Text/Hong Xiaochun
With the consumption upgrading and channel changes brought about by market iteration, cross-border integration of the building and ceramics industry has become a trend, which is why rock slabs are currently so popular. According to incomplete statistics, nearly 40 slate production lines are currently in operation in China. Coupled with the recent large-scale construction of slate production lines in various places, some industry insiders predict that "by the end of 2021 The number of domestic slate production lines will exceed 100”.
A few days ago, when the author was chatting with an insider of a ceramics company, he talked about an interesting phenomenon: "Some brands of slate production lines were still producing large slabs in 2017 and 2018." This means It can explain why the rock slab can form a large explosion in such a short period of time. While marveling at the development momentum of slate slabs, the author also found that the so-called technical barriers to the production of slate slabs do not exist for construction and ceramics companies that originally produce ceramic tiles. Even for companies that invest in slate slabs across borders, it seems There is no threshold either. It can be seen that the production technology of rock slabs ultimately relies on equipment.
Today, the author will take stock of the selection of production equipment of Zhongsheng slab brands and their respective advantages.
One
Inventory
Foshan production area: Gold Medal, Shuncheng, Mona Lisa
Gold Medal Enterprise is the first enterprise in the industry to take advantage of the “rock slate crab”. On November 23, 2017, the first large-size slate production line of a gold medal enterprise was officially put into operation at the Sanshui production base in Foshan. This slate production line is equipped with 30,000-ton System press, inkjet printer and other imported equipment. With one of the few large-tonnage presses in the industry, the gold medal company also became one of the only three companies in China that could produce products with a specification of 1600×3200㎜. On May 18, 2020, the gold medal company's new slate production line was officially launched; on June 8, the gold medal company's Quanzhi slate production line was officially put into production of thin plates. It is understood that the newly added slate production line of the gold medal enterprise was constructed by Modena, and the kiln equipment was made of Modena. The thermal kiln equipment developed by the board integrates automation, intelligence, digitalization and environmental protection, including low-temperature and high-speed hot air self-circulation MRD-HB7 seven-layer drying kiln, high-efficiency glaze line drying kiln, high-stable self-circulating kiln front Drying kiln, MOD.MDS rock slab firing kiln.
▲Gold Medal Asia’s new slate production line
Shuncheng Group officially entered the field of rock slabs in 2019. On November 2, 2019, Shuncheng Group's slate intelligent production line held a lighting ceremony at the Gaoming production base in Foshan. Shuncheng Group introduced Italian SACMIThe company's continua+ infinitely long continuous forming slate intelligent production line was launched at the 2019 Guangzhou Ceramics Industry Exhibition. As the first ceramic company to acquire it, Shuncheng Group immediately became the technical benchmark for professionally manufacturing slate products. Subsequently, many domestic companies also successively introduced this set of slate production equipment.
Mona Lisa Group has always been famous for the production of large-sized thin plates. It was officially released in 2019 that the concept of rock slabs was released. On July 4, 2019, the first HT36000 press jointly developed by Mona Lisa and Henglitai was produced in Xiqiao The one-time trial production of the base was successful; on July 9, Mona Lisa Group held a new product launch conference for super stone slates and officially released 3600×1600㎜ super large slates. According to the Mona Lisa Group, the "Mona Lisa Super Stone Slate" is made from Guangdong black mud, which has been pressed and formed by a 16,800-ton press, combined with NDD technology and fired in a kiln at a temperature of 1,300°C.
Qingyuan, Guangdong: Xiangda, New School, Sublimation
▲The Italian SACMI booth at the 2019 Guangzhou Ceramic Industry Exhibition
Xiangda Enterprise’s slate production line was newly built in September 2019. The company's production line equipment comes largely from Italian ceramics companies. For example, the press uses a 38,000-ton continuous roller press from Italy's SACMI. It also introduced an Italian LB cloth machine and an Italian BMR intelligent polishing line. It is said that it also spent huge sums of money. ConfiguredItaly SACMI’s large-sized inkjet printing machine is claimed to be the top of the line in domestic slate production lines. Regarding the choice of kiln, Xiangda Enterprise’s slate production line uses Foshan’s local Ruitao kiln. Judging from the "meat and vegetable combination" of equipment used when building the slate production line, Xiangda Company must have its own set of tricks, and the cost-effectiveness of its slate products is also unexpected by other slate companies.
At the beginning of 2019, Guangdong Xinyipai Building Materials Co., Ltd. invested 300 million yuan in the construction of a slate production line. When it comes to the selection of rock slab production equipment, the new school seems to only "love" the presses of Henglitai. On June 12, 2020, Henlitai YP16890 press was successfully put into production in Xinyipai. Up to now, Xinyipai has a total of three slate production lines using Henlitai's YP8890, YP16800, and YP16890 presses respectively. The YP16890 press recently put into production has a maximum pressing force of 168,000kN. The current main pressed product specifications are 1,200 ×2400㎜, 1200×2700㎜, 800×2600㎜.
▲System moldless press
Qingyuan Shenghua Ceramics Co., Ltd. also joined the slate army not long ago. On June 18, 2020, Shenghua's two large slate production lines were officially put into operation. It is understood that the slate production line equipment of Sublimation Ceramics comes from ItalySystemand the domestic Henlitai. After it is officially put into production, the thickness range of slate products that can be produced is 6- 20㎜.
Zhaoqing, Guangdong: General, New Pearl, Nengqiang·Qianghui
Jiangjun Enterprise This year plans to build three new slate lines. On May 29, 2020, Jiangjun Enterprise held a strategic signing ceremony with Modena. On May 18, there was a slate The production line is officially started. The slate production line of Jiangjun Enterprise was built by Modena Company. It is the first double-layer kiln slate production line in China and the longest in the world. It is understood that the Jiangjun slate production equipment uses Modena's HB7 seven-layer drying kiln and MDS double-layer kiln; the other roller presses, inkjet machines, glaze spray cabinets and other equipment are from Italy.
▲Modena booth at the 2019 Guangzhou Ceramics Industry Exhibition
New Pearl Group The project application to build six slate production lines was approved in 2017. The project plans to invest 250 million yuan. The annual production capacity reaches 14.4 million square meters. On May 30, 2020, the industry's first wide-body slate production line of Xinmingzhu Ceramics Group was put into operation. It plans to build two slate production lines this year. It is understood that the modern industrial 4.0+ digital intelligent high-end slate kiln and high-efficiency drying kiln projects of the New Pearl Group were developed by Delitai< /span>Constructed.
Nengqiang·Qianghui GroupAt the beginning of 2020, Italy SACMI held a strategic signing ceremony. On May 24, 2020, the first slate production line of its Zhaoqing production base was successfully produced and officially mass-produced. The group plans to build four slate production lines by the end of 2020. It is understood that Nengqiang Qianghui Group has invested 200 million to introduce a slate production line from Italy's SACMI, which can produce a maximum specification of 3900×1600㎜, and the product can achieve flexibility of 3-15mm thickness. Customized.
Jiangxi production area: Xinzhongyuan, Weimei
Xinzhongyuan Ceramics launched a 1200×2400㎜ large-size ceramic plate production line at Jiangxi Gaoan production base in May 2018 , is currently producing rock slabs stably. It is understood that this set of production equipment has introduced the Henglitai YP16800 press (the same model as the Mona Lisa and Xinyipai).
Weimei Group In 2019, two intelligent slate production lines at the Fengcheng production base in Jiangxi were successfully completed and put into operation; it is understood that , Weimei Group's slate production line equipment comes from System, and the maximum size that can be produced is 1600×3200㎜.
Cross-border investment: Lingbiao Technology, Beautiful Group
Hubei Hao Group is the first cross-border enterprise to enter the field of rock slabs.The Hao slate production line was officially put into operation at the Honghu production base in Hubei Province on December 23, 2019. This is also the first domestic production line capable of producing ultra-thin slate slabs with a thickness of 3mm. It is understood that the beautiful ultra-thin slate production base has introduced System complete line equipment, and the kiln is a fully automatic closed computer The temperature-controlled roller kiln and press are the most advanced extrusion equipment in the world. Together with the back fiber web production line and the laser linear arbitrary cutting machine production line, it integrates cloth, pressing, glazing, inkjet, kiln and finished product cutting. , the rock slab products produced have the characteristics of "large, thin, light, soft and beautiful". It is reported that the investment in this slate production line is as high as 280 million yuan, and the annual output can reach 1.65 million square meters.
▲Dongpeng Thermal Energy Booth at the 2019 Guangzhou Ceramics Industry Exhibition
Qinhuangdao's Lingbiao Technology also announced its cross-border slate field in 2020. On June 11, Hebei Lingbiao Technology, located in Shimen Industrial Park, Lulong Economic Development Zone, Hebei, was constructed by Guangdong Zhongpeng Thermal Energy Technology The opening ceremony of the new energy-saving ultra-thin rock slab project was held. The total investment of the entire project exceeds 2 billion yuan, covering an area of 325 acres. It is planned to build 4 new energy-saving ultra-thin slate production lines (divided into two phases), with a single line annual output of more than 2 million square meters of new energy-saving ultra-thin slate. In addition to using Zhongpeng Thermal's kiln equipment, the slate production line also purchased an Italian fully automatic roller press, a fully automatic glaze spraying system, a fully automatic printing machine and a fully automatic pressurizing system, a digital inkjet machine, and automatic polishing and edge grinding. There are more than 600 sets (sets) of machines, multi-disk cutting machines and other equipment.
二
Analysis
Which molding method is better for rock plate press
As a large-sized ceramic plate, rock slabs cannot be produced without a press with extremely large pressing force to ensure that the texture of the product is more complete; and high-density rock slab products leave fewer seams when paving, making the overall application easier. The effect is closer to natural stone. There are currently about three types of forming technologies and equipment used in the production process of rock slabs.
Dry-pressed traditional molding method:Dry-pressed traditional ceramic tiles use a molding method - that is, molded. The Henlitai YP8890, YP16800, YP16890 used by New School, and the first HT36000 press used by Mona Lisa are all dry presses. Compared with other molding methods, dry pressing presses are easier to achieve breakthroughs in pressing force. However, if the pressure between the middle and the surrounding sides of the bricks is inconsistent during the production process, it will cause ripple problems in the rock slabs.
Roller pressing continuous forming method:The roller pressing process is realized through two very hard motorized belts. Under the simultaneous operation of the motorized belt and the pressing roller, the powder is gradually "continuously" pressed into shape. The Continua+ press of the Italian SACMI company uses the roller continuous forming process. The core of the CONTINUA+ continuous forming production line is the PCR pressing equipment, which has greater pressing force and higher density than traditional presses; it can not only cut green ceramic tiles into smaller sizes, and its thickness can be produced from 3-30mm, truly realizing flexible customization. At present, there are many domestic slate production lines using Sacmi Continua+ technology, such as Shuncheng, Nengqiang·Qianghui, Yinuo, Xinjincheng, etc.
Moldless belt forming method: Belt forming does not require a mold. There is a circulating belt at the top and bottom of the press, and the lower belt is laid out For ceramic powder, the belt transports the powder to the pressing area, where it is pressed and formed between the two belts. The most representative one is the System LAMGEA moldless press, which uses a specially designed hydraulic circuit with a maximum pressure of 50,000 tons. The pressure is evenly distributed to the ceramic tile surface by the hydraulic system. The molding process of the gold medal slate slabs uses System's 30,000-ton belt flexible pressing. The advantage of this process is that the thickness of the center of the finished product is consistent with the surrounding thickness, and the deviation is so small that it can be ignored. According to Gold Medal Asia, they have conducted experiments and found that there is basically no error when the brick body is produced from the edge to the center, even through instrumental testing. At present, domestic companies that use System LAMGEA presses include New Pearl and Nobel.
New slate kiln with hundreds of flowers blooming< /p>
Among the kiln equipment for the slate production line mentioned above, there are multi-layer kilns, wide-body kilns, intelligent temperature-controlled kilns, etc. As we all know, the temperature requirements in the slate production process are relatively high, so temperature control and energy saving should be the first choice for introducing kilns into the slate production line. In addition, rock slab production has many high requirements and standards for kilns. Let’s take a look at the advantages of format kilns.
Zhongpeng Thermal Energy's "High-speed Railway Kiln": Zhongpeng Thermal Energy's high-speed railway era roller kiln (KOHSTA) has high-precision transmission, 3Hi energy-saving technology, kiln waste heat comprehensive utilization system, kiln data management system, "large-screen display system", roller detection and coding machine, roller coating machine and other industry-leading technologies; at the same time, Zhongpeng Thermal Energy also targets common rock slabs We have come up with a solution to the existing problem of cutting cracks - rapid cooling will cause the stress of the rock slab product to be unable to be released, leading to cutting cracks. By optimizing the firing system to achieve uniform cooling, we will ensure perfect processing of the rock slabs through heavy processing.To protect.
Deli Tai "Wide Kiln":The production of large rock slabs has great requirements on the width of the kiln, Deli Special wide-body kiln equipment for Thai slate slabs (including the 4.0+ digital intelligent high-end slate kiln and high-efficiency drying kiln put into use in Xinmingzhu) can not only meet the production of oversized products, but also has low energy consumption and high efficiency. advantages.
Modena "Multi-layer Kiln": Ceramic rock plates have particularly high requirements on the transmission design and installation accuracy of the kiln. Modena adopts DRI transmission system design, the application of SKF imported bearings, and a single motor independent through-shaft design to reduce shaft connections. The MDS double-layer kiln put into production by Modena in Jiangjun Enterprise occupies only half the area of a traditional single-layer kiln; it saves more than 5% of fuel consumption than a single-layer kiln; through optimized pipeline design and reasonable selection, it adopts new energy-saving Through the comprehensive utilization of burners, nano-insulation materials and waste heat, the comprehensive energy saving of double-layer kilns can reach more than 15%. At the same time, Modena is also the first company to develop seven-layer drying. Asia's first slate line using Modena's seven-layer drying kiln was put into use at the Indian LIOLI Company in early 2018.
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