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Deca Brazil Chooses SACMI for Sanitaryware Production

Deca Brazil, company belonging to the Duratex Group, has once again put its trust in SACMI by placing a major order for its Queimados production site – an all-new plant that, once fully operational, will produce yearly 2,4 million pieces sanitaryware.

The new production line is based on the three SACMI-supplied ALS 150 high-pressure casting machines for the manufacture of washbasins and WC tanks. Fully automatic, each of these machines can, at the subsequent piece checking and finishing stages, be managed by just one worker. These installations ensure both quality and productivity, two aspects that also characterise the glazing department. Extremely versatile and designed to handle all the vitreous China models, the fully automated glazing line features two GAOL robots for offline glazing. This is the second Gaiotto system supplied to Deca Brazil; the first one, installed at the Jundiai (WC tank plant), has already reduced glaze consumption by minimising overspray. The new glazing line installed at Queimados is designed to manufacture daily 1150 WCs and 240 tanks. Equipped with an incorporated mass-control system that checks the characteristics and quantity of the delivered glaze, it lets the worker effect real-time monitoring of piece quality, while advanced control software and a remote assistance module allow real-time troubleshooting – at the click of a switch and with minimal downtimes – of any production problems. In building this entire production line, Deca has focussed on process automation, with high efficiency piece movement and handling solutions minimising the need for workers to carry out manual tasks. Moreover, optimisation of energy consumption is also
ensured by the firing solutions provided by SACMI-Riedhammer. The high degree of automation and real-time monitoring of all process parameters (from output data to consumption data) on the two tunnel kilns should also be pointed out. Completing the order, then, is a further shuttle kiln for refire: this features a “pulse firing” combustion system that ensures optimal process control and extremely  contained electricity and gas consumption.

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