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NEWS 2013  

IN SOUTH EAST ASIA DRY GRINDING IS MANFREDINI AND SCHIANCHI

On 08 August 2008, the day of the inauguration of the Beijing Olympics which according to Chinese numerology is the luckiest day ever, the Vietnamese group Prime ordered from Manfredini & Schianchi the largest production unit for dry grinding for single firing from floor in the world.

Step by step, the Sassuolo company, which blew out its 2012 candles in 50, has placed other very important orders also in Thailand with THAI CERAMIC CO. (SCG GROUP) and ROYAL Ceramic, another historic Saraburi company which last year came under the control of the UMI group (UNION MOSAIC) and entered production with a high quality monoporous line completely powered by the MS- preparation process DRYTECH.

The latest innovations developed by the R&D department of Manfredini & Schianchi have made it possible to use materials that are not very suitable for the traditional dry grinding process due to the high humidity present. but particularly high-performance from a ceramic point of view.

The MOLOMAX pendulum mills in fact guarantee high performance by means of new drying air circulation systems and allow the treatment of clays and raw materials in general with humidity levels above 20% with practically zero gas consumption with a consequent reduction in costs and environmental impact.

 


MANFREDINI E SCHIANCHI OBTAINS OHSAS 18001 CERTIFICATION

 

OHSAS 18001

OHSAS 18001 - UNI 9001

 


Manfredini & Schianchi Srl boasts an important new international certification: after the UNI 9001:2008, the very important OHSAS 18001 certificate is the new recognition that the company can boast of.

The OHSAS (Occupational Health and Safety Assessment Series) certification system certifies the voluntary application, within an organisation, of a system that allows for adequate control regarding the Safety and Health of Workers, in addition to compliance with current regulations.

The achievement of this not easy objective guarantees a system and a healthy working environment with safety standards higher than the European average and is a further guarantee for collaborators, suppliers and customers of the willingness of the ownership and company management to invest in every area potentially improvable in order to guarantee the best quality in the productions and services provided.

The company takes this opportunity to thank all the staff involved and all the collaborators for their precious participation throughout the difficult certification procedure, certain that this achievement will only be the starting point for constant improvement.

 

 


THE COLLABORATION BETWEEN EL KHAYYAT AND M&S CONTINUES

Manfredini & Schianchi will supply two new and additional fired waste grinding lines in the two production plants EL Khayyat Red Brick Co. (Saudi Arabia).

These two systems will be installed at the Al Kharji and Sudair production sites.

The heart of this supply, the grinding phase of fired tile and brick waste, are the SLAMMER Hammer Mills which, thanks to their robust structure and armor and the use of special hammers, are able to process extremely difficult material and to have great resistance to wear.

The installation can accept input sizes up to 250 mm and has a production capacity of 15 t/h with output grain size < 2 mm. with an electricity consumption of 12 kWhr/ton.

With the latter there are a total of 7 systems supplied by M&S to El Khayyat in the past 10 years.

El Khayyat

 


MARISTELLA IN BRAZIL GROWS IN QUALITY THANKS TO MANFREDINI AND SCHIANCHI

Toptelha

Maristella

Ceramica Maristela, known in the Brazilian tile market with the brand Toptelha, is located in the municipality of Leme (state of Sao Paulo).

The history of this important Brazilian company begins in 1943, from a winning idea of ​​its founder, Fernando Marchi, and has always been a cutting-edge factory because it has continuously invested in modern technologies capable of helping the industrial process to improve production costs and quality of the final extruded product.

Maristela's last important investment was in the preparation of raw materials, in fact two years ago it was decided to abandon the previous technology equipped with a rolling mill and rolling mill (which did not solve the problem of eliminating the impurities present in the tiles) to move to dry grinding technology with Manfredini and Schianchi.

The plant in question, supplied through the Brazilian branch Manfredini e Schianchi do Brasil Ltda, must treat two types of clay which are first ground by the MAXI-PIG primary mill, subsequently the sieving and classification phase takes place through the work of 5 screens MS/XIV/265, while the recirculated material is ground again by a PIG/A finishing mill.

