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Inkjet and glazing technology in ceramic production is about to enter a new year
1. Ceramic inkjet has entered a new ultra-high-definition era of digital printing. Large ink volume and multi-channel have become the trend of ceramic inkjet printers.
It is understood that most of the relatively mature multi-channel inkjet printers currently on the market have 12 channels. In the future, the market will need diversified and personalized products, in addition to ordinary In addition to inks, there are many multi-color and multi-functional ink combinations, so multi-channel must be the mainstream of the future development of ceramic inkjet printers. So at this Guangzhou Ceramics Industry Exhibition, what are the new technical highlights of inkjet printers? Let’s follow Mr. Zhongtao to have a look.
Hope Booth
1. Hope
This year, the TF series 800DPI ultra-high-resolution inkjet machine launched exclusively by Hope Company at the Guangzhou Ceramics Industry Exhibition made its debut for the first time. Zhongtaojun learned that in addition to 8 printing channels and an 800dpi ultra-high-resolution system, this device can also choose a single-machine 16 printing channels and 400dpi printing mode. With its advanced performance, this equipment attracted the attention of a large number of manufacturers at this exhibition.
Hope Company is the first to launch a ceramic inkjet machine equipped with a Starlight SG600 nozzle. It has a 600dpi ultra-high resolution and a significantly improved ink volume based on the 400dpi nozzle. It is reported that this new series of TW inkjet machines can adapt to larger printing distances, and is compatible with a variety of nozzles on the market, which can be configured according to customer choices. At present, the new series of TW inkjet machines equipped with Seiko RC1536 printheads have been successfully used in Dongpeng Group and are in stable production.
In addition, in order to comply with the development trend of ceramic large panels, Hope Company took the lead in launching the BDD ceramic large panel inkjet machine. Zhongtaojun learned that the first equipment of this model has been put into use in Nobel, and is currently producing 1.6x3.2m and 1.6x4.8m ceramic large plates stably online; the first fully digital large plate in New Pearl is water-free glazing The line uses three machines in series, and the synchronous transmission and positioning are more accurate, and 1.6x3.2m ceramic large plates are stably produced online; large plate products produced with the Hope BDD ceramic large plate inkjet machine were also seen at this exhibition. .
Mejia Booth
2. Meijia
Zhongtaojun learned from the introduction of Lu Yonghua, general manager of Meijia Company, that the latest underglaze industrial 4.0 ceramic inkjet printer (three machines in series) launched by Meijia Company Instead of using a transition roller table, a belt is directly used to connect multiple digital inkjet machines. The laser sensor tracking and positioning is used to solve the error of the belt being too long and stretched, so that the direct alignment accuracy of the three devices is guaranteed to be 0.2MM. within the range. The launch of this set of equipment can make up for the shortcomings of previous production by using a length of 16 meters, and it can also save energy, reduce emissions, and reduce labor, thereby enhancing the market competitiveness of the company. It is reported that this equipment has been used stably for one year at Best Ceramics Factory under Shuncheng Group, and the effect is remarkable.
In addition, Meijia's large ceramic inkjet printer is specially designed for the currently popular large-size ceramic tiles, which perfectly supports the latest XARR2001+ (720DPI) or Starlight 1024 (400DPI) )/SG600 (600DPI) nozzle, which can realize large ink volume printing, high-speed printing, fine printing and other modes. Importantly, this equipment has an automatic cleaning system and a precise alignment assist system to ensure stable production by ceramic manufacturers in all-weather industrialization.
Keira Jet Booth
3. KERAjet
As the world's first ceramic inkjet printer manufacturer, Kelajite first launched a 12-channel inkjet printer in 2015. So far, Kelajite has There are already more than 4,000 devices worldwide.
At this year's Guangzhou Industrial Exhibition, KERAjet M7 series equipment was unveiled in the country for the first time. Kelajite has launched a set of flexible combination solutions of inkjet machines, powder spraying machines, inkjet machines and other equipment, which can tailor-make the entire digital line for manufacturers and help manufacturers shorten the decorative line. , to achieve efficient production. With free combination, there is no problem if the decorative line reaches more than 20 channels, and the nozzle is compatible with any brand of nozzle. It is worth mentioning that in addition to the traditional vertical spraying method, Kelajite's equipment spraying method can also adjust the spraying path at various angles, and achieve a 3D three-dimensional effect only by spraying glaze without the need for grinding tools.
Kelajite has created a series of ceramic inkjet printers for daily use. Its China business manager Tu Lei told Zhongtaojun: the dish printer in this series of equipment It has been successfully put into production in Dongguan in the first quarter of this year, and the results are excellent. Daily-use ceramic inkjet printers sold to Hunan and other places will also be put into production one after another. Using machines to replace manual drawing and decals will be an epoch-making technological innovation in the field of daily ceramic production.
The presence of Xaar at the exhibition < /p>
4. Purcell
After talking about inkjet printers, we have to mention its protagonist - the nozzle. Stable, high-quality printing is an important foundation for ceramic production. The nozzle gives people a "delicate" impression. How to make the nozzle work "healthy" for a long time in a harsh industrial environment is a headache for many manufacturers.
On the morning of the 19th, Zhongtaojun had the honor to interview Gerard Winn, senior product manager of Xaar Company. He told us: XARR2001+ series injectorThe nozzle has been launched in 2017, and Xaar has been committed to improving its reliability, so it is still the most comprehensive nozzle on the market. At this exhibition, Zhongtaojun saw that the latest inkjet printers from Xinjingtai, Jingtao, Meijia and other companies still use this XARR2001+ nozzle.
There are three main reasons why Xaar’s XARR2001+ series nozzles are so popular:
Resolution: Offering three models with different ink drop sizes, plus 720DPI resolution, Xaar2001+ is the only nozzle that can fully meet manufacturers' digital ceramic printing and special requirements Series;
Large inkjet: In the large ink volume coverage mode, the inkjet volume can reach 170g/㎡ at a line speed of 25/min; in two-color mode, the same print head can produce 25 /min line speed can reach 85g/㎡ inkjet coverage;
Inline filter: The filter configured in Xaar2001+ can intercept impurities in the inkjet system and effectively prevent the problem of missing jets. After all, replacing the filter is more important than replacing the nozzle. It seems much simpler and more affordable.
Gerard Winn told Zhongtaojun: Based on their experience in the European market, the future trend of China's ceramic production must be in the direction of intelligence. By then, mechanical equipment and parts will The stability and reliability requirements will be higher. Xaar Company is very aware of this, so it spends a lot of energy to continuously improve the reliability of the nozzle.
2. Water-based ink, digital glaze and other technologies have become mature and have obvious advantages. Will their application be equally smooth?
Compared with solvent-based inks, water-based inks are highly adherent to the glaze component, which reduces the separation of glaze ink and has smaller restrictions on the color range, so Use water-based inks to improve printingQuality can play a very big role. It is known that the chemical solvents used to clean the inkjet system will have a certain impact on the sustainability of the production process, and water-based inks can indeed avoid this problem. Not only that, water-based inks have extremely low organic components, and the volatile organic matter is more volatile than solvent-based inks. It has been reduced by more than 90%, which is very consistent with the environmentally friendly production currently advocated.
Yangtze exhibits
Compared with traditional glazing methods, the advantage of digital glazing is that it can achieve precise positioning of functional ink or glaze through digital on-demand printing, avoiding the need for Unnecessary waste of materials, special surface effects of ceramic tiles can be achieved even without the use of molds, reducing production costs and improving production efficiency. At the same time, it can achieve a water-free workshop, which is more green and environmentally friendly.
Dahong Glaze Exhibits
At this Guangzhou Ceramics Industry Exhibition, EFI focused on launching water-based inks; Dahong Glaze Chairman Cai Changxian was very proud to take Zhongtao Jun to watch the use of their digital Abrasive-free Chinese relief tiles produced with glaze; Yangziyan even launched finished tiles with water-based digital glaze...
3. Regarding the development of new technologies in inkjet and glazing, Zhongtaojun interviewed Qiu Ziliang, general manager of Foshan Zitao Ceramics Technology Co., Ltd. Zhongtaojun gave the following answers one by one:
1. Digital glaze equipment and glazes are basically mature and can be used once the cost drops.Widely used.
The advantages of digital glaze are very obvious. It can spray glaze directly on the flat body at fixed points to produce the texture effect of the mold. Combined with the inkjet ink By working together, the effect of complete alignment can basically be achieved, and production is not limited by presses and molds, and is not limited to specifications and sizes. The concept of digital glaze has been proposed in China for more than five years, but there is still the problem of high cost in promotion.
2. Because it is not compatible with previous solvent-based inkjet equipment, it is difficult to promote water-based ink.
Water-based ink has many advantages such as deeper color, better printing effect, no interference with glaze, green and environmentally friendly and less volatile organic matter, but it has In terms of application, in addition to requiring a specific nozzle, it is not applicable to traditional inkjet printers. It can be seen that at this exhibition, EFI Kuadaping launched a new inkjet printer while launching water-based ink. If you want water-based ink, you have to replace an inkjet equipment. This cost is too high, so the development of water-based ink will not make a big leap in a short period of time.
3. The 12-channel inkjet equipment on the market will be unable to meet the increasingly rich functional inks.
Nowadays, there are more and more functional inks on the market, including white ink, gloss ink, glitter ink, sunken ink, peel-off glaze ink, glue ink, metallic ink, etc. , bringing the surface effect of ceramic tiles from 2D into the 3D era, which has greatly promoted the entire inkjet process. So we can see that the current inkjet printers are producing more and more channels, and ceramic manufacturers are also paying great attention to this aspect. For example, New School directly bought the stand-alone 20-channel equipment launched by Senditech at the exhibition.
Downstream: I just want to be big, upstream: Hao Le Guest Officer
Mobile phones pursue the feeling of large screens, large apartments are more grand, and the large IMAX screens in theