Deca Brazil, a company belonging to the Duratex Group, has once again put its trust in Sacmi by placing a major order for its Queimados production site, an all-new plant that, once fully operational, will produce 2.4 million pieces a year. Built in full compliance with the most advanced workplace safety and ergonomic requirements, the Queimados facility stands out on account of its excellent production efficiency, as the need to obtain a quality product has effectively been combined – thanks to the chosen technological solutions – with optimisation of costs.
The ‘stars’ of this new line are, first and foremost, the three Sacmi-supplied ALS 150 casting machines for the manufacture of washbasins and WC tanks. Featuring automated piece de-moulding, these form a high pressure casting plant characterised by outstanding efficiency and a contained investment outlay. Fully automatic, the machine can, at the subsequent piece checking and finishing stages, be managed by just one worker.
These installations ensure both quality and productivity, two aspects that also characterise the glazing department, fully automated thanks to solutions by Sacmi-Gaiotto. Extremely versatile and designed to handle all the Vitreous China models, the glazing line features two GA OL robots for offline glazing. This is the second such system Gaiotto has supplied to Deca Brazil; the first, installed at the Jundiai (WC tank plant), has already reduced glaze consumption by minimising overspray.
The new glazing line installed at Queimados, designed to manufacture 1,150 WCs and 240 tanks per day, offers the right combination of high-tech and user-friendliness, thanks to the new GA OL robot that works in concert with the belt conveying systems. Equipped with an incorporated mass-control system that checks the characteristics and quantity of the delivered glaze, it lets the worker effect real-time monitoring of piece quality, while advanced control software and a remote assistance module allow real-time troubleshooting – at the click of a switch and with minimal downtimes - of any production problems.
In building this entire production line, Deca has focussed on process automation, with high efficiency piece movement and handling solutions minimising the need for workers to carry out manual tasks. Moreover, optimisation of energy consumption is also ensured by the firing solutions provided by Sacmi-Riedhammer. The high degree of automation and real-time monitoring of all process parameters (from output data to consumption data) on the two tunnel kilns should also be pointed out. Completing the order, then, is a further shuttle kiln for re-fire: this features a “pulse firing” combustion system that ensures optimal process control and extremely contained electricity and gas consumption.