Fusion®

The Sustainable Tile Technology

Thanks to constant R&D work, MS Greentech patented the new frontier of dry production technology: FUSION®. This new technology allows for a highly qualified ceramic body for the following products:

Monoporosa

white and red paste for ceramic cladding

Double-fired

tiles in white and red paste for ceramic cladding

Porcelaingres

with no limits on formats and thickness (traditional mold pressing or slab ribbons)

Extruded Products

(terracotta vases, cotto floor tiles, porcelain, clinker)

The benefits of employing this technology rather than wet systems with spread dryers are:

Reduction of Water Consumption

Dramatic reduction in the consumption of water (from 32 ÷ 40% used in wet grinding processes to max 4%)

Reductions of Emissions and Pollution

Reduction of the pollution caused by spread dryers (an average reduction on 80% in the use of fossil fuels)

Circular Process

Recovery of waste. Increased flexibility in the use of secondary raw material in the production of the ceramic body

Productive Flexibility

Same quality and production parameters of ceramic products produced with conventional technologies

FUSION goes through the following steps:

The mixture’s components are directed to specific hoppers to stock the mixture. 

According to the components’ size and humidity, extraction is carried out through vibrating channels (1) and double rod extraction valves (2), which, in turn, power continuous and discontinuous weight scales (3). 

From the weight scales the various components of the mixture are carried to conveyor belts in different strata (4), for the primary grinding of the plastic component, and straight to the micronization step for abrasive components (sand and feldspars).

You should always install a Magnetic Plate (5) and a Metal Detector (6) on the conveyor belts. These are essential to avoid the unfortunate and dangerous presence of iron and non-magnetic metal impurities – which can potentially harm and break the machinery during the remainder of the process.

Primary grinding is carried out by highly performant hammer mills or with a shredded in case the plastic component’s humidity is greater than 20%. In both cases, these technologies allow the user to receive incoming dimensions up to 200mm. Moreover, hammer mills allow for the direct use of previously shredded baked scraps.

An important stage is the possibility to use raw materials with specific humidity between 8-10% and with lumps up to 10mm and to power the materials inside the mill, avoiding all the issues related to the traditional primary drying systems.

The dry tubular mill – utterly covered in ALUBIT – is a key point of this technology. The perfect size of this machine allows for high levels of granulometry (beyond 80% < than 40 μm) in an open cycle, ensuring a strong and constant productive performance.

At this point, the material (a mixture of plastic, feldspars and sand) is sent to the Molomax Pendular MOLOMAX. These mills, thanks to the double powering system and to the presence of internal distributors inside the ploughshares – that optimize the loading process into the grinding unit – ensure high levels of productivity and ideal granulometry. 

Final grinding is carried out by robust pendulums that – by means of centrifugal force – apply a strong pressure to the sectors at the base of the mill. After that, the material is gathered in the mill’s upper section through a depression created by the “downstream” filter and, then, collected by an efficient separator.

The particles the separator discards fall back into the grinding chamber to be treated again with the “new” material coming from the double powering system, ensuring perfect homogenization in the mixture among the lightest, finest particles and the most unrefined ones. This operation (called “airstream grinding”) is utterly hermetic and does not spread particulate matter in the environment.

Moreover, the MOLOMAX mill can operate with high humidity raw materials since you can employ hot gases through an airburner with low heat power (an average of 650 KCAL/LT) or through recovery from ovens, with excellent heat performance results and the guarantee of constant humidity in the outcoming material. This notably benefits the next humidification and granulation steps.

The MS vibrating screens are installed after the MOLOMAX filtering process since their function is to ensure ceramic quality control. Their purpose is to filter small impurities (wood, rubber, plastic, etc.) from the ground mixture, which can be present due to their inferior specific weight compared to the mixture and, thus, are not filtered by the dynamic separator. 

Vibrating screens can be equipped with specific equipment which further amplify the quality of their control performance, such as the self-cleaning automatic system of the sieve, the oleodynamic opening of the control component and the Automatic Control for potential damage or malfunction.

Immediately following the sieving step here is the iron removing stage, which endures an efficient removal of the iron impurities from the ceramic body through Self-Cleaning Iron Removals with neodymium magnetic bars.

The humidification stage is a determining part of the process.

The MADIREX wetter carries out two main functions:

  1. It provides the right tone of water in the ceramic mixture through specific disk nebulizers.
  2. Through a series of “reels” placed along the diameter of the machinery, the wetter spins the mixture spirally, which, combined with the effect of the nebulizer, gives a perfect homogeneous humidity in all the granulometric fractions of the mixture.
  3. It is possible to include, in the powering stage of the wetter, colored pigments too, to produce mass colored mixtures with the homogeneous and intense characteristics you would get with conventional technology.

The main benefits of this technology can be seen especially in the next granulation stage.

An important, fundamental control function is the wetter’s humidity management, carried out by the automatic moisture gauging systems which determine and maintain the desired percentage of moisture with high precision. 

The fine dust moisturized by the MADIREX wetter, are subject to a mechanical compression given by FUSION technology, so as to activate the underlying molecular covalent and the electromagnetic forces. The result is that this process guarantees an excellent compenetration of all the formula’s raw materials and an exceptional stability. The specific goal is to reach excellent homogeneity, fluidity and density in the final granulated material and the realization of ceramic products with no limits in the format, thickness and typology. 

The material is stocked in silos and rests for at least 24 hours. Then it is conducted to the press. You can choose whether you want to dry color it further or whether you need to change the shade in case of previous coloring through MADIREX or even if you need to simply glaze the product.

Moreover, this stage blends the various granulometric particles, making the mass homogenous and optimizing recovering and annulling the press’s squaring and calibration defects.

The brain of the process is the Electricity Management system, which supervises and monitors all the various stages of the process.

Thanks to the revolutionary INVERTERS, designed and set to operate the main automation in the various stages of the process, you can dramatically reduce the consumption of electric energy and improve the performance of machinery without losing productivity, even if the machines’ components have to be urgently replaced.

The smart Electricity Management comes with remote control, which allows the MS Greentech customer service to assist our customers whenever necessary.

Conclusions and Considerations

MS Greentech is revolutionaizing the process of ceramic body production to reduce process costs and emissions while keeping the same quality levels.

Thanks to a thorough analysis of raw materials – provided by our customers – MS Greentech and its technical team, R&D labs and experimental plants developed the necessary mixture to realize a high-quality and reproducible product with FUSION.

The DRY-TECH evolution allows for the dry production of any ceramic product. The results are fully compliant with the UNI regulations.

Cost comparison between the MS Dry Production and Wet Production**

Consumption

DRY TECH

Wet Production

Water (L/t)

36

266

Electricity (kW/t)

36-48

40-55

Natural Gas (mc/t)

1-9

28-36

Staff per Shift

2 People

4 People

Global Maintenance Cost (€/t)

2-4

3-5

**The data about the wet production are drawn from manufacturers located in the province of Sassuolo, Italy, and vary for the different types of product. Source: ACIMAC.