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NEWS 2015 

CERAMICA CONSTRULAR IN BRAZIL DOUBLES PRODUCTION THANKS TO M&S TECHNOLOGY

Thanks to the activity of its Brazilian branch Manfredini e Schianchi do Brasil Ltda, the brick market in Brazil has undergone notable transformations in terms of the final quality of the product over the last 20 years.
In fact, by dry processing the raw material, with high production efficiency systems, many Brazilian companies have been able to rise in the market by conquering high added value sectors, thanks above all to the NBR 15.270 quality certification (requirements 1,2 and 3) which means Brazilian high quality product.

One of these companies is undoubtedly the Ceramica Constrular LTDA, located in Pouso Redondo, in the state of Santa Catarina.

M&S in this case provided an extension to the plant previously installed in 2010 for the production of hollow bricks and equipped with all the latest dry milling technologies such as PIG hammer mills combined with screening. The important phase of the new supply is the part that concerns humidification, in fact in this case the new Forgia F9 wetting machine was installed which is capable of humidifying up to 40 tons/h of raw material at an output humidity of 17% , consequently improving the performance of the brick maker in the next phase of the work cycle.

Thanks to this notable investment, Ceramica Constrular has moved on to produce approximately 500 tons/day of perforated bricks, thus satisfying the ever-increasing demand for quality products that the Brazilian market imposes.

The history of this important Brazilian company begins in 1982, and since then it has always been at the forefront 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 , thanks also to trusted partners such as Manfredini and Schianchi

Aracemco


EL KHAYYAT IN ARABIA CONTINUES TO GIVE TRUST TO MANFREDINI AND SCHIANCHI

Horizon 2020


The historic collaboration between the Sassuolo company, specialized in the preparation of raw materials, and the well-known Arab brand continues EL Khayyat Red Brick Co. Collaboration that has been consolidated for more than 15 years now

Manfredini & Schianchi will in fact supply new and additional fired waste grinding lines in the ALKHUMRA production plant near Jeddah, (Saudi Arabia).

This plant is very similar to the two previously supplied two years ago 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 maintaining great resistance to wear.

The installation can accept input grain sizes up to 250 mm and has a total production capacity of the two lines of 30 t/h with output grain size < 2 mm with an electricity consumption of 12 kWhr/ton.

With this latest system, a total of 9 systems have been supplied by M&S to El Khayyat in the past 15 years


TURBO START FOR ARACEMCO WITH MS-DRYTECH TECHNOLOGY

The ARACEMCO ceramic group, a historic Egyptian company operating since 1975, has chosen MS-DRYTECH TECHNOLOGY for the renovation of its raw material preparation plant to replace the old wet preparation technology.

The plant is mainly made up of primary grinding which takes place via the PIGHD mill while the subsequent refining phase uses the Molomax 6/230 mill which is capable of producing over 30 tons/h, guaranteeing a final production of tiles with surfaces uniformly smooth, ideal for applying super-gloss nail polishes and digital decorations.

The powder agglomeration and humidification phase is entrusted to the Madirex granulator (covered by a world patent), currently considered the technological reference in granulation for dry ground powder.

The technical advantages deriving from the use of Madirex include:

  • Productivity up to 40 tons/h
  • Electricity consumption: < 0,3 kW/ton
  • Zero heat consumption
  • Maintenance costs practically non-existent
  • Reduced space required for installation and easy adaptability even to existing systems
  • Constant grain size curve with very high percentages of granulated material, ideal for forming large formats

All the objectives set for increasing productivity: first choice, energy saving, use of "KM 0" raw materials and recycling of production waste have been largely achieved with great satisfaction on the part of the customer who has seen a significant increase in sales and relative profit allowing an extremely short “Return on Investments ROI”.

The Egyptian ceramic sector, despite the recent political problems that have precluded the country's economic growth, has had a triple-digit increase in recent years and ranks as the undisputed leader in Africa and among the top ten countries in the world.

This enormous escalation in production led ARACEMCO to choose a technology that would allow it greater competitiveness in production and quality terms to always remain a leader in its market segment, demonstrating once again that Manfredini & Schianchi is the winning choice.

Aracemco


MANFREDINI & SCHIANCHI PROJECT FOR HORIZON 2020

Horizon 2020

 


Horizon 2020 is the new Program of the integrated funding system for the research activities of the European Commission which will support the EU in global challenges by providing researchers and innovators with the tools necessary to realize their projects and ideas. the structure of Horizon 2020 considers it strategic and fundamental to support the innovation of European companies in all its forms with the program "Innovation in Small and Medium-Sized Enterprises - SMEs.

Within this instrument our company successfully submitted an application which with great satisfaction obtained approval. The efforts that Manfredini & Schianchi srl has conducted over the years in Research and Development projects, aimed at the ever better use of the natural resources involved in the preparation of raw materials for industrial processes, are crowned with another important recognition.

The Manfredini & Schianchi srl project, selected by Horizon 2020, plans to develop an innovative plant for the preparation of raw materials for the ceramic industry, created and organized on technologies currently being validated, with the expected result being a significant reduction in the consumption of process water, compared to current granulation operations.

The expected result will allow thermal energy consumption to be limited by several orders of magnitude compared to traditional processes. The project fully falls within the theme of sustainable and low carbon emission technologies in highly energy-intensive industrial processes, capable of promoting competitiveness, improving resource and energy efficiency and reducing environmental impact. of highly energy-intensive processing industries.

 


YET ANOTHER MS-DRYTECH ORDER FROM CERAMIC ALMEIDA

The Almeida Group, a leading Brazilian manufacturer active since 1938, has recently commissioned a new MS-DRYECH raw material preparation line for the production of single-fired floor and wall tiles in large formats which will be totally decorated with the latest digital technologies. The main innovations of the system, compared to those previously supplied, can be summarized in the following points:

For the first time in Brazil, the concept of "open cycle" grinding complete with air drying (suitable for receiving raw materials with humidity up to 16%) is introduced which allows to obtain a perfectly homogenized ceramic mixture, with constant humidity, a much finer grain size cut, suitable for obtaining super shiny surfaces in the final product. Furthermore, with the future installation of the hot air recovery system coming from the oven cooling, the consumption of methane gas in grinding will be practically zero.

The finishing mills are the brand new MOLOMAX 6/190 MEGA which guarantee high performance (up to 50 m3/hr) and "zero" maintenance transmission parts specifically designed by the M&S technical department in collaboration with the Swedish multinational SKF, a company that does not need of presentation.

Again for the first time in Brazil, the granulation takes place using the patented MADIREX granulators which since 2012 have been the technological point of reference for obtaining an agglomerate with humidity, density, flowability index and mold filling similar to the best atomised ones.

Manfredini & Schianchi is once again chosen by a highly prestigious ceramic group such as the Almeida group, confirming that behind the success of a large company, there are always great partners of which the Sassuolo company is honored to be part.

Almeida ceramic

 

 


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Email: plants@min-ind.it