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NEWS 2007

M&S PRESENTS THE NEW DRY PROCESS FOR PORCELAIN STONEWARE DRYTECH PORCELAIN IN BRAZIL

In Santa Gertrudes (São Paulo) in Brazil, the 22nd Congress of the Ceramic Cladding Industry was held from 26nd to 2007th October XNUMX, at the ASPACER headquarters, organized together with ABRACOLOR.

The congress was sponsored by ASPACER (Associaçao Paulista das Ceramicas de Coating) and organized by Prof. Anselmo Boschi of the Ceramic University of Sao Carlos. There were 5 intense days of debates where several speakers were present and listened to by a large and participating audience.
M&S took advantage of the opportunity to present to the Brazilian ceramic world the latest technology born from its technological laboratory in Sassuolo: THE DRY PROCESS FOR PORCELAIN STONEWARE: DRYTECH PORCELAIN.

The report was presented by the commercial director of Manfredini e Schianchi do Brasil Ltda, Mr. Arlindo Voltolini and was debated for over an hour and a half with interesting interventions and questions from the public present in the room. The report illustrated how Manfredini & Schianchi has been active in the search for winning solutions for the production of porcelain stoneware tiles since 2002 with laboratory tests, industrial tests and optimization of its dry preparation systems.

The results of an important production unit located in Italy, which successfully uses Drytech Porcelain technology, were illustrated.
The audience in the room was able to touch some samples of porcelain stoneware tiles and verify their surprising technical data, such as: absorption, mechanical resistance, surface hardness, resistance to abrasion, frost and stains.

All data that demonstrated that i products obtained with the DRYTECH PORCELAIN dry process, are practically the same as those obtained with the traditional method but with the great advantage that with dry technology the costs of the industrial transformation process are reduced by 70%.
In a world in which energy costs will continue to rise, this latest figure must give rise to reflection and be of fundamental importance for the future development of the Brazilian and global ceramic industry.

dry porcelain stoneware

MANFREDINI E SCHIANCHI PRESENTS THE NEW MOLOMAX 4/230 PENDULAR MILL

Molomax

Manfredini & Schianchi, on the occasion of the CERSAIE 2007 ceramic trade fair and taking advantage of the large presence of its customers, officially presented the New MOLOMAX 4/230 Pendulum Mill.

The MOLOMAX 4/230, the latest addition to M&S in terms of pendulum mills, was designed to be able to operate with considerable quantities of clays and raw materials having both medium-high hardness such as ceramic bodies for single firing, bodies for porcelain stoneware, feldspars and dolomite and with high humidity levels (up to 20%) as in the case of ceramic mixtures for tiles and exposed bricks.

An important feature of the MOLOMAX 4/230 is that of being able to offer a high production capacity (up to 55 tons/h with primary grinding through PIG-MAXI Hammer Mill) at the cost of extremely low thermal (400 kcal/lt) and electrical (8 kW/ton) consumption.

Technically, in the MOLOMAX 4/230, the 4 grinding pendulums of new shape stand out which, coupled with the new rolling track, give greater pressure on the material allowing grinding capable of obtaining grain sizes of up to 30 microns. Furthermore, it is worth highlighting the extensive use of Alubit (alumina) applied in various parts of the machine with the aim of guaranteeing the correct functioning of the MOLOMAX 4/230 with low maintenance costs.

The MOLOMAX Pendulum Mill, thanks to this new concept, is perfectly suited to the grinding of components suitable for obtaining a perfect mixture for the production of porcelain stoneware for "dry street", thus allowing to obtain a final product of high technical quality with notable energy savings compared to porcelain stoneware obtained by "wet process".

With this further innovation Manfredini & Schianchi confirms itself as a leader in the manufacturing sector DRY GRINDING for the sector ceramic and bricks with over 150 plants installed worldwide which respectively produce almost 1 billion m4 of tiles and over XNUMX million tonnes of brick and similar products per year.


MANFREDINI E SCHIANCHI GROWS IN COAL GRINDING

Manfredini and Schianchi has recently started two types of plants in two different corners of the globe suitable for grinding different types of coal into fine powders.

With the costs of classic energy sources continuing to grow, the whole world is reevaluating energy sources that were considered outdated but which, if properly prepared, can be both economical and low-polluting, such as coal.

The first M&S ​​Coal Grinding plant was installed in Brazil, at Mineraçao Caravaggio, located a few kilometers from Criciuma, in the state of St.Catarina. This system is essentially equipped with a MOLOMAX 3/120-AIR Pendulum Mill with internal drying system and process filter. The plant operates on charcoal with an initial humidity of 10% and has a production of 5,5 tons/h and with a 90% separation cut below 40 microns.

The same installation philosophy was adopted in Portugal at Fabricas Jeronimo Pereira Campos Filho located in Alvaraes. These are 2 grinding units again with MOLOMAX 3/120-AIR pendulum mills, equipped with internal drying systems and process filters. The plant processes micronized petroleum Coque and has a total production of 9 tons/h, with a 98% separation cut below 70 microns.

