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NEWS 2016

SAVOIA ITALY CHOOSES MS TECHNOLOGY

The recovery of pressed raw ceramic waste (glazed and unglazed) associated with that of fine dust from the extraction system is an excellent solution for those factories which, not having their own raw material preparation plant, purchase the mixture from external suppliers .

This solution considerably reduces the cost of disposal and raw materials; it also helps to reduce the environmental impact due to the transport of raw waste by truck.

The system is mainly based on the use of an MSF1 Hammer Mill complete with calibrating grid which, thanks to a suction system installed downstream of the mill itself and a dosing device, is able to accurately feed the conveyor belt of the atomized material without creating problems in the subsequent pressing phase.

The average productivity of this plant is around 500-1000kg/h with marginal maintenance and management costs and an extremely rapid return on investment.

This solution is already operational at other ceramic groups in the Sassuolo area such as: Rondine ceramic group, Ceramica Artistica Due, Ceramiche Gold Art, Ceramiche Mandrio Correggio.

Vilgacera Halong


IMPORTANT CREATION OF MS IN THE GRINDING OF PORCELAIN STONEWARE WASTE

 

 

 

Ceramics Gold Art

The management of porcelain stoneware waste has always been an annoying problem managed in different but never satisfactory ways, now MS has developed a new plant line to simplify and reduce costs in the grinding of porcelain stoneware chamotte and/or other type of high hardness raw materials.

The heart of the plant consists of the new SLAMMER Mill (which will be possible to view at stand 166 Hall C3 of the Tecn clay fair in Rimini from 26 to 30 September) which has been designed to be able to deal with and grind materials with even greater hardness of 7 Mohs like porcelain stoneware.

The final result is that, in the face of very low transformation costs, an output grain size of 10%<63micron, 60%<1mm and 100%<5mm is obtained, with flow rates of 7-8T/h and infeed dimensions up to 250 mm.

It is clear that cost-effectiveness and simplicity are the main aspects of this plant line capable of responding to the most difficult and onerous grinding processes.

It is also important to underline the simplicity of maintenance interventions, as the machine is equipped with doors with pneumatic openings, a complete replacement of the grinding parts can be carried out in 1 hour.

Yet another system will be installed at Gold Art ceramic by Pavullo n/f by the end of 2016.


VIGLACERA HALONG CONFIRMS ITS TRUST IN M&S TECHNOLOGY

Viglacera Ha Long, a well-known Vietnamese manufacturer of fast-firing extruded terracotta tiles, has renewed its trust in DRY TRCH Heavy Clay preparation technology.

This is the fourth supply in less than 15 years, confirming that the quality of the product is always measured by the efficiency of the technology used, in fact, dry grinding with the PIG /8/HD dryer and PIG/8/ hammer mills A dryer, allows an ideal output grain size both to eliminate impurities derived from the limestone and to obtain a good performance in subsequent drying and firing cycles.

The final product is a ceramic that focuses on the naturalness of clay, with the possibility of being able to further enrich it graphically with surface applications without affecting its natural reference to mother earth.

Vilgacera Halong


MS DRY-TECH ECO FRIENDLY TECHNOLOGY FOR THE CERAMICS OF THE FUTURE IN THE CHINESE MARKET

 

V-Tong

The reuse of industrial production waste is the challenge for the ceramic sector and Manfredini & Schianchi wants to be a protagonist.

For this reason, SHANDONG V-TONG has chosen the eco-friendly MS-DRYTECH technology for its new factory which will start production within the first months of 2017 in the city of Zibo.

The peculiarity of this product is that it reuses up to 75% of production waste derived from cement factories, which, when suitably homogenized with plastic raw materials during the grinding phase in the MOLOMAX 4/150 MILL, allows to obtain a ceramic mixture having the same characteristics as the PORCELAIN STONEWARE.

