The easy factory. At Tecna 2024, SACMI presents its project for a new ceramic industry

Productivity, control, environment-friendliness: three key drivers of the SACMI-designed ‘easy factory’ that’s set to play a pivotal role at the 2024 edition of Tecna, the International Exhibition of Technologies and Supplies for Surfaces (Rimini Expo Centre, 24-27 September). As always, the focal point for visitors will be stand B1, with machines on display and live demos throughout the event.

A zero-emissions factory

SACMI’s thermal process control revolution starts with the kiln. The first company in the world to develop a 100% hydrogen kiln, SACMI now presents - exclusively, at Tecna 2024 - its new 100% electric kiln prototype. 
SACMI is building a ‘zero-emissions’ factory that also focuses on new hybrid solutions: spray dryers and dryers, patented and already on the market, to make the most of customers' investments in renewable energy and ensure production continuity at all times. 
Key products on display at Tecna include the new 7-tier dryer module, a new-concept solution that maximizes operational flexibility, enhances process control and reduces maintenance.

A powerful, productive factory

Pioneering plant engineering aims to take performance to a whole new level while reducing consumption and streamlining management.
On the forming front, SACMI presents new hyper-productive PCR versions from the Continua+ family. These have output rates as high as 12 linear meters per minute and over 30,000 m² per day, and can produce fired widths of up to 200 cm, all with the market’s lowest specific consumption (0.04 kWh/m² at the compaction stage), ultra-low levels of scrap regardless of size (note that all scrap can be recycled back into the process), plus a 90% reduction in hydraulic oil requirements compared to a traditional or discontinuous press. Easy control, powerful results.
On the sorting line, instead, visitors to the stand will have an exclusive preview of the latest packaging machine model. The new D-Roll, which completes the SACMI Dinamica Line, has the highest productivity on the market (13 packs/minute in the 60x60 cm size). What’s more, its outstanding autonomy means it can run for an entire shift without an operator. Visitors to the fair will see this solution ‘paired’ with the new D-P&P gantry palletizer - equipped with a ‘smart’ picking gripper - and Spinner, SACMI’s revolutionary 100% electric multi-wheel automatic vehicle that can maneuver through tight gaps.

An automatic, digital, connected factory

At Tecna, SACMI will be showcasing ultra-advanced machining and finishing control based on exclusive BMR technology: a factory where human-machine interaction is smoothed by smoothly integrated mechatronics, inspection systems and AI that optimizes tool consumption through the use of digital/vision controls.
Other developments on display at Tecna include the brand new Squadra Dry Vision Plus dry squaring machine, designed to maximize operational flexibility and control while significantly reducing noise levels: a solution that makes workers’ tasks easier by delivering outstanding ergonomics. Another key proposal is the BMR-patented LeviCompact for lapping, satin finishing and polishing large slabs: this works faster and more homogeneously than traditional machining, thanks also to the two 10-head parallel, tilting bridges that reduce floorspace requirements by up to 45%.
What’s more, the Italvision vision system range now delivers 100% digitalized quality control. The result: zero waste and zero additional costs, fewer defects and higher quality, creating an intelligent factory where machines ‘keep a close eye’ on process control. 
New products on show include OneVision. This advanced self-learning raw material inspection system boosts overall quality, reduces defects (and the relative costs) and adapts to changing manufacturing scenarios. And there’s more: Deep Digital decoration line control is streamlined by new devices, such as the Line UP optical synchro-aligner which upgrades management of complex decoration lines and multiple in-sequence machines. Decoration Line Manager, instead, is a system that provides integrated control, while Optima DHD checks for any defects and retroactively adjusts the main DHD parameters.
Downstream from the kiln, SACMI will be showcasing Flawmaster+, able to detect any kind of ceramic surface defect simply, quickly, accurately and repeatably. Alongside it stands OPTIMA Kiln, a cutting-edge camera inspection system designed to keep pace with the digital evolution of SACMI kilns: by combining precise, accurate color, flatness, size and defects, it allows feedback-driven real-time kiln parameter correction.
The SACMI digital factory guarantees more controls and fewer unexpected events: this begins with the latest modules in the HERE suite, such as the body preparation control room and the ID-Tiles product tracking system: the latter creates a unique ‘identity card’ for each individual tile by keeping track of every single process undergone by every single product. Moreover, new ‘line controllers’ improve and streamline control of the individual stages of the process, such as digital decoration or tasks downstream from the kiln (lapping, squaring, BMR finishing lines) to produce unique, infinitely repeatable products.
SACMI assistance continues to benefit from the introduction of new digital tools which, in addition to the consolidated Smart Service plans, boost performance with data-driven decisions. An IoT framework allows in-Cloud sharing of machine operating data, taking maintenance towards predictive logic.

Intralogistic automation

With SacmiCassioli Intralogistics and interconnection via digital tracking, SACMI is able to deliver fully automated intralogistic, with high levels of ceramic-specific customization.
This advanced automation actually shifts the focus back onto the workers by simplifying tasks and management - even in the face of growing system complexity - and improving the workplace environment.
Increasingly clean and quiet, the SACMI factory is designed to deliver a perfect balance of human-machine resources that further sharpens competitiveness while responding to the burgeoning need to reduce the impact of manufacturing on the environment, people and communities.

Sanitaryware and Tableware: change the way you manage your factory 

As you’d expect from the industry’s long-standing technological leader, the SACMI Sanitaryware & Tableware range on show at Rimini Fiera is all about sustainability and automation.
The Sanitaryware & Tableware division’s tagline for this event within the event is “Explore our solutions to create your perfect mosaic”. This is because, at the core of the range, lie the tesserae used to form a veritable mosaic of solutions: a mosaic designed to boost plant automation and digitalization while focusing on circularity. 
For example, ultrafiltration solutions make it possible to reduce plant water requirements by over 80%, allowing comprehensive recovery of wastewater and raw materials, converting them into resources. With both green (inside the casting cells) and white robotic finishing, greater automation goes hand in hand with higher-quality work and a cleaner factory environment.
Here too, SACMI’s key strength is high configurability. This ensures achievement - in close collaboration with customers - of automation and productivity goals according to a circular economy logic.

SACMI Open Week

Simultaneously with the Tecna fair, SACMI will once again be organizing presentations and dedicated events at its facilities, giving visitors a unique opportunity to experience some of the most innovative proposals first-hand.

See you at Tecna 2024.