Coal Grinding

HIDRACOR BELIEVES IN M&S TECHNOLOGY

hidracor

Manfredini and Schianchi, in addition to coal grinding, is developing important experience in sectors in which the market requires technology that can produce materials with fine grain sizes around 50-40 microns, such as the construction sector.

This is the case of Tintas Hidracor S/A, an important company of Grupo J.Macedo, located near Fortaleza (Brazil) and national leader in the production of plasters, plasters, paints, varnishes and colors for the building industry, which in this case has decided to rely on M&S to improve the production quality of its product range.

Manfredini & Schianchi has in fact recently tested and started up 2 production units both equipped with MOLOMAX 6/190-Cyclone Pendular Mills.

These mills are equipped with centrifugal fin separators to optimize the percentage of fine material after grinding and both are equipped with 2 large cyclones which, driven by a high-powered fan, unload the material directly ready to be bagged and transported to destination. Thanks to the automatic control of the internal depression, the MOLOMAX separates the silica particles inside the raw material which are discarded and automatically collected at the base of the mill itself

The first mill grinds dolomite with a production of 3,5 tons/h at a separation cut of 99,8% below 40 microns.
The second mill grinds hydrated lime with a production of 6,5 tons/h with a separation cut of 90,5% below 40 microns.

This is an important step for Manfredini & Schianchi especially because it opens up new scenarios in the field of fine grinding in sectors currently dominated by low productivity mills.


Terra Tile Consortium, a new production company of ceramic bodies for the extruded products sector, located in Thrissur in the state of Kerala (southwest India) has chosen the technology of Dry dough preparation MANFREDINI & SCHIANCHI.
The plant mainly consists of PIG-DRYER Fixed Hammer Mills, Screens MS/XIV/265 e MS Wetting Mixer complete with MU7685 Humidity Meter, for a total production of over 35 tons/h.
The very high quality of the final product that this system guarantees (perfect homogenisation of the mixture, elimination of limescale, controlled humidity) will allow TERRA TILE CONSORTIUM of being the most advanced company in the brick sector in the entire Indian territory, managing to produce an infinite number of products that can range from tiles (Roman, Marseille), to bricks (exposed, handmade) up to sunshades.

Brick systems

CECOL RELYS ON M&S

Cecol mill

Cecol-Ceramica Cordeiropolis Ltda (located right in Cordeiropolis, near the Brazilian industrial center of Santa Gertrudes), has recently put into operation a new latest generation dry grinding plant, branded Manfredini and Schianchi. The plant is equipped with the latest innovative technologies in the preparation of ceramic raw materials. The heart of the process is certainly the revolutionary MS-6/190-AIR Pendulum Mill, equipped with a Process Filter with a high capacity of 57.000 Nmc.
In addition to the MS-6/190 mill, the plant is equipped with MS/38/KSTB-AL wetting-granulating machines, which allow the ceramic mixture to be uniformly granular, significantly improving the ceramic process in the pressing phase.
Cecol is one of the historical realities of Brazilian ceramics, with more than 60 years of history. A major industrial restructuring has recently been completed.
Thanks above all to the new MS grinding, Cecol's production capacity will go from the current 500.000 m1.000.000/month to XNUMX mXNUMX/month of single-fired flooring and coverings.

The Cecol website can be consulted at the following address: www.cecol.com.br


THE GROWTH OF MANFREDINI & SCHIANCHI CONTINUES IN THE BRAZILIAN MARKET

In addition to the order acquired with Ceramica Majopar, Manfredini e Schianchi concluded another important supply with Ceramica Incopisos, also in the Brazilian ceramic hub of Santa Gertudes.
The system is completely similar to that of Majopar; It's always about technology for Dry grinding Dry-tech, made up of machines of absolute value such as PIG mill, High performance screeners MS, Pendular Mill with Process Filter, MS/38/KSTB Vertical Wetting MachinesAll controlled by a general electrical panel capable of controlling the system via the internet and by the flexible management of the production parameters and the elements that make up the grinding through a sophisticated frequency variation system.
The plant will have a capacity of 40 tons/h and will have to serve two new lines for a production of 600.000 m²/month of single-fired red body tiles each. Thanks to this plant, Incopisos will be able to produce approximately 1.750.000 m² every month.
In addition to Majopar and Incopisos, Manfredini and Schianchi has concluded several orders in recent months with the most important ceramic producers in the industrial center of Santa Gertrudes such as Cecafi, Lef, AcroPisos, Cedasa, Formigres, Artec. Confirming itself as the undisputed leader in the "mass preparation" sector in the Brazilian ceramic industry.

Incopisos

CERAMICA MAJOPAR RELYS ON MANFREDINI & SCHIANCHI

majopar

Manfredini & Schianchi, through its Brazilian branch, has recently acquired a new important order in the Brazilian market.
Majopar, a large company in the Santa Gertrudes area, has commissioned a complete "dry" raw material preparation plant of over 40 tons/h with the most modern grinding, screening and granulation technologies which will allow the customer to obtain a final product with low absorption intended for flooring in medium-large formats.
The heart of the plant is certainly the new MS granulation-pelletization system which allows a perfectly homogenized distribution of humidity and excellent loading to the press, guaranteeing high productivity and a strong reduction in drying and cooking times.
The new milling will serve 2 complete lines for a production of 600.000 m²/month each. To these must be added the 2.100.000 m²/month that Majopar already produces with existing lines, again with M&S technology.


