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"Gresestruso rapido" at Vitro (South Africa)

In the Samca Group, the leading South African producer of dry-pressed ceramic tiles and sanitaryware, production of extruded floor tiles has always played a key role. Manufacturing activities at NCI (split tiles) and at Vitro (flat extruded tiles) have now been combined at the new Vitro plant in Vereeniging: old technologies have been abandoned in favour of “gresestruso rapido” (registered Sacmi trademark) manufacturing techniques. Two new production lines were installed in 2001, a further line being added in 2002. All three lines use rapid roller driers, rapid roller kilns and the TEP cutter unit - specially designed by Sacmi for “gresestruso rapido”. Highly significant advantages in terms of automation, low running costs and product quality have been obtained. The end result? A superb vitrified product with excellent mechanical and geometrical characteristics and decidedly competitive production costs. The product: “Gresestruso Rapido” in the standard 300x300x8.5 mm size with glazed and non-glazed porosity of less than 2%. Body colour: red. Other sizes: 240x240 and 400x400mm The production plant: following renovation and expansion, the plant is now made up of: - dry grinding department Utilises a base clay plus two other components and the chamotte. The department has a crusher mill for the chamotte, the main mill being a vertical roller mill. Raw material silos, batching, the discontinuous moisturising and mixing unit and the extrusion department feed line follow. - three production lines, working 24h/day and 7 days/week, made up of: . clay shredder . flat extruder . Sacmi TEP electronic cutting device for “gresestruso rapido” with column-mounted wheel cutters. - green glazing line - Sacmi E4P rapid 4-level roller drier with compenser at infeed. Length 30m, width 2850 mm - dry glazing - kiln infeed compenser - JMS pre-kiln in line with the single-layer Sacmi FMS kiln, total length 110m and width 2500mm - automatic sorting line connected to kiln outlet. The plant consists of two identical lines (kilns with total length of 110 m) and a third line with smaller kiln and drier. Output data for each of the two main lines is as follows: . net kiln output: 7500m2/day . extrusion moisture content: 18-19% . cutter unit output rate: 72 pcs (300x300 mm) per minute (36 cuts, each producing 2 pieces) . 39-minute drying cycle (inlet moisture content 18-19%, outlet moisture content less than 1%) . firing cycle: 38 minutes (pre-kiln included).

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