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NEWS 2015 
 

THE BRAZILIAN COMPANY CERAMICA CONSTRULAR DOUBLES ITS PRODUCTION THANKS TO M&S TECHNOLOGY

Thanks to the activity of the Brazilian branch, Manfredini e Schianchi do Brasil Ltda, over the past 20 years the brick manufacturing market in Brazil has undergone a substantial transformation in terms of quality of the finished product. In fact, by processing raw materials with the dry process and using high efficiency systems, many Brazilian companies have managed to find a prestigious place in the market by offering quality product with many added values. This has also been made possible thanks to the NBR 15.270 quality certification (requisitos 1, 2 and 3), which means top quality Brazilian products.

One of these companies is Ceramica Constrular LTDA, based in Pouso Redondo, in the state of Santa Catarina. In this particular case, M&S was in charge of enlarging the system installed in 2010 for the production of hollow bricks, which featured all the most modern dry milling systems such as P.I.G. hammer mills and screening systems.

The most important stage of this supply involved the moistening equipment. In fact, the new Forgia F9 Wetting Machine has been installed. This machine can moisten up to 40 tons/h of raw material to obtain a 17% moisture content, hence improving performance of the brick moulding machine during the subsequent stage of the work cycle. By means of this important investment, Ceramica Constrular now manufactures 500 tons/day of hollow bricks to fulfil the growing demand for quality products that the Brazilian market needs.

The history of this leading Brazilian company begins in 1982. Since then, the company has always led the field by continuously investing in modern technology. The aim is to improve the industrial process, reduce costs and increase quality of the final extruded product, thanks also to trustworthy partners, such as Manfredini e Schianchi.

Aracemco


IN SAUDI ARABIA, EL KHAYYAT ONCE AGAIN PLACES ITS CONFIDENCE IN MANFREDINI E SCHIANCHI

Horizon 2020


The long-lasting cooperation between the Sassuolo-based company, leader in the field of raw material preparation, and the renowned Arabian brand EEL Khayyat Red Brick Co. continues.

The two companies began working together over 15 years ago. Manfredini & Schianchi will be supplying more milling lines for fired scraps for the production facilities of AL KHUMRA near Jeddah, (Saudi Arabia).

This system is basically similar to the two supplied two years ago for the production facilities of Al Kharji and Sudair.

SLAMMER hammer mills are the essential part of this system, which has the purpose of milling discarded scraps of roof bricks and bricks. Thanks to its sturdy structure, armour plating and special hammers, it can handle even the hardest and most troublesome material. It also features an exceptional resistance to wear.

The system can handle incoming scraps with a size of up to 250 mm. The two lines have a production output of 30 t/h and the size of outgoing pieces is < 2 mm. Electrical consumption is only 12 KWh/ton. With this new addition, M&S has supplied 9 systems to El Khayyat during the past 15 years


ARACEMCO STARTS AT FULL SPEED WITH MS-DRYTECH TECHNOLOGY

The ARACEMCO ceramic group, an Egyptian company that began its activity back in 1975, has chosen MS-DRYTECH TECHNOLOGY for refurbishing its raw material preparation department and replacing former wet preparation technology.

The system is basically composed of a rough milling system consisting of a P.I.G.HD mill. Subsequent refining takes place in the Molomax 6/230 mill that can produce over 30 tons/h. This system allows for the production of tiles with extra smooth surfaces, ideal for application of glossy glaze or for digital decoration.

Agglomeration and powder moistening is performed by the Madirex granulator (covered by an international patent), which is today's benchmark when it comes to granulating dry milled powder. Amongst the advantages of Madirex:

  • Output of up to 40 tons/h
  • Consumption of electricity: < 0.3 kW/ton
  • No heat consumption
  • Virtually no maintenance costs
  • Very small space requirements for installation and easy to adapt to existing plant
  • Consistent grain size curve with an extremely high percentage of granulated material, ideal for producing large sizes

All the expectations in terms of increased production output and quality, such as first grade material, energy saving, use of local raw materials and recycling of rejects, have been fulfilled.

The customer is therefore one hundred percent satisfied and has already experienced a considerable increase in sales and profit and as a consequence a “Return of Investments ROI” in a very short time. Despite the political issues that have compromised the growth of the country, the production of ceramics has tripled.

Egypt has become a leading manufacturer in Africa and is amongst the first ten ceramic manufacturers of the world.

This considerable escalation has led ARACEMCO to choose technology capable of increasing its productivity and quality and enabling it to lead the field. This once again proves that Manfredini & Schianchi is a winning choice.

Aracemco


PROGETTO MANFREDINI & SCHIANCHI PER HORIZON 2020

Horizon 2020


Horizon 2020 is the new EU funding Programme for research, which will help the European Union tackle global challenges by providing the necessary tools for implementing research and innovation activities and promoting the realisation of ideas.

According to the Horizon 2020 Programme, the strategic and fundamental target is to support all kinds of innovation in European companies, by means of a programme for “Innovation in small and medium sized enterprises”. Within the scope of this programme, our company has submitted a proposal that, to our great satisfaction, has been approved.

The efforts that Manfredini & Schianchi srl has made over the years in terms of R&D projects, aimed at optimal use of the natural resources needed to prepare raw materials for industrial processes, have been awarded an important recognition. The project of Manfredini & Schianchi srl, selected by Horizon 2020, is based on the development of an innovative system for preparing raw materials for the ceramic industry. The technological development, which is now going subject to validation, has the result of drastically reducing the consumption of water with respect to methods currently adopted for granulation.

The result we are expecting will allow us to reduce consumption of thermal energy considerably with respect to conventional processes. The project can be included in the field of sustainable technology, with a low emission of carbon, for industrial processes with a high energetic intensity. This technology offers great advantages in terms of competitiveness, improved efficiency of resources and energy, reduction of the environmental impact of transformation industries with a high energetic intensity.


ANOTHER MS-DRYTECH ORDER FROM CERAMICA ALMEIDA

The Almeida Group, leading Brazilian manufacturer of ceramic tile, established in 1938, has recently ordered a new MS-DRYTECH raw material preparation line for the production of single-firing floor and wall tile in large sizes, which will be decorated using the latest digital technology. The main new features of the system, with respect to those of the previous supplies, are the following: The concept of "open cycle" milling is employed for the first time in Brazil.

This cycle implies the use of a direct air flow drying system (for raw material with a moisture content of up to 16%) for obtaining a ceramic body that is perfectly blended, that has a consistent moisture content and a finer particle size, namely ideal for super-glossy surfaces.

Furthermore, after installation of the system for recycling hot air coming from kiln cooling section, the consumption of methane gas used for milling will be virtually zero. For the finishing operations, the system features the brand new MOLOMAX 6/190 MEGA mills, which guarantee a particularly high performance (up to 50 m3/h) and "maintenance-free" transmission components, thanks to the cooperation with the Swedish multinational corporation SKF, that needs no further presentation.

For the first time in Brazil, granulation takes place by means of the patented MADIREX granulators. Since 2012, the latter have been the technological reference point for obtaining a compound with a moisture content and density, as well as a smoothness and an easy die filling index, similar to that of the best spray dried mixtures. Manfredini & Schianchi has once again been chosen by a renowned ceramic group, such as Almeida.

This proves that behind the success of a great company, there is always a team of exceptional partners, of which Manfredini & Schianchi is proud to be part.

 

Ceramica Almeida

 

 


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