Deca Brazil, a company belonging to the Duratex Group, has once again entrusted Sacmi with a major order for its new Queimados production site. Built in full compliance with the most advanced workplace safety and ergonomic requirements, the Queimados facility stands out for its excellent production efficiency, combining product quality with optimisation of costs. It will produce 2.4 million pieces a year when fully operational.
The key items in the new line are the three Sacmi ALS 150 casting machines for the production of washbasins and WC tanks with automated piece de-moulding. The resultant high-pressure casting system achieves high efficiency for a limited investment. The ALS 150 is fully automatic and can bemanaged by a single operator prior to the checking and finishing stages.
The glazing department also combines quality and productivity thanks to the line supplied by Sacmi-Gaiotto. Extremely versatile and designed to handle all Vitreous China models, it is equipped with two GA OL robots for offline glazing. This is the second plant supplied by Gaiotto to Deca Brazil following the one installed at the Jundiai facility (for WC tank glazing), which has already reduced glaze consumption by minimising overspray.
This new glazing line is designed to manufacture 1,150 WCs and 240 tanks per day. It combines advanced technology and user-friendliness thanks to the new GA OL robot which operates in conjunction with the belt conveying systems. Equipped with an incorporated mass-control system that checks the characteristics and quantity of delivered glaze, it allows the operator to constantly monitor product quality. The advanced control software and remote assistance module allow production problems to be solved instantly with a click, thereby minimising downtimes.
Sacmi-Gaiotto has focused special attention on process automation, delivering high efficiency piece movement and handling solutions which minimise the need for manual operations.Optimisation of energy consumption is guaranteed by the firing solutions supplied by Sacmi-Riedhammer, while industrial PCs monitor all production and consumption data for the two tunnel kilns. The order is completed by a re-firing shuttle kiln with a “pulse firing” combustion system that ensures optimal process control and very low electricity and gas consumption.