MANFREDINI AND SCHIANCHI PLANT IN ZEBEDIELA BRICKS

Manfredini e Schianchi has completed the supply of a complete plant for the preparation of raw materials using dry technology DRYTECH for extruded products, at the South African company Zebediela Bricks near the city of Johannesburg.

The plant has a production capacity of 20 tons/h and the ceramic mixtures, made up of multiple clays, were studied and created together with the customer after a careful analysis of the available raw materials.

The plant is equipped with a Hammer Mill PIG/A/8, of a MS-4/150-AIR Pendulum Mill, and a humidification system mainly equipped with a MS2000 wetting machine and a MS Wetting Mixer, integrated by a Automatic final humidity control apparatus.

The grinding area is technologically equipped to manage an incoming humidity level of up to 15%.
Thanks to this industrial initiative, Zebediela Bricks places itself as a point of reference in the southern hemisphere, in terms of economic technological innovation for the production of extruded products.

Extruded

EL KHAYYAT RELYS ON MANFREDINI AND SCHIANCHI

Brick waste recovery plant

El Khayyat Red Brick Co. (Saudi Arabia), a leading company in the production of bricks, as part of the renovation of two existing factories with cutting-edge technologies, has decided to rely on Manfredini and Schianchi with regards to brick waste recovery technology.
Manfredini & Schianchi is a leader in this specific plant engineering application, thanks above all to the use of the potential of MAXI-PIG Hammer Mills, capable of grinding any type of material with input dimensions up to 400 mm with reduced management costs and a very high particle size reduction.
The plant is equipped with final size control, an adequate system for humidifying the powder and a high precision dosing apparatus to reintroduce the material into the production cycle.
The supply in question includes two identical plants, for a total production of 45 tons/h which are added to two other units supplied previously.


NEW NETWORK CONTROL TOOLS AT NOMENTANA CAVE SRL

Installing the new ones CR88MS Mains Failure Monitoring Tools have allowed NOMENTANA CAVE Srl to significantly qualify its final product (limestone coming from the Oricola AQ quarries).

The main problem for limestone producers is the lack of guarantee that the separation cut of the product is below the desired value, with the consequent lowering of both the quality level and the value of production.

The simple insertion of these instruments allows you to immediately detect the breakage of the screens of a screening system, alerting the operator with both a visual and acoustic alarm.
The resulting prompt intervention avoids pollution of the material and the problems mentioned above.

Network control tool
Phase 1 Phase 2 Phase 3 Phase 4

NEW MS-4/230 PENDULUM MILL

MS-4/230 Pendulum Mill

The new MS-4/230 Pendulum Mill was conceived for the refining of raw materials having medium-high hardness (red ceramic bodies, porcelain stoneware bodies, feldspars etc...) with humidity levels of up to 20%, and high production capacities (up to 55 tons/h in the version AIR with MAXI PIG Primary Mill ) and with extremely low thermal (400 kcal/lt) and electrical (8 kW/ton) consumption.

The main characteristics of the machine are the new shape of the grinding pendulums and the rolling track which give greater pressure on the material, allowing grinding capable of obtaining grain sizes of up to 30 microns.

With this further innovation Manfredini & Schianchi confirms itself as a leader in the manufacturing sector DRY GRINDING for the ceramic and brick sector with over 150 systems installed worldwide which respectively produce almost 1 billion square meters of tiles per year and over 4 million tonnes of brick and similar products.


600 X 900 TILE MADE WITH AL MAHA COMPOSITION

Al Maha Ceramics, a new ceramic company in the Persian Gulf region, has commissioned Manfredini & Schianchi for a complete plant of Dry preparation of raw materials PPFV-CDP intended for the production of floor and wall tiles in large formats. The new ceramic plant will be built in the industrial area of ​​Suhar (Oman) and will have a total annual capacity of 4.700.000 m² of tiles. The preparation plant will feed two complete lines commissioned by the customer to the B&T/Siti Group of the latest generation and high performance for single-fired flooring, in the 330x330 - 450x450 – 600x600 – 750x750 formats and monoporosa covering, in the 250x300 – 300x450 – 330x450 formats .
The main characteristic of the now established M&S technology is that of the high production flexibility, treating both the flooring and covering compositions with different raw materials on the same line.
The raw materials according to the Customer's availability were analyzed by the Manfredini & Schianchi laboratories and the compositions were created in collaboration with the B&T/Siti Group in their respective highly equipped technological centers with a global guarantee on the quality of the final product.
The start-up of the plant is expected in mid-2007 with the lines becoming fully operational.

600x900 tile

 

 


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Email: plants@min-ind.it