The CERSANIT Group recently purchased - from SACMI, of course - and tested an AVI integrated casting centre for the high-pressure casting of complex WCs.
CERSANIT has chosen to equip its plant in Krasnystaw, Poland, with the most advanced technology available (state-of-the-art in terms of casting and pre-drying). This highly innovative technology is particularly suitable for the manufacture of complex WCs at medium production levels.
This latest acquisition sees Cersanit begin a capacity expansion process for high-range articles that is characterised by a sharp focus on cost containment and user-friendly manufacturing/maintenance.
The AVI casting centre revolutionises the casting machine concept. The mould is mobile and moved by a robot that carries out all operations in complete autonomy. Hence the machine tag AVI, in which the A stands for Alta pressione (High pressure), the V for Vasi (WCs) and the I for Indipendenti (Independent).
The integrated casting centre is thus extremely simple, with the leading role being played by the robot.
In addition to the usual tasks, in fact, the robot can also move all the mould parts, including the mould as a whole: this ensures model changeovers require only minimal amounts of time and manual work.
Bearing in mind the importance of this part of the plant, SACMI has decided to employ a 700 kg FANUC M-900i/B robot.
The section needed to execute casting includes 2 mould clamping units, complete with 2 rim holder devices (i.e. suitable for the simultaneous casting of 2 pieces).
Casting accessories are single, simplified units: the fluids control unit, the slip and glue tanks, the sump water intake system, the wall-mounted WC overturning system and all the relative tools.
Moreover, just-demoulded pieces are, after initial inspection and sponge-finishing, treated in the FPV chamber to aid the hardening needed to allow their manual handling.
In the FPV acronym the P stands for Pre-dryer, F for Finishing and V for Vertical: this ventilated chamber can treat 4 just-demoulded pieces and execute initial maturing at controlled temperature and humidity. The pieces, positioned on polyurethane supports, undergo an initial consolidation stage: this lasts about 90 minutes and reduces moisture content by 2% or thereabouts.
This moisture-losing process (and the associated controlled shrinkage) significantly reduces the risk of pre-drying cracks, a problem that can, above all, affect WCs of complex shape and size.
In short, the AVI integrated casting centre introduces technological innovations that confirm the SACMI Group's position as the world's leading ceramic plant engineering provider.