LBXTRA AND MIGRATECH 4.0: THE TECNOLOGICAL EVOLUTION FOR LARGE SIZE TILES
In 2017, the Italian manufacturers of ceramic tiles will make a total production of 420 million square meters, corresponding to approx. 3% of the total quantity produced worldwide; they represent the excellence in terms of technical qualities, aesthetical expression and technological innovation of the manufacturing plants.
The Italian ceramic sector is universally known for its highest superiority in tiles’ manufacturing and the values related to the “Made in Italy” brand have been once again represented in the last edition of CERSAIE, which has confirmed the Italian leadership in setting the technical and aesthetical trends of the sector.
Since almost 50 years, LB has been collaborating with the world leading companies, interpreting their exigencies, continuously investing in research and development of technical, technological, mechanical and plant solutions; this, with the aim to satisfy the growing needs to operate in a global market requiring quality, flexibility, innovation.
To summarize, the LB clients demand:
-unique, exclusive and hardly replicable products
-increase of productivity and flexibility
-larger dimensions and higher thickness of the slabs
-reduction of operating and maintenance costs, as well as reduction of the production layouts
-reduction of the environment impact
-technologies and services compliant with the principles of the Smart Factory (Industry 4.0)
The answer of LB, with reference to the current needs of the biggest and most important world players of the ceramic market, is fruit of the continuous activity of analysis, research and development; the results became concrete with the last evolutions proposed in the occasion of the Open House, that took place in the same period as the Bologna “kermesse”.
The new technologies are already installed at the laboratory of LB, completely updated and improved in summer 2017.
Visiting the new Technology Centre of LB, now fully in operation with two production lines, it is possible to understand and appreciate the operation of all the recent technological evolutions, being at complete disposal of the clients.
Namely, testing can be performed of:
- Migratech 4.0: the revolutionary microgranulation technology by LB, allowing to realize a granule for the forming phase of the tile or ceramic slab, for all the types of finished product that the customer wants to realize, with enormous saving in operation and maintenance costs and a very huge reduction of the environmental impact;
- DIVARIO: the evolution of the press feeding, for all the types of porcelain products, technical as well as decorated in line;
- Freestile ed LBXTRA: the only existing technology to realize the color and the powders decoration directly while feeding the Kit for the aesthetical effects, also applicable to the production of large size tiles. Among the various aesthetical effects, there is also the “through-passing vein” for full-body “thick” products.
- AST4 PLUS and STAR: the cockpit software for the preventive and proactive maintenance of machines and plants, using also all the potentialities given by the applications of the virtual and augmented reality. The so said Smart Factory, the progressive diffusion of the new technologies that are radically modifying the factories.
In the last 24 / 36 months approximately 40 new lines for the manufacturing of large and very large ceramic slabs have been installed worldwide; the size is up to 160 cm x 320 cm, with a variable thickness up to 3 cm. LB, with over 80 % of the plants to feed these lines all over the world (Argentina, Brazil, Egypt, India, Italy, Poland, Russia, Spain, Turkey, Ukraine and USA), is for sure the main partner of the ceramics manufacturers to give uniqueness, aesthetics and innovation to the finished product, using the technologies COLORBOOST, FREESTILE and LBXTRA.
The production of slabs requires a special treatment of the granule, in terms of flowability and granulometry, before the forming phase.
The innovative technological proposal MIGRATECH 4.0 represents the main solution to grant the optimum granule compactation or “pressing”, with a very high saving in the activities of management and operation of the production lines, in addition to decreasing approx. 60 % the emission of CO2 into the atmosphere.
MIGRATECH 4.0 is therefore the real modification in the process of granule preparation.
The process, the plant and the method are covered by patent and are currently in the final phase of technological and plant testing, in the LB laboratories as well as on the industrial production line of world leading groups of companies.
As an evidence of the innovative features of the technology MIGRATECH 4.0, allowing to manufacture all the types of ceramic products, the LB group has obtained an important financing from the region Emilia- Romagna and from the Minister of the economic development.
LB proses new plants for the production of slabs with high technical and aesthetical content, realized with a reduced environment impact, integrated with all the management software systems.
The technologies are the following: MIGRATECH 4.0 for the granule preparation with energy saving and reduction of the environmental impact; EASY COLOR BOOST, Freestile and LBXTRA for unique and hardly replicable aesthetical effects; AST4 PLUS and STAR for the compatibility with Industry 4.0 and the Smart Factory.