industrial experimental plant 1 icscm

INDUSTRIAL EXPERIMENTAL PLANT

Sandra López Molina – Industrial Management EngineerAlfonso Cortés Izurdiaga – Process Engineer

Technologies for R&D in the stone industry

General Summary

1. CTAP Introduction

2. Industrial Experimental Plant

i. What is the Industrial Experimental Plant?

ii. Industrial Experimental Plant values

iii. Industrial Experimental Plant Technologies

3. Successful Projects

0Summary

1Introduction

ctap

The Technological centre for stone is a private foundation

created in 2002 with thanks to entrepreneurial drive and

the collaboration of The Economic, Innovation and Science

Council.

Occupying a position within the Andalusian system of

knowledge and as a National Technological Centre

approved by The Ministry of Science and Innovation,

developing our activities at a national and international

level.

01

Mission:

Our mission is to improve the competitiveness

of businesses in the sector, through the generation

and transfer of knowledge and the implementation of

new business models.

CTAP Introduction

Areas of work

The activity in Ctap is organised into three interrelated working areas. The working areas are composed of highly specialised professionals in different disciplines, investigational departments and strategy experts. Each working area has its own differentiated lines of work and in turn carries out successful projects, which are transferred and implemented within businesses.

-The R&D Working Area

-Eco-sustainability

-Businesses and competitiveness

01CTAP Introduction

Technological Centres, Institutes and Universities

TECHNOLOGICAL

CENTRES

Spanish TCCTMNC, France

CTP, Belgium

ESBULCO, Bulgary

CETEMCO, Morocco

CETEMAG, Brazil

MQTC, Egypt

CVALOR, Portugal

01CTAP Introduction

UNIVERSITIES:

School of Mechanical Ingenieers of

Metz (France)

University of Gante (The Netherlands)

Spanish and Andalucian Universities

Enterprises 01CTAP Introduction

ctap

Ctap grows with the industry

624 Clients

70 private projects since 2007

21 internal R&D projects since 2007

€ 9.849.280,15 of investment in equipment and

technological infrastructure since 2002.

4 known patents

5 patents on course

R&D Laboratory for resins and polymers

CTAP is a member of Fedit (The Spanish Federation of

Technology Centres).

01CTAP Introduction

2Industrial Experimental Plant

02

1. What is the Industrial

Experimental Plant?

2. Objectives and values of the

Industrial Experimental Plant

3. Industrial Experimental Plant

Technologies for R&D


What is the industrial experimental plant?

1. WHAT IS THE INDUSTRIAL EXPERIMENTAL

PLANT?The Industrial Experimental Plant is the best place where Knowledge Agents, Enterprises

and Technology Developers can join and work togehter for the development of new

products, new processes and new technologies for the natural and artificial stone sector.

The Industrial Experimental Plant is not a production factory!


FIGURES:

•Installed in 100% business

environment

•Accounting for 10.000 m2 of

buildings

•More than 22.960 m2 of land

•Investment of 7.5 M € in High

Technology

2. OBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL

PLANT

Objetives and values of the Industrial Experimental Plant

3 DISTINCT AREAS

•Traditional stone processes

•Quality and Production control

processes

•Confidential R&D processes


Objetives and values of the Industrial Experimental Plant 02TARGET 1: To deeply develop knowledge of the stone

transformation process.

Deepen knowledge in stone processing

TARGET 2: To become a training centre of excellence for

human resources in the sector.

The human factor: from Operator to Stone Specialist

TARGET 3: To create a common space where enterprises

have the possibility to improve their productive processes

and generate new uses.

Up to date technologies for Stone Innovation


Objetives and values of the Industrial Experimental Plant

TARGET 4: To be the major shuttle of industrial development projects

Technology transfer to companies as the final purpose

TARGET 5: To establish a culture of cooperation between public and

private agents and businesses.

Together we can go further

TARGET 6: To attract investment for knowledge generation.

Future: the Industrial Experimental Plant as the hub of stone

R&D


3. INDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY

SUMMARY

• Surface Chemical Treatment

Technology

• Surface Mechanical

Treatment and Texturing

Technology

• Stone Block Sawing

Technology

• Industrial Mixing Laboratory

for Composites

Industrial Experimental Plant Technologies 02Industrial Experimental Plant

Machinery VS Technology concepts

• Maximum open operating parameters

• Whichever type of fungible and tools can

be used

• Tools change will be very simple both to

minimize time and procedures

• The machinery must be compatible with

any stone material or material derived

from stone (at least covering the largest

possible range)

• Evolving Technologies: Machinery

suppliers must be open to further

cooperation in order to carry out

modification / improvements to the

existing technologies

Industrial Experimental Plant Technologies 02

OPEN INNOVATION

PROCEDURE


1. Surface Chemical Treatment Technology

Limitations of current technologies

• Actual chemical treatment lines are composed mainly by one or, at most, two curing

systems. Industrial application processes are defined based on laboratory tests and

resin suppliers recommendations.

• Limitations in Vertical Thermal Ovens:

• Just two independent sections, no matter the number of floors available: drying section and

curing section.

• No air control (humidity and flow).

• Limitation of maximum operating temperature at 60ºC.

• There’s no scientific evidence to demonstrate the advantage provided by a vacuum

unit.

• Dosage, mixture and application automated systems are not versatile (for fillers

and resin change).

• UV and IR ovens do not permit a wide range of parameterization.

• Process parameter definition and modification is hard with actual interfaces.


Surface Chemical Treatment Technology

Selected supplier for technology:

Main characteristics:

• Three kinds of oven available: thermal, UV and IR

• Thermal oven with 8 independent sections (5 floor each). Temperature and air regulation (flow, humidity and inversion period of circulation).

• Automated and versatile system for resin dosing, mixing and application (work in progress).

• Easy user interface for process cycles definition.


PARAMETERS MAP:


2. Surface Mechanical Treatment and Texturing Technology


• Machines available are not versatile to work with both marble and granite

(heads and polishing systems are completely different).

• Individual pressure control available per head but always above the head

weight (the minimum pressure is the one caused by the head weight).

• Rotation speed of heads fixed.

• Refrigerating water flow completely uncontrolled and unmeasured.

• No slab thickness calibration system available for natural stone slabs.


Surface Mechanical Treatment and Texturing Technology



• Two kinds of head available: marble and granite type.

• Fast tool change for heads and abrasives.

• Control of main process parameters, including:

• Absolute pressure of the head on the stone slab

• Water flow per head (work in progress)

• Rotation speed per head (in both calibrating and polishing heads)

• Easy user interface for process cycles definition


PARAMETERS MAP:


3. Stone Block Sawing Technology


• Sawing loom changing and distance regulation is very time consuming.

• The loom beats are unable to be controlled and also the frequency of the

main motor.

• Block sawing process demands high energy consumption.

• Refrigerating water flow is completely uncontrolled and unmeasured.


Selected supplier for

technology:

Main characteristics:• Download speed of loom

frame variable between 0 – 100

cm/h.

• Two detachable loom frames.

• Fast loom frame change (under

two hours).

• Frequency variator for main

engine with two principal

advantages:

• Number of frame beats

adjustable

• Recovery of connecting

rod dropping power,

usable in the connection rod

rising (50% power saving).

• Refrigerating water flow

control (work in progress)


4. Industrial Mixing Laboratory for

composites formulation



• Rotating and inclined mixing pan. This promotes

material transportation towards the center of the pan and

the mixing tool.

• Excellent for powder and solid mixing. It also allows

liquid addition during the mixing process.

• Easy user interface for process cycle definition,

including the following parameters (work in progress):

• Rotating mixing tool speed

• Power consumption

• Automatic filler addition

• Compressing unit and molds for composite conforming

(Work in progress).


3SUCCESFUL PROJECTS

P-201100470: APPLICATION PROCESS FOR A BRAND OR LOGO OVER NATURAL OR ARTIFICIAL STONE SURFACES

• Definition of the diamond tool and the machining process

• Exclusive resin formulation for high transparence and gloss

• Water proof

• Polishing process definition for a two phase material (resin + stone)

03Successful projects Surface Chemical Treatment Technology

• Different surface finishes to define a family of products derived from a single and exclusive material

• Surface process treatment definition: types of abrasives, sequences of abrasives and machine parameters

• Process optimization to minimize operating costs

• Brand definition and market positioning

Surface Mechanical Treatment and Texturing Technology Successful projects

Gutiérrez Mena

03

• R&D + Design applied for spa and wellbeing equipments made of stone.

•Development of completely new technologies for stone heating, water flow system along stone components and lighting stone components.

• Chemical protections for water and oil environments.

• Industrial protection pending for every product and two patents for the general technology.

Successful projects Surface Chemical Treatment Technology

Idispaces

03

P-201100356 y P-201100355

•Characterization and analysis of industrial wastes from the Andalusian Stone industry.

•Definition of a preparation method for these wastes towards their reuse in the formulation of new materials.

•Development of a new formulation of bituminous materials including these wastes (2 patents generated).

Successful projects Industrial Mixing Laboratory for Composites

Industrial Wastes Reuse 03

•Design and construction of pilot plant for the production of electroplated diamond tools.

•Process parameterization and definition for each geometry and size.

•Development of all tools needed for the processes (control systems for chemical baths, piece holders and chemical contacts, quality control systems based on computer vision).

•Specific tool design for any need.

Successful projects New technologies in the stone industry

Indálica del Diamante 03

P-200502077: Stone mosaics automatic manufacturing system.

•Automated manufacturing system based on multiple piling up and stacking stages.

•Exclusive formulation for a high mechanical resistance and waterproff adhesive.

•Use of stone industry by – products

•Robotization of stone processes (loading and piling up of slabs and resine application).


Tarsia

03


Computer Vision and dimensional control

P-201001319 Recognition System for natural and artificial stone tiles.

U201001042 Dimensional Control MachineNew processes for quality control for stone products: computer vision and automatic measurement. •Exclusive computer operators to determine main characteristics of stone tiles.•Identification VS classification to give the stone a unique visual identity.•Fully compatible with current production technologies.

03

New possibilities for stone classification and stone compositions

Stone composition based on Computer Vision – every tile is worth it!


Computer Vision and dimensional control 03


Computer Vision and dimensional control

A new concept for stone and arquitecture 03

THANKS FOR YOUR ATTENTION!

See you at the Industrial Experimental Plant!

[email protected]

[email protected]

mailto:[email protected]

mailto:[email protected]

industrial experimental plant 1 icscm

Technology

industrial experimental

industrial experimental

ctap introduction ctap

stone innovation

hub of stone rd

stone specialist target

stone processing target

enterprises ctap introduction