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Lasselberger chooses Sacmi-Kemac technology to expand in European Russia

Two complete lines for the manufacture of decorated ceramic tiles and trims

A long-standing Sacmi brand that leads the way in the design and provision of third fire and trim production plants, Kemac has now scored another major success on the European market. More specifically, multinational ceramic and construction materials firm Lasselberger commissioned Kemac to boost output capacity at its plant in Ufa (the capital of the Republic of Bashkortostan, in European Russia) to respond to the growing demand for decorated ceramics on the Russian market.

This new line is already operating at full output capacity, that is, 1500 square metres a day. Fully built using Sacmi-Kemac technology, the system stands out on account of its excellent flexibility and can produce a wide range of decorations on formats ranging from 150x150 up to 600x600 mm.

Pivotal to this order are two screen printing lines equipped with DK3 machines, the most modern available in the traditional ceramic decoration sector; these ensure maximum precision during application of screen printing pastes while also maximising productivity, user-friendliness and size changeover speeds. Downstream from the two lines - the first of which has 6 screen printing machines for third fire decoration, the second 3 machines that can also be used in fourth fire for the application of precious metals - are vertical rack-type driers with ultra-fast size changeover. These are equipped with Sacmi PL7 burners to maximise drying performance even where screen-printing pastes are applied thickly.

Kiln feed is fully automated. Moreover, upstream from the kiln there are further systems for dry decoration of the product. The need to achieve high output rates while keeping production flexible has driven Lasselberger to purchase 2 high-performance kilns, specially designed by Sacmi to meet the special needs encountered in third firing (i.e. frequent cycle and firing temperature changes), thus minimising preparation times. Both kilns - 30 and 21 meters long respectively - have PL7 burners and an effective inlet width of 1800 mm, therefore maximising temperature homogeneity inside the firing chamber. Advanced Winklin software allows accurate adjustment of firing curves and, therefore, maximum production flexibility. This result also stems from the downstream integration of 2 cutting lines complete with Roller Cut Dry driers: these allow one-step manufacturing of decorated, finished trims that are dried instantly and immediately ready for packaging.

Begun in 2012, the new lines were completed in May 2015, allowing the Russian plant – established in 2009 – to raise tile output capacity to the current 13 million square metres, with further prospects for consolidation and growth in the coming years.

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