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The Easymud: Efficiency and Cost Saving Production of Soft-Mud Products 

The Easymud: Efficiency and Cost Saving Production of Soft-Mud Products 

An unique production line, born in the 90s, was deeply renewed in the last two years by the Capaccioli R&D team resulting in a strong reduction of raw material, time and energy combined with a high production standard according to the principles of lean manufacturing. Easymud, Capaccioli’s fully automated production line for shaping bricks, floor tiles, roofing tiles, brick slisps and special pieces of soft mud, is a line production and technology patented by Capaccioli since 1997 with substantial innovations to manufacture soft-mud products on an industrial level in order to ensure the transition from one product to another in a short time. 

Over the past two years, Easymud has been the subject of a thorough renovation that led it to unique performance in its sector. The extensive use of robot-based technology has led to new important results. The current machine allows shaping of brick slips and other decorative materials of small dimensions with a roughness similar to those of bricks. This type of brick slips, a high demanding product, is commonly produced by cutting two external sides of fired bricks, discarding the central part with a great material waste and consequent production inefficiency. 

Producing strips with Easymud means to have no more product waste as well as considerable energy savings. The new Easymud production system also guarantees an accurate surface finish of the mortar or glue application face, allowing to be applied with glues requiring tolerances in the order of tenths of millimetres. Another interesting feature of Easymud is shaping of corners or special pieces, to be applied on the wall corners. These are usually made by shaping whole bricks, firing and then cutting them. This procedure involves a large amount of waste. 

The Easymud system allows the production of corners of various sizes, shaped without waste. The robotic shaving process ensures the desired surface accuracy. The shaving trimming is reintroduced into the working cycle. The wide use of robotic technology has led to a significant progress in the principles of lean manufacturing. The use of mobile parts as well as special machines has been reduced to a minimum, with benefits on reliability, time management of the plant and maintenance times. 

The latest changes have also made it possible to reduce format change times even more, integrating every aspect of this function, including the management of mould sets, into the machine design. The Easymud system enables to simplify and reduce maintenance and production costs, to drastically reduce the consumption of raw material and consequently also the general consumption of energy, both compared to previous machines and compared to the current technology on the soft-mud production.

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