This new system of "making ceramics" will open up important perspectives on how to reuse industrial waste, allowing the redevelopment of heavily polluted industrial areas for truly eco-sustainable development.


AT KERAMA MARAZZI CERAMIC WASTE BECOMES A VALUABLE RAW MATERIAL

Manfredini & Schianchi will supply a new cooked waste grinding line to the production plant Kerama Marazzi Russia located in the city of Orel.

The heart of the plant is the SLAMMER Hammer Mill, a machine specifically developed for the treatment of materials with a high degree of abrasiveness (fired ceramic waste, sanitary ware, feldspar, quartz etc...).

The installation can accept input sizes up to 450 mm and has an average production capacity of 12 t/h with output grain size <2 mm.

The electrical consumption is <12 kW/t and the wear of the spare parts is particularly limited, allowing an operating time of more than 400 hours.

With this solution, all fired waste (glazed and unglazed) is completely recycled as a high-quality raw material, with all the advantages associated with saving on disposal costs.

 

Kerama Marazzi

 

 


200 TH SALT PRE-WASHING SYSTEM IN IRAQ

IRAQ salt pre-washing system

IRAQ pre-wash system

Salt washing plant

Manfredini & Schianchi together with BAKHERT ALSALAMA TRADING & CONTRACTING CO won the tender for the supply of a 200 T/H sea salt pre-washing plant to the municipality of Basra (IRAQ).

This product will then be distributed to various local refineries.

The supply includes two MS washing screws of 100TH each powered by special MS feeders, a 200TH vibrating centrifuge and a belt system for storing the washed salt outdoors as well as all the engineering for the washing brine recovery tanks.

The final guaranteed purity is over 99%

In addition to the supply and installation of the system, MS also provided complete training to the personnel in charge at its headquarters.


BRAND NEW MS SALT PRODUCTION AND REFINING PLANT IN OMAN

Manfredini & Schianchi, which in recent years has become the largest European plant engineering company for mechanical salt refining systems, has designed and is under construction a brand new installation for the production of salt in Oman on behalf of AL-GHALBI INTERNATIONAL, a well-known and consolidated local company specializing in gas and oil extraction systems.

After having carried out the initial feasibility study, including assessments of the geological and climatic analyzes of the area, and after approval by the customer, MS was tasked with carrying out:

1) Complete project for the construction of salt basins for a total annual production of 135.000 tons of sea salt. In this case, over an area of ​​one square kilometre, a specific configuration of crystallisation tanks was designed to have, by exploiting the favorable climate, a continuous monthly collection instead of the classic seasonal collection used in areas with a Mediterranean climate. .

2) Design, supply and installation of the relevant turnkey refining plant for a global hourly production of 40 TH of salt with a final purity of 99.8% including:

  • Washing via MS special washing screw.
  • Centrifugation.
  • Drying.
  • Salt selection using MS inclined screens.
  • Grinding via Mixol mill
  • Packaging.
  • Total recovery of the superfine part coming from the dryer filters and sent to the production of briquettes for water softening via MS compactor.

Salt refinery plant

These very high final purity values ​​allow the customer to be able to market, at an extremely competitive price, the finished product to customers (petrochemical industry) who were previously forced to purchase only recrystallized salt (vacuum) at high prices.

These high percentages of purity, with mechanical refining methods, are possible both thanks to the training that MS provides to the personnel dedicated to the production and collection of salt and to those dedicated to processing and to the plant, made to measure with special modifications to the purification which, to date, represents the state of the art as regards washing, centrifugation, drying and selection of the finished product.

For the construction of the salt basins, Manfredini & Schianchi, in addition to the complete project, guarantees the end customer all the technical and engineering assistance necessary to be able to effectively interface with local suppliers and periodic visits to check the progress of the works and ensure correct training of all staff.

