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Record-breaking pressed clinker production plant at Cerrad ceramics, Poland

SACMI has supervised renovation and extension of the Starachowice plant

The start-up and commissioning of a double layer kiln with a total tile output of 12,000 m2/day is, these days, nothing out of the ordinary. However, if one bears in mind that the upper channel is used to produce medium-large floor tiles while the lower one simultaneously produces 7,000 m2/day of 245x65 mm trims (that’s more than 300 pieces per minute), all directly from the presses and that output is sorted and packaged automatically, then this is a plant that is truly record-breaking! This, then, was the challenge set by the siblings Karolina and Aleksander Sznyrowski, owners of Cerrad, Poland’s long-standing, highly successful clinker producer – a challenge that Sacmi has risen to admirably.

To meet such ambitious, complex needs, SACMI has drawn on all its best and most recent technology: first of all, there are two PH3200 hydraulic presses with an inter-column clearance of 2,450 mm, capable of pressing 22 cavities in a single row or, alternatively, medium-large floor tiles. The presses have also been equipped with the all-new CRS (rapid mould changeover) device, which means downtimes of less than thirty minutes and levels of mould changeover manoeuvrability, accessibility and simplicity never seen before. Thanks to the brief downtimes, the handling system, for both unfired and fired materials, is direct, with fixed 1-hour storage boxes for both planned and unscheduled stops; Sima’s engineers have come up with innovative and personalised solutions for the safe and secure management of production rates that can peak at 360 pieces/minute per channel. At the kiln outlet lie four Nuova Fima sorting and packaging lines, equipped with all the devices needed to handle the difficult range of sizes. With regard to the drying and firing stages, Sacmi Forni has provided two horizontal multi-channel ETP driers and the double layer FBN kiln, designed to give effective, efficient separation of the channels so they can handle the most varied sizes and cycles independently of each other. Moreover, a look at the figures shows that, compared to existing machines, this Sacmi Forni solution gives specific gas savings in the order of 30%
So, with a more productive, automated and less energy-hungry line than before, Cerrad is getting ready to face the challenge of the coming years with determination, certain in the knowledge that it can count on a partner like Sacmi, ready to listen to and satisfy its needs.


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