The product is stored in 10 silos and then moves on to the humidification phase through the use of a twin-shaft wetting mixer.

The plant produces 50 tons/h and is one of the most modern in Brazil.

Thanks to the improvement in the productivity and quality of the ceramic body, Maristela today produces approximately 2.500.000 pieces/month, managing to diversify its product range and presenting itself on the market not only with the classic colonial tile, but also with the Mediterranean tile, special pieces , ventilated walls, bricks.


CERAMICA ALBERDI DOUBLES WITH MANFREDINI AND SCHIANCHI

Alberdi ceramics, an important and prestigious Argentine industry active since 1907, commissioned Manfredini and Schianchi to double the dry grinding line for raw materials at the Salta plant.

The new mill came into operation in January 2013 and faithfully reflects the previous installation also supplied by M&S in 2008.

The total production capacity is now around 60 tons/h and, thanks to this, Ceramica Alberdi can produce around 11.000.000 square meters per year of low-absorption single-fired tiles with formats up to 52,2 x 52,2 cm.

The heart of the plant are the two Molomax MS-6/190 pendulum mills, while the agglomeration and granulation phase is managed by the Forgia MS38/AL.

Ceramica Alberdi sa, expertly managed by the Rappallini family, has doubled its production capacity and equipped itself with the most advanced technology for the production of single-fired tiles throughout the Latin American continent.

pyramid thieves

 


IN THE SASSOLE DISTRICT, THE DRY GROUND PORCELAIN STONEWARE MIX IS BRANDED “MANFREDINI & SCHIANCHI”.

cbc roup

The technological partnership between Manfredini & Schianchi e CBC GROUP, a rapidly expanding group and owner of the well-known REMIX company (the whitener "par excellence" for bodies and glazes which 100% replaces the use of zirconium) has made it possible to market some types of porcelain stoneware bodies obtained with the MS-DRYTECH PORCELAIN process.

Several companies in the Sassole area have already been using them for several months with excellent results from a qualitative point of view, without any production limits and above all with energy savings reduced by over 70% compared to atomized powder.

In a context where energy and related costs have an ever-increasing impact, the MS-DRYTECH PORCELAIN process is the right answer to guarantee productivity, high quality and environmental respect for an increasingly "eco friendly" ceramic product.



MADIREX THE NEW GRANULATION SYSTEM

A few months after its presentation at the Tecn clay 2012 fair, the Madirex Granulator (world patent) has already made headlines and is already considered the technological reference in granulation for dry ground powder.

Manfredini & Schianchi, in this short period, has already installed several machines in its dry raw material preparation plants (Europe, Asia, North Africa and South America), obtaining incredible results and many other units will be installed in the coming months.

The main technical advantages of using Madirex can be summarized in the following points:

  • Productivity up to 40 ton/hr,
  • Electricity consumption: < 0,3 kW/ton.
  • No or negligible heat consumption.
  • Maintenance costs practically non-existent.
  • Little space required for installation and therefore easily adaptable to existing systems.

The technological advantage can be summarized by stating that MADIREX is able to transform any type of ceramic powder into a soft granulate with humidity well distributed over the entire surface, whose main characteristics (such as specific weight and degree of smoothness) remain similar to any atomized powder, opening new and interesting perspectives to dry grinding.

Manfredini & Schianchi has a complete pilot plant inside which, by testing each case at an "industrial" level, allows it to guarantee its customers the certainty of the required performance.

pyramid thieves

Granualto madirex

 


OBJECTIVE: SAVE WATER
(Interview with Fabio Schianchi - Source: Ceramic World Review)


Fabio Schianchi Interview

Saving water resources is attracting growing attention from tile manufacturers in various parts of the world, giving new impetus to plant engineers' research into new dry production techniques: from the preparation of raw materials, in fact, the "dry" now enters fully also in the finishing phase of the product, more precisely in squaring. But what could be the future developments for these technologies and in which parts of the world will there be greater opportunities for diffusion? We asked Fabio Schianchi (Manfredini & Schianchi Srl)

CWR: Manfredini & Schianchi has been embracing research in the field of dry grinding for years. What are the latest developments?

