Seramiksan, the ceramics company which has long been among the top five Turkish tile manufacturers, has just started up a brand new sanitaryware plant with a production capacity of approx. 2.500 pieces per day of medium-high range quality.
Located in Turgutlu, near Izmir, the plant can certainly be defined as the leading factory in the world for its optimization of technological, technical and system aspects in harmony with flexibility and energy savings.
The high-pressure casting department is organized into cells with 16 single-mould machines (model AVM 150) for casting WC bowls and 3 multi-mould machines (model ADS 150) for casting other pieces including one for console washbasins in Fine Fire Clay up to 160 cm wide.
Within the casting cells, vertical and horizontal pre-driers guarantee optimum conditions that remain even and constant during the most critical stage which is drying the half-finished pieces (for all kinds of article).
Sacmi has supplied the complete modelling developments and microporous resin moulds; the latter are part of the 55% of all resin moulds installed in sanitaryware factories around the world that have been supplied by Sacmi.
All stages of handling of the unfired pieces inside the casting cells are performed by a robot, including loading of the pre-dried pieces onto trolleys. The pieces are then transferred on these trolleys up to the inspection station by laser-guided vehicles.
Product flow, controlled by a laser-guided handling system, then proceeds towards 6 Sacmi intermittent driers mod. LWD 2/8 provided with automatic doors.
The robotized glazing of all pieces, carried out by 3 Gaiotto GA2000 robots provided with mass control, is fully automated in order to ensure top quality and to favour environmental sustainability: from automatic piece infeed, which minimizes rejects, to cleaning the piece support, from inside glazing of the siphons to the application of dry filters for total glaze recovery with the elimination of glazing booth washing water disposal.
The system is completed by two Riedhammer kilns: a TWS tunnel kiln (108 m long) and an HWS intermittent kiln (with 84m3 working volume) provided with the most recent technical developments to guarantee the best possible uniformity throughout the firing zones.
Another important feature in terms of energy sustainability is the heat recovery system from the cooling zone of the tunnel kiln.
Sacmi’s participation in this important project was not limited to the supply of machinery since it has also been the technological partner of Seramiksan’s experts in the formulation of bodies and glazes using the best raw materials available in Europe: the objectives being to optimize the overall productivity of the plant and the final quality of the product.
From a technical / system point of view, the machines have been arranged according to a layout which was very carefully and precisely designed by a joint Sacmi-Seramiksan team in order to obtain the most linear, but at the same time flexible, production flow possible.
All the spaces allocated for storage, from raw materials to finished product, have been specially designed to guarantee the safest and best conditions both for the operators and the half-finished products in terms of temperature, humidity, light and dust load.
In designing and implementing the layout the space and services potentially required to double production capacity in the near future were taken into due consideration.
In order to react quickly to changes in market demand, Sacmi and Seramiksan devised a plant provided with quick product change-over reducing any potential production inefficiencies to a minimum.
For this reason the customer chose to use single-mould machines for the casting of WC bowls and multi-mould machines for other pieces with quick mould change-over system. At the same time all casting, handling, drying, glazing and firing operations are controlled by PLC.
The decision to invest in state-of-the-art technology clearly confirms Seramiksan’s intention to guarantee their customers products with higher quality than the average currently found not only on the Turkish, European and Middle-Eastern markets, but also on the Russian, American and Asian ones.