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NEWS 2008  

1.000.000.000 SQUARE METERS OF TILES PRODUCED EVERY YEAR WITH THE MAXIMUM RESPECT FOR THE ENVIRONMENT

Tecn clay 2008

Tecn clay 2008

These are the results of Manfredini & Schianchi technology in the dry treatment of ceramic raw materials as of 2008. From the beginning in the 60s to the Brazilian experience (today Brazil is the world's second largest producer of tiles with 637 million square meters per year) to today, the company has made giant strides in what is the most economical and ecological method of clay preparation known.

Thanks to its technological laboratory and pilot plant, M&S manages to ensure that ceramic companies can use mixtures created with clays both found locally and, in some cases, not completely pure, and still obtaining, in the face of a considerable savings, a final product of the highest quality.

In addition to the very low production costs relating to thermal (natural gas and coal) and electricity consumption, the M&S dry technology uses an irrelevant quantity of water (3 - 4%) compared to that required by wet grinding (33 - 43% ) in addition to the total elimination of highly polluting chemical additives for soil treatment (deflocculants). All these factors have meant that in addition to areas with a strong impact such as Brazil, where M&S has signed 90% of the installations, many other ceramic groups, including many of the largest such as RAK CERAMICS (second world producer with 140 million meters paintings per year) and PRIME GROUP (which ranks fifth with 80 million), have chosen the M&S DRYTECH dry method for their production plants.

The Company's commitment, however, is not only aimed at the very current and very important issues of energy saving and environmental impact, which alone would imply an enormous added value by increasing the competitiveness of the final production, but also towards a constant improvement in the quality of the produced up to products, such as porcelain stoneware, which until recently were considered achievable only with the wet method.

Further support for the choice of the dry method of preparing mixtures can be found in the fact that several companies producing ceramic systems and until recently avid supporters of the atomizer, now present themselves as expert installers of dry grinding systems.

At present only Manfredini & Schianchi, thanks to the tenacity it has had in over 40 years of activity in sustaining the advantages of its technology, can boast of being the only real world point of reference in the technology of dry preparation of ceramic bodies.


CERAMICA ALMEIDA (BRAZIL) DOUBLES

The Almeida Group, a leading Brazilian manufacturer active since 1938, has recently launched a production doubling plan for large format floor tiles which should allow it to achieve a monthly output of 2,5 million mXNUMX.

To achieve this objective, the company commissioned Manfredini & Schianchi to double the dry dough preparation department for the Santa Gertrudes (San Paolo) plant. Designed to produce 50 tons/h, it consists of two pre-grinding hammer mills, ten high-performance MS265 screens, which transfer the material to a Molomax MS-6/190 pendulum mill, sucked directly by a high head process filter.

Molomax mills were designed to guarantee a high quantity of production (by increasing the size of the grinding organs) combined with low energy consumption.

The plant, after grinding, moves on to the granulation phase, carried out by the Forgia MS38 granulators, capable of 'forming' a granular mixture which increases the quality of the ceramic product during the pressing phase.

Almeida

 


RAK CERAMICS AND MANFREDINI & SCHIANCHI A SYNERGY THAT LASTS OVER TIME

RAK Ceramics

The MC09 factory of the well-known United Arab Emirates group is being expanded, and this time too the dough preparation department will make use of the "MS-DRYTECH" dry technology.

The collaboration between RAK CERAMICS and MANFREDINI & SCHIANCHI began in 2001 and since then M&S has already supplied 7 "turnkey" lines in two separate factories (MC07 and MC09) for a total production capacity of almost 100.000 m2/day of single-fired covering and flooring.

Thanks to a highly qualified technological service carried out by both parties in the MIUR research center of M&S in Sassuolo, a highly performing mixture was obtained which uses local and much more convenient raw materials which were previously unused with traditional wet or alternative preparation systems .

Thanks to the advantages of the "MS-DRY TECH" technology, an increase in productivity at the press, dryers and kilns of over 20% has been achieved compared to ceramic products that use atomized bodies and a significant reduction in engobe and glaze in the production phase. glazing which, added to the already considerable energy savings of the preparation, give the aforementioned production lines the leading role in the cost/profit ratio.

The “MS-DRY TECH” dry ceramic body preparation technology, with over 200 installations worldwide and a production capacity that exceeds one billion m2/year, confirms itself as the ideal technological solution for reducing production costs, respecting the environment (not there are emissions of fumes and co2), the maximum quality and performance of the production plants with a significant increase in profits.


MASA CERAMIC: MANFREDINI & SCHIANCHI TECHNOLOGY IN SYRIA

Masa Ceramic, a very important new reality in the Syrian ceramic industry, inaugurates the new factory in Damascus for the production of quality porcelain stoneware and coverings, making use of Manfredini & Schianchi technology for its technologically cutting-edge preparation department.

The M&S pre-treatment plant will manage all the raw materials entering the plant for a total of 600 tons/day, reducing their size in order to obtain better yields and high production in the traditional grinding process.