Fabio Schianchi: Today we can affirm that our technology is able to guarantee all types of glazed ceramic products, without any quality, production or size limits. Over 150 plants in the world with a global productivity of 1,2 billion mXNUMX/year are our business card. The research always starts from the raw materials supplied by the manufacturer and from the possible recovery of production waste (glazed and unglazed chamotte, sanding and enamelling sludge, lime from filters and above all new raw/secondary materials such as glass or other inert industrial waste), and from here we create an ad hoc dress based on the product requested by the company, focusing on a single objective: the final product at the lowest possible cost and with maximum first choice performance.

CWR: What are the advantages perceived by the market compared to alternative solutions?

Fabio Schianchi: The first interest of those who approach dry grinding is energy saving. Subsequently, other advantages are discovered (and appreciated), namely: the composition of the ceramic body which allows less expensive raw materials, the more rational consumption of glaze and engobe, the maximum yield of presses, ovens and dryers, and above all a higher efficiency first choice almost always above 90%. The sum of these factors means that, with the same product quality, the production cost differential between tiles obtained using wet methods and those obtained with MS-Drytech technology exceeds 50% in most cases.

CWR: Dry grinding is still often linked to the "poor ceramic product".

Fabio Schianchi: The perception that this technology was only suitable for production of medium-small formats with opaque glazes (or similar low-range products) was one of the factors that limited its diffusion throughout the world, together with the actual technical problems connected to the degree of humidity of the raw material.
These limits have been completely eliminated with the introduction of new machines - Pig Dryer and Molomax primary hammer mills - capable of grinding mixtures of different raw materials, with high humidity levels even up to 20% and without the need of primary drying, ensuring homogeneity and constant granulometric control.
Our great strength is the industrial dry grinding system installed at our R&D center (registered in the register of research laboratories of the Emilia Romagna Region) which allows us to produce large quantities of ceramic bodies by simulating what would actually happen at the customer's factory. In this way we can "industrially test" the various mixtures developed for customers, taking care of every detail and reducing the industrialization and set-up times of the production line at the ceramic company.
Not only that, the industrial test also allows us to study and develop new machines to be inserted on the line, as in the case of the Madirex 2400 granulator, conceived and perfected thanks to the continuous use of the industrial plant, which has allowed us to present to the market a machine already extensively tested and performing. In the field of granulation for dry powders in the pressed ceramic sector, Madirex (more correctly called "agglomerator") is the only technology capable of transforming fine powder into "granular agglomerates", with little addition of water (on average < 45 l/ton) and without the need for subsequent drying, allowing considerable plant savings and simpler management for the operator. The agglomerated powder has a degree of smoothness similar to atomized powder and is therefore suitable for the production of tiles of any size.

CWR: Among the markets that were the first to reward dry grinding, there is Brazil. Why?

Fabio Schianchi: The explosion of dry grinding in Brazil occurred with the birth of the production center in the state of Sao Paulo, while in the southern state of Santa Caterina, the cradle of the Brazilian ceramic industry, it has always been produced using the wet method. We have contributed significantly to the development of the new industrial district, with the introduction of innovative ideas and cutting-edge technologies. Dry raw materials (which today are no longer even crucial) gave us a hand, but it was not the only factor: Brazilian entrepreneurship very well received the expertise we had developed in the Sassuolo district, favoring the creation of a close collaborative relationship to the benefit of both parties.

CWR: In which other countries has dry milling spread?

Fabio Schianchi: In countries such as Iran and Turkey, the interest responds to the need to reduce high energy costs. In the Arabian Peninsula and North Africa it is the problem of water resources that makes the difference. I think the next frontier will be South East Asia which is opting for our technology in response to a very strong attention towards "eco friendly" products, and from this perspective dry milling is certainly the most eco-sustainable raw material preparation technology. In the future, who knows, I wouldn't even rule out that in Europe we could start evaluating the transformation of many wet plants to reduce production costs and environmental impact.

 

 

 

 


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Email: plants@min-ind.it