Objective
Realization of a new line for the production of crockery in porcelain characterized by a low energy consumption (thermal and electric), by an elevated production, by the elimination of intermediate stocks of semifinished products, by the reduction of working time by the elimination of the environmental impact.L%
The project's technical success is good, on the whole, both for production returns (quality and quantity wise) and in so far technical performance of the whole production line and of each machine is concerned. In particular, by comparing initial estimates, the following can be highlighted:
- Thermal energy consumption: average thermal energy consumption evidenced was equivalent to approximately 1,367 kcal/Kg of fired product over 1,350 estimated in plans. Therefore, the result is excellent.
- Electricity consumption: average consumption was 0,056 kWh/Kg per fired product, over fired 0.051 kWh/Kg estimated.
Increase in consumption, equivalent to approximately 10% is entirely satisfactory it is the result of output in a machine which is not quite under steady conditions yet and which has to deal with frequently changing product shapes, with subsequent production losses and therefore higher specific consumption.
- Line productivity: current line productivity is approximately 7 tons per day. This value is 30% lower than estimated during planning. This is explained by a production mix which is still too variable and which inevitably leads to production losses at each mould change.
This situation, which is connected to marketing factors, should soon be stabilized and allow reaching estimated production capacity.
- Productivity for worker: this is higher than estimated. In fact, the whole production line works with 5 people. Obviously not included are service staff, employees and warehousment.
- Impact on the environment: excellent results were obtained in this sector. In fact the microclimate in the plant is extremely good. Noise level is low, in fact lower than limits provided for by law. Powders dispersion is practically non existant. Impact on the environment outside the plant:
- no dust emission;
- atmospheric emission (smoke etc) within limits provided for by the law. Important changes were not made to the plant, generally, and none were made to machines individually.
The novelty consists in the design and realization of a system that foresees the use of components and technology already known and applicated in other sectors.
The new process foresees the following phases :
dry pressing of atomized powders-finishing-rapid drying-automatic spray glazing-single firing.
The traditional cycle foresees : plastic forming-drying of the semifinished products-finishing-final drying-first firing-glazing-second firing.
Therefore, there is an elimination of the drying of the semifinished products while the final drying is needed to eliminate about 4-5% of water (compared to the 12-14% of the traditional cycle) from the semifinished products what's more, the first firing will also be eliminated.
Other than the obvious energy saving, there will be a remarkable reduction of cycle time (passing from 18-36 hours to 2 hours) with a growing flexibility of the productive system.
Another process peculiarity of the new process, compared to the traditional process isrepresented by the lack of charge stocks of semifinished products as a consequence of the linkage of a production phase of a productive phase with the following.
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Programme(s)
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Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Coordinator
01033 Civita Castellana Viterbo
Italy
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.