Industrial Experimental Plant

INDUSTRIAL EXPERIMENTAL PLANT
Technologies for R&D in the stone industry
Sandra Lpez Molina Industrial Management Engineer Alfonso Corts Izurdiaga Process Engineer
Summary
General Summary
1. 2. CTAP Introduction Industrial Experimental Plant i. ii. iii. 3. What is the Industrial Experimental Plant? Industrial Experimental Plant values Industrial Experimental Plant Technologies
Successful Projects
Introduction
CTAP Introduction
01
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.
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
CTAP Introduction
01
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 The -Eco-sustainability EcoEco -Businesses and competitiveness Businesses
Technological Centres, Institutes and Universities
CTAP Introduction
01
TECHNOLOGICAL CENTRES Spanish TC CTMNC, CTMNC, France CTP, CTP, Belgium ESBULCO, Bulgary CETEMCO, CETEMCO, Morocco CETEMAG, CETEMAG, Brazil MQTC, MQTC, Egypt CVALOR, CVALOR, Portugal UNIVERSITIES: School of Mechanical Ingenieers of Metz (France) University of Gante (The Netherlands) Spanish and Andalucian Universities
Enterprises
CTAP Introduction
01
CTAP Introduction
01
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).
ctap
Industrial 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?
02
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!
Objetives and values of the Industrial Experimental Plant
2. OBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL PLANT
02
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
3 DISTINCT AREAS Traditional stone processes Quality and Production control processes Confidential R&D processes
02
TARGET 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
TARGET 4: To be the major shuttle of industrial development projects
02
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
Industrial Experimental Plant Technologies
3. INDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY SUMMARY
02
Surface Technology
Chemical
Treatment
Surface Mechanical Treatment and Texturing Technology Stone Block Sawing Technology Industrial Mixing Laboratory for Composites
Industrial Experimental Plant Technologies 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 Technologies: be open to further cooperation in order to carry out modification / improvements to the existing technologies
02
OPEN INNOVATION PROCEDURE
1. Surface Chemical Treatment Technology Limitations of current technologies
02
Actual chemical treatment lines are composed mainly by one or, at most, two curing systems Industrial systems. 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. sections, No air control (humidity and flow). Limitation of maximum operating temperature at 60C 60C C.
Theres no scientific evidence to demonstrate the advantage provided by a vacuum unit 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 interfaces.
02
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: MAP
02
2. Surface Mechanical Treatment and Texturing Technology
02
Limitations of current technologies

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
02
Selected supplier for technology:
Main characteristics:
Two kinds of head available marble and granite type. available: 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: MAP
02
02
3. Stone Block Sawing Technology
Limitations of current technologies

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 motor. Block sawing process demands high energy consumption 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. frames. 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
02
power, 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 Selected supplier for technology: Main characteristics:
Rotating and inclined mixing pan This promotes material pan. transportation towards the center of the pan and the mixing tool. Excellent for powder and solid mixing It also allows liquid addition mixing. 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).
02
SUCCESFUL PROJECTS
Successful projects
03
P-201100470: 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)
Surface Mechanical Treatment and Texturing Technology
Successful projects
03
Gutirrez Mena
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 positioning and market
Successful projects
03
Idispaces
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.
Industrial Mixing Laboratory for Composites
Successful projects
Industrial Wastes Reuse
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).
New technologies in the stone industry
Successful projects
Indlica del Diamante
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
03
Tarsia
P-200502077: 200502077: Stone manufacturing system. system.
mosaics
automatic
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).
Successful projects
P-201001319 Recognition System for natural and tiles. artificial stone tiles. U201001042 Dimensional Control Machine
New 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.
Computer Vision and dimensional control
03
Successful projects
New possibilities for stone classification and stone compositions
03
Stone composition based on Computer Vision every tile is worth it!
Successful projects
A new concept for stone and arquitecture
03
THANKS FOR YOUR ATTENTION! See you at the Industrial Experimental Plant! acizurdiaga@ctap.es sandralopez@ctap.es

Industrial Experimental Plant - 1ICSCM

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Technologies for R&D in the stone industry

Technological Centres, Institutes and Universities

Ctap grows with the industry

CTAP is a member of Fedit (The Spanish Federation of Technology Centres).