Al Ghalbi

Salt ponds

Oman salt plant

Omani salt plant

Salt plant Oman

Salt plant Oman

Salt briquetting unit

 


TOPTELHA AIMS AT PRESSED TILES WITH MS TECHNOLOGY

Top Telha

Top Telha

Top Telha

Top Telha

Top Telha

Top Telha

Top Telha

Top Telha

 



Source: Brick World Review N.3/2015

Based in Leme, in the State of Sao Paulo (Brazil), Maristela Telhas, better known as Toptelha, is a modern brick kiln that produces brick roof tiles.

A monthly production capacity of 2,5 million pieces, equivalent to 7.500 tons, 60 employees and particular attention to the environment and workers' health. Founded in 1996, initially as the second division of Maristela Ceramica, in 2000 it became part of the Uralita Group, a Spanish multinational company, among the leaders in the construction materials sector, and in 2005 it was taken over by the Marchi family (of Italian origins) active in the industry for more than 50 years.

Luiz Fernando Marchi Jr., general director of the company, thinks that to counter the current contraction of the Brazilian construction market, we need to keep up with new technologies. “Because the market renews itself and reinvents itself at high speed” – he declared. “And investments in technology help in medium and long-term business strategies.” We interviewed him to learn more about his company.

BWR: What is the construction trend in Brazil?

Luiz Fernando Marchi: In 2014 the Brazilian economy entered a phase of stagnation. Last year's GDP practically did not grow (+0,2%) and the forecast for this year is an estimated decline of 3%. This also had a significant impact on the construction market. In the years 2007-2011 the sector experienced a real boom and, to support the demand for construction materials, the furnaces equipped themselves with more efficient technologies to increase production capacity. Subsequently, due to the uncertainties created by the mismanagement of public funds, the sector suffered a setback and today supply is much higher than demand. Companies are operating at 70% of production capacity and sales prices have fallen by 2013% compared to 15.

BWR:Is it therefore plausible to think that the economic difficulties can also be attributed to political issues?

LF Brands: I would say yes. The lack of political guidelines and an understanding between the National Congress and the Executive Power have left the country without prospects. Due to this general uncertainty, there has been a drop in consumption, entrepreneurs have slowed down investments, reduced production and made staff cuts, causing the unemployment rate to rise.

BWR: How much is the national consumption of brick?

LF Brands: The state of Sao Paulo alone, the flagship of the country's development, has an installed capacity of 80 million pieces/month. It currently produces 60 million pieces, maintaining stock of 2 months of production. The "Minha Casa Minha Vida" program, created by the Federal Government in recent years and still in existence, has given a great boost to the construction of affordable housing, also motivated by forecasts relating to the increase in the population which, according to estimates, will go from 193,25 million in 2010 to 209,38 million in 2022.

BWR: How many players are present in the State of Sao Paulo?

LF Brands: We are around 2000 producers and produce 50% of national production. BWR: How did 2014 end for TopTelha? LF Marchi: As already highlighted, the Brazilian economy experienced stagnation in 2014 which severely penalized the construction sector and, therefore, also our business which lost around 10% of its turnover. 2015 is also proving to be quite difficult. As far as we are concerned, however, we are implementing all the necessary strategies to return to 2013 levels. We must not forget that in our country a significant housing deficit persists which will have to be filled in the coming years. The demand for new homes is mainly concentrated in the regions of the South-East (with a demand of 2,05 million housing units) and the North-East (where the demand is for 1,95 million housing units).

BWR: What does TopTelha produce?

LF Brands: The TopTelha range includes tiles from the Mediterrânea, Colonial, Especials, Margon series, in the terracotta and colored versions, and the entire line of accessories and special pieces to complement them. Our product range is also enriched by external ventilated facades under the Terreal brand. This is a collaboration that TopTelha signed with the French group a few years ago and which is giving excellent results in terms of commercial results.

BWR: Besides the national one, what other markets do you supply?

LF Brands: The quality of our products is also requested in the United States, Curaçao, Dominican Republic, Angola and Paraguay. Overall we export around 8-10% of our production.

BWR: What technologies are you using?

LF Brands: We use the best technologies available in terms of production efficiency and automation, on which our major investments are directed. Today TopTelha is considered one of the most modern production companies in Brazil and South America. The best Brazilian and Italian suppliers are protagonists of this fantastic evolution together with us.

BWR: What was the investment that allowed you to make a substantial leap in quality?

LF Brands: Certainly in 2008, when we decided to completely change the raw material preparation system. We have in fact moved from the traditional wet system to the dry grinding system. The technological project was managed by Manfredini and Schianchi, present in the state of Santa Catarina with its own production branch. The improvements on the product were immediately evident: total elimination of impurities such as lime; greater resistance (>300kgf); lower water absorption (<13%); improvements in the tile glazing phase. Dry milling has also allowed us to significantly increase production efficiency in the extrusion, drying and cooking phases.

BWR: Controlling environmental impact is particularly important to you. What measurements do you use?

LF Brands: In our factory there is full compliance with the regulations adopted by the country. TopTelha tiles are produced following the most rigorous quality standards according to the ABNT NBR 15310 standard, a guarantee that is valid for a period of 25 years starting from the date of purchase. They are also certified by the CCB (Brasil Ceramic Centre), a conformity assessment body accredited for the certification of products and the quality management system. Our product is certified within the PSQ (Sectoral Quality Program for Ceramic Roofs led by Anicer), and linked to the PBQP-H – Brazilian Program of Quality and Productivity in the Habitat, of the Ministry of Cities. The program verifies the qualification and classification of materials, the growth of Brazilian civil constructions and the integration of the production chain. We are also particularly careful to create working conditions to safeguard the health of our employees.

BWR: At the 44th Encontro Nacional, held last August, there was much talk about the energy crisis in Brazil. How are you preparing?

LF Brands: In fact, the energy crisis is proving to be particularly severe and is now causing numerous blackouts on a daily basis, to the detriment of economic activity. Furthermore, a sudden drop in the price of crude oil continued to weaken the national currency. The latest problem, completely unmentioned, is the drought in the São Paulo region, one of the most serious in the last 80 years, with non-negligible consequences on the economy. The only solution is to invest in high production efficiency technologies with low energy consumption, which is what we have tried to do in recent years. The good news is that methane gas has finally arrived in the municipality of Leme, undoubtedly a valuable aid for production activities.

BWR: Upcoming investments in technology?

LF Brands: By 2015 we will upgrade all cooking systems to run on natural gas (currently fuel oil is mostly used). Among the future investments already planned by TopTelha, a new production line for dry pressed tiles with a rapid drying and firing process. The plant will be equipped with presses, dryer, roller kiln and glazing system. The main purpose of the plant project is to expand our reach by satisfying the demand in this new segment. The estimated production capacity in the first phase is 1.200.000 tiles/month, but in the coming years, market permitting, we expect to double this. The pressed tile system requires the same energy consumption as traditional processes, but the qualitative result is significantly better.

BWR: And what will the future of brick in Brazil be?

LF Brands: Brick is part of our culture. We think that, due to the particular climatic factors of the country, it is the most suitable material and will therefore continue to hold a significant market share in support of the Brazilian economy.

 


UNCLE CERAMICS CHOOSES MS DRY-TECH DRY PROCESSES

Source: Ceramic World Review N.114

Uncle Ceramics of Morbi (Gujarat) is a young Indian company founded in 2014 by Jayantilal P. Bhoraniya, a manager with 25 years of experience in the ceramic sector. The company specializes in the production of tiles intended for flooring high traffic areas (such as car parks), a very technical product manufactured in the 30x30 cm format.

Launched in May 2015, the Uncle Ceramics plant is equipped with Italian technology and is the first in Gujarat to adopt the dry preparation technology of raw materials proposed by Manfredini & Schianchi.

The Dry Tech plant has a production capacity of over 8 tons/h and was designed with extreme flexibility in mind: in fact, it can be used both for the floor tile production line and for the one dedicated to stone coverings. double firing. We caught up with Jayantilal P Bhoraniya to learn more about the new company and its goals.

CWR: What was the idea behind the birth of Uncle Ceramics?

Jayantilal P. Bhoraniya: The basic idea starts from the assumption that, to counter increasingly fierce competition, it is necessary to approach the technological aspect in a new way, designing systems that guarantee high levels of efficiency, cost reduction and maximum quality in the finished product. The best results can only be achieved by adopting cutting-edge technology, thus abandoning production schemes based on traditional technologies, now outdated but still very widespread in India.

CWR: What do you produce specifically?

JP Bhoraniya: We specialize in the production of outdoor tiles for high traffic areas, which in India we call "parking tiles". These are materials that are in great demand on the Indian market; indeed, demand continues to record constant rates of increase. It is a product made with porcelain stoneware body, characterized by high resistance and low water absorption (0,5%). We produce it in the 30x30 cm format and with thicknesses from 9 to 12 mm.

CWR: When did production begin and in which areas has marketing already begun?

JP Bhoraniya: The plant was started up last May with a production capacity of 5.000 mXNUMX/day. We have a network of distributors that already covers the geographical areas of the country with the highest consumption. The target segments are residential, industrial and public construction projects. Having just started, we have not started any export activity at the moment, but we are also evaluating this possibility.

CWR:Can you describe the system to us?

JP Bhoraniya: We have chosen advanced Italian technology, such as the Manfredini and Schianchi dry preparation plant for raw materials, Sacmi double-channel ovens and Durst technology for digital printing. We have focused on high levels of automation to make the production process increasingly efficient. The attention to environmental protection was also important, evident already in the choice to equip ourselves with dry preparation technology which eliminates water consumption (therefore avoiding any possibility of water pollution) and reduces emissions to practically zero. The plant is also equipped with a system for recovering fine dust from environmental filters to be reused as raw material.

CWR: What benefits have you noticed in these first months of production with the dry process?

JP Bhoraniya: Certainly the simplicity of the process, the efficiency and environmental sustainability compared to wet systems with atomizer. It also allows great flexibility and speed in product changes. In these first months we have achieved tangible results in both the performance and quality of the tiles, with less waste and more production efficiency, which add to the enormous savings in terms of fuel costs, labour, materials and electricity.

CWR: Does the system also allow the recovery of sanding waste?

JP Bhoraniya: That's right, and this aspect also represents a great advantage, both economic and environmental. On the one hand, recovering the waste from the sanding phases as raw material solves the problem of their disposal, which is not a small one here in Morbi; on the other hand, the high number of factories that produce polished porcelain stoneware in our district guarantees great availability in the supply of waste, which reduces production costs considering the type of product you want to produce. This opportunity is only practicable with dry preparation systems; in wet processes, in fact, the recovery of waste is severely limited by the fact that the economic advantage is canceled out by the parallel increase in fuel and additive consumption (such as STPP, sodium tripolyphosphate); furthermore, it would penalize the final quality of the product.

CWR: What are your next goals? JP Bhoraniya: We intend to double production within a year through new investments to expand production capacity. At the same time we will work to expand the range of flooring and covering materials. CWR: What is the scenario for the Indian ceramic industry?

JP Bhoraniya: The Indian ceramic industry has enormous growth potential. The greater demand for products and the booming economy have led, in the last year alone, to the creation of dozens of new production units. The scenario is also very promising for the future, but the sector now finds itself at a turning point: there is a "hunger" for innovation and more efficient technology that allows us to reduce costs to increase competitiveness in a market often oriented towards price. I believe that the Indian ceramic industry is ready for this leap in quality.

Uncle Tile

Uncle Tile

Uncle Tile

 

 

 


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