6,5 t/h with a separation cut of 90,5% under 40 microns. This is important progress for Manfredini & Schianchi as, above all, it opens new scenarios in the grinding field in sectors dominated Today by low productivity mills.
|
|
Terra Tile Consortium, new productive reality of final ceramic compositions for the heavy clay sector, located in Thrissur in the state of Kerala (South-West of India ) selected the raw materials Dry Processing Technology of Manfredini & Schianchi.
The plant mainly consists of fixed Hammer Mills type P.I.G.DRYER, Vibrating Screens type MS/XIV/265 and a Mixing-Wetting system type MS equipped with a Moisture Meter type MS/MU7685 for an overall capacity of more than 35 t/h.
The ultimate quality in the final product that such a plant grants (perfect homogenizing of the body, elimination of calcium carbonate defects, monitored humidity content) will enable TERRA TILE CONSORTIUM to become the most developed reality in the Heavy Clay Sector in India with large flexibility in the final products ranging from Roofing Tiles (Roman & French style) to Bricks (Facing & Handmade style) as well as Sunbreakers.
|
|
CECOL OPTS FOR M&S TECHNOLOGY
|
|
Cecol-Ceramic Cordeiropolis (situated in Cordieropolis, close to the Brazilian Industrial center of St. Gertrudes) has recently put into operation a new latest generation M&S Dry Milling Plant.
The Plant is equipped with the latest innovative technologies for the preparation of ceramic raw materials. Undoubtedly, the revolutionary Pendular Mill type MS-6/190 is at the heart of the process, and is equipped with a High Capacity Process Filter. Besides the MS-6/190 Mill the plant is also supplied with Wetting-Granulator machines type MS/38/KSTB-AL which allows the ceramic mixture to be uniformly granulated, thus noticeably improving the ceramic process during the pressing phase.
Cecol is one of the most well-know Brazilian companies who have been operating for more than 60 Years, and who have recently completed a very important Industrial restoration. With thanks, above all to the new M&S Grinding plant, Cecol’s production capacity of single firing floor & wall tiles will now go from 500.000 m2/month to 1.000.000 m2/month. The web-site of Cecol-Ceramica can be consulted at : www.cecol.com.br. : www.cecol.com.br
|
CONSISTENT GROWTH OF MANFREDINI AND SCHIANCHI ON THE BRAZILIAN MARKET
|
Besides the mentioned prestigious project with Ceramica Majopar, Manfredini & Schianchi has finalised another important supply with Ceramica Incopisos located in the Brazilian district of Santa Gertrudes.
The plant is totally similar to the one for Majopar.
It deals with a Dry Tech milling technology with dry technique consisting of definitely high renown equipment such as P.I.G Mill, M&S High Efficiency Sifters, Pendular mill with Process Filter, Vertical Humidifiers MS/38/KSTB.
All of that is monitored and remote controlled by a general electrical switchboard capable to adjust the working parameters of the milling stage thanks to a sophisticated system of frequency inverters.
The plant will have a capacity of 40 Tons/Hr. and it will serve 2 new lines of red body once fired tiles with a capacity of 600,000 m2/month each. The overall capacity of Ceramica Incopisos will thereby reach 1,750,000 m²/month.
As well as Majopar and Incopisos, Manfredini & Schianchi has just finalised in the latest months several projects with the most important ceramic factories in the industrial district of Santa Gertrudes such as Cecafi, Lef, Acropisos, Cedasa, Formigres, Artec.
This represents a further confirmation of their leadership in the body preparation area in the Brazilian ceramic industry as well.
|
|
CERAMICA MAJOPAR RELIES UPON MANFREDINI & SCHIANCHI
|
|
Manfredini & Schianchi with their Brazilian branch has recently acquired new projects on the Brazilian market.
Majopar a renowned entity in the area of Santa Gertrudes contracted our Company with a complete raw materials processing plant through dry technique with a capacity of over 40 Tons/Hr. displaying the latest breakthroughs in the milling,screening and agglomerating stages which will enable the Customer to obtain high quality low absorption products for floor coverings with medium to large sizes.
The core of the plant is certainly the new M&S granulating/pelletising system which secures a perfectly homogenised distribution of water and an excellent press loading stage in order to pave the way to high yield and a substantian reduction of drying and firing stages. The new milling plant will serve 2 complete lines for a monthly capacity of 600,000 m² each.
Such a capacity should be added to the present 2,100,000 m²/month Majopar already manufactures with M&S technology in the existing lines.
|
MANFREDINI & SCHIANCHI PLANT IN ZEBEDIELA BRICKS
|
Manfredini & Schianchi, has just completed the supply of a Raw Materials Dry Body Preparation Complete Plant with DRYTECH Technology for Extruded Products at the South African Zebediela Bricks located in the surroundings of Johannesburg.
The Plant has a capacity of 20 t/h consisting of a ceramic body with several clays duly analyzed together with the Customer according to their needs and the thorough testing of raw materials available.
The Plant is equipped with Hammer Mill type PIG/A/8, a Pendular Mill MS-4/150-AIR and a humidifying plant consisting of a Wetting Machine MS2000 and a Humidifying Mixer type MS, both are supported by an Automatic Moisture Level Meter.
The milling area displays a particular technology capable to accept moisture levels in the infeed material up to 15%.
Thanks to this Industrial initiative, Zebediela Bricks becomes a milestone in the Southern hemisphere in terms of technological and economic breakthrough for heavy clay products.
|
|
EL KHAYYAT RELIES ON MANFREDINI & SCHIANCHI
|
|
El Khayyat Red Brick Co. (Saudi Arabia), prominent Company in brick manufacturing contracted Manfredini & Schianchi’s exclusive system in recovering waste bricks within a process of revamping two existing factories with advanced technologies.
As a matter of fact Manfredini & Schianchi is highly skilled in such a specific plant application thanks to the high yield of Hammer Mills type PIG. Maxi which are capable to handle an infeed material size up to 400 mm with limited running costs and high size reduction.
The plant is equipped with final grain size monitoring, suitable powder humidifying stage and the high accuracy batching apparatus to recycle the material to the production cycle.
The present supply consists of two identical plants with an overall output of 45 t/h which are added to the two units previously supplied.
|
NEW PENDULAR MILL MS-4/230
|
|
The new MS-4/230 Pendular Mill was designed and built to refine raw materials with a medium/high hardness, (red body compositions, porcelain stoneware formulas , feldspar etc.), with humidity contents up to 20%, high production capacity (up to 55 T/h in the AIR version with Primary Mill type MAXI P.I.G.) and extremely low thermal (400 kCal/lt) & electrical (8 kW/T) consumptions.
The main characteristic of this mill is the new design of the pendulums and rolling sector tracks that apply higher pressure on the material, making it possible to obtain grain sizes up to 30 microns.
With this latest innovation, Manfredini & Schianchi confirms its leadership in the DRY GRINDING ceramic and heavy clay sectors, with more than 150 Plants installed Worldwide with a respective production of nearly one billion m2 of tiles per Year and more than 4 million tons of heavy clay and similar products.
|
600 X 900 TILE MADE WITH AL MAHA COMPOSITION |
Al Maha Ceramics a new reality in the Persian Gulf region, contracted Manfredini & Schianchi for a complete raw materials dry processing plant type PPVF-CDP bound to large sized wall and floor tiles.
The new ceramic factory will be installed in the industrial area of Suhar (Oman) and it will yield a yearly output of 4,700,000 m2 of tiles.
The processing plant will feed two complete, latest generation and high output lines contracted to B&T/Siti Group for once fired floor tiles in the sizes 330 x 330 -450 x 450-600 x 600-750 x 750 and once fired wall tiles in the sizes 250 x 300-300 x 450-330 x 450.
The main feature of the already renowned M&S technology is placed in the high production flexibility, dealing with floor and wall tile compositions with different raw materials through the same line.
Raw materials made available by the Customer were duly analysed in Manfredini & Schianchi labs and the compositions were established in partnership with B&T/Siti Group in their highly equipped technological centres with a global guarantee on the qualità of the endproduct.
The commissioning of the plant is foreseen in mid 2007 with the start up of the lines at full capacity
|
|
|