The plant is based on two different grinding units: a PIG MS/8/A high performance fixed hammer mill where the clays and chamotte will be treated, and an ARO Medium with a rotating ring for the reduction of hard materials.

The totally automated and user-friendly management allows the operator to work in absolute tranquility with all the raw materials without the possibility of error.

Masa Ceramic

 


M&S SIGNS THE LARGEST DRY RAW MATERIALS PREPARATION PLANT EVER BUILT IN ASIA

PrimeGroup

PrimeGroup, the most important ceramic producer in Vietnam as well as the fifth largest tile producer in the world (80.000.000 mXNUMX/year - source Ceramic World) will build, in collaboration with M&S, the largest center for the dry preparation of raw materials for ceramics of all Asia.

This plant will make full use of M&S DRY-TECH technology, the primary grinding will be entrusted to two PIG MAXY/DRYER hammer mills which will feed 3 MOLOMAX 4/230-AIR Pendulum Mills, all in order to guarantee a production of over 100 t/h of very high quality ceramic body. The agglomeration of this mixture will be entrusted to 4 FORGIA MS38-AL Granulators and all the production will be used to feed 3 of the group's production plants in Vietnam.

In addition to the complete "turnkey" system supplied by M&S, all factories will be equipped with M&S rotary screens (patented technology) which will guarantee both ideal homogenisation and perfect loading of the material to the press.

Also in this case, the composition of the ceramic mixture is the result of research carried out by the M&S technological laboratory.

The final production will be 80000 square meters per day of very high quality single-fired tiles in formats up to 600 x 600.

The economic savings obtained by choosing M&S technology will allow an economic return on the investment calculated in two years.

Also thanks to this very important achievement, M&S confirms itself as the most important technological partner in the dry preparation of raw materials for ceramic producers worldwide.


NEW M&S EXPANSION TO CORTINES CERAMIC

The important Argentine group "Cortines ceramic" of Buenos Aires, has commissioned the third expansion of its M&S DRY-TECH raw material preparation plant.

M&S, through the installation of FORGIA Granulators in Weighing Belt/Volumetric Water Control configuration and heated Mills and Screens, will guarantee additional production which will be used to create single-fired tiles for semi-stoneware floors of the highest quality.

In addition to the renewed trust provided by Ceramica Cortines, with this latest creation in addition to the previous ones (Ceramica Alberdi and Cerro Negro), Manfredini & Schianchi consolidates its leadership in the production of dry preparation systems for raw materials, in Argentina, in South America and all over the world.

Cortines ceramic

 


MANFREDINI & SCHIANCHI CONQUERS ARGENTINA

black hill

black hill, an important and prestigious Argentine ceramic company and part of the very important global group CRH, chooses M&S DRY-TECH dry technology for the preparation of ceramic bodies.

The heart of the plant will be formed by grinding via a mill PIG A and a mill MOLOMAX 6/190 and a final agglomeration phase using a granulator FORGE MS38-AL.

This installation will have a production of 30 t/h of ceramic body which will ultimately serve two lines each having a daily production of 15000 square meters of single-fired floor and wall tiles with formats up to 600 x 600 mm.

The main data in addition to productions are:

  • Maximum electrical consumption: 15 kW per tonne
  • Zero heat consumption up to 5% humidity and 3,7 cubic meters of gas per ton maximum with humidity above 10%
  • Maximum water consumption: 35 liters per ton

The composition of the ceramic mixture was studied and created by the Manfredini & Schianchi technological centre


M&S CONSOLIDATES ITS PRESENCE IN RUSSIA

Manfredini & Schianchi has built and recently started up a new dry grinding plant for the production of exposed bricks at the Tverskayya brickyard located 200km from Moscow (Russia).

This installation allows a production of 32 t/h of 8% humidified product. Upstream of the plant the material to be transformed enters with a size varying between 0 and 20 mm and with a humidity > 20% and is highly contaminated with calcium carbonate.

The technological line is composed of a rotary dryer, primary grinding using a PIG Maxi hammer mill, grain size selection using 4 high-performance MS/XIV/256 screens, secondary grinding using a PIG Finisher Hammer Mill and final wetting using 2 MS2000 humidifiers.

The M&S process allows the customer to use locally available raw materials and to be able to 100% manage the problem of calcium carbonate pollution, making, at the end of the process, the ground clay perfectly suitable for the production of high quality brick .

The plant has an output of 60 million pieces per year.

Brick


NEW M&S COOKED WASTE RECOVERY LINE IN SAUDI ARABIA

Recovery of cooked waste

Manfredini & Schianchi implements a new and additional fired waste grinding line in the fourth production plant of El Khayyat Red Brick Co. (Saudi Arabia).

This plant includes a PIG A Hammer Mill for the grinding phase and an MS/X/215 process screen.

Also in this fourth plant the novelty is the wetting of the ground chamotte downstream of the process using the MS2000 humidifier, a phase which serves to make the powder obtained from the recovery of waste perfectly mixable with the normal process clay.

The installation can accept input sizes up to 250 mm and has a production capacity of 12 t/h with output grain size < 1 mm.

Electricity consumption is 8 kW/t.


MANFREDINI E SCHIANCHI CONSOLIDATES ITS LEADERSHIP IN THE SOUTH AMERICAN MARKET

Ceramica Alberdi SA, an important and prestigious Argentine company operating in the ceramic sector since 1907, has commissioned Manfredini & Schianchi to build a new complete dry raw material preparation plant with a production capacity of 30 tons/hour.

The plant is characterized by the latest technologies for grinding and managing raw materials for ceramic use with a maximum electrical consumption of 18 kWh/ton, a thermal consumption of 1,7 cubic meters of methane/ton and a use of only 40 liters of water /ton of ceramic mass ready for pressing.

The new production unit will be installed in the province of Salta in the north of the large Latin American country with the aim of producing 5.600.000 square meters per year of low-absorption single-fired tiles with formats up to 52,2 x 52,2 cm.

The complete technology provided by Manfredini & Schianchi includes the in-depth study of the available raw materials and the personalized creation of the preparation department, with the aim of producing excellent quality ceramic products with low production costs and very high production performance in the pressing phase, drying and cooking.

The ceramic composition prepared dry by Manfredini & Schianchi will serve a line with 2 3020 ton presses, a 5-storey dryer and a single-layer kiln 159 meters long and 3,05 meters of useful width.

With this new production unit of Ceramica Alberdi sa, expertly managed by the Rappallini family, it is equipped with the most advanced technology for the production of single-fired tiles throughout the Spanish-speaking Latin American continent.

Manfredini & Schianchi thus reaffirms its leadership in the sector of dry preparation of raw materials for ceramics of which it holds 95% of the installations worldwide.

Alberdi ceramics

Let Water Flow...


M&S DRYTECH TECHNOLOGY FOR LARGE FORMATS IN INDIA

Murudeshwar Ceramics Ltd

Drytech india

Murudeshwar Ceramics of Hubli (State of Karnataka in southern India), thanks to the Manfredini & Schianchi dry preparation system DRY TECH, is producing red vitrified single-fired tiles for floors in squared and rectified sizes up to 60x60.

This type of product, highly sought after in the Indian market, is the result of a collaboration between MIUR Technological Center of Manfredini & Schianchi (the only laboratory in the sector to have this qualification) and the marketing, production and sales managers of Murudeshwar.

Manfredini & Schianchi has completely developed the ceramic body, focusing its research on the supply of raw materials in areas close to the production unit, thus allowing high economic savings compared to the use of similar wet-treated bodies.

The customer's needs to have a high quality product (with a smooth surface, use of brilliant enamels imitating marble, granite, wood and so on) with particularly low costs and therefore a consequent increase in sales profitability, have been totally satisfied.

The Manfredini & Schianchi DRY TECH Technology is the ideal solution for all those companies that want to introduce particularly innovative and high quality products but without the use of expensive atomized mixtures.


IN MEXICO PROBA EL AGUILA GROWS IN QUALITY WITH M&S

Proba El Aguila SA, an important manufacturer of glazed tiles located in the city of Leon in Mexico, recently inaugurated a new dry raw material preparation plant with Manfredini and Schianchi DRY TECH technology.

The Sassuolo company supplied the Mexican manufacturer with the complete system in all its phases including a MOLOMAX 4/150 Pendulum Mill.

The main features of this installation are:

  • A production of 20 tons/h with a maximum output grain size of 6% > 0,15 mm
  • Thermal consumption 600 kcal/litre
  • Electricity consumption 12 kWh/ton of finished product
  • Noise level 85 dB

Thanks to this new clay preparation plant, La Proba El Aguila significantly increases its tile production capacity and, thanks to the reduction of cooking and drying times, increases the quality of the final product, improving the surface, decreasing porosity and increasing the mechanical resistance. Furthermore, thanks to the savings in the quantity of glazes to be used, production costs are also drastically reduced.

Proba El Aquila, founded in 1987, is today a strong and rapidly expanding production company.

The official website is: www.tejaselaguila.com

Proba El Aguila

M&S NEFELINA GRINDING PLANT IN RUSSIA

Nepheline grinding

Manfredini & Schianchi opens an important mineral grinding plant in the heart of the former Soviet Union, thus continuing its growth in the raw material preparation sector.

The plant in question deals with nepheline, a material in which Siberia is very rich, and is made up of 4 MS-Major Rotary Ring Mills having ideal characteristics for finely grinding hard materials.

After grinding, we move on to a screening station made up of 8 MS/X/215 Vibrating Screens and ends with the phase of elimination of ferrous impurities via 8 MS/7/300M iron removers equipped with neodymium magnetic rods.

The production characteristics are:

• Production 40 tons/h
• 100% separation cut < 0,5 mm
• Electricity consumption 9 kWh/ton of treated product

 

 


Via GM Dallari, 2 - 41049 Sassuolo (MO) - Italy
Tel. +39-0536-801207 Fax: +39-0536-807248
Email: plants@min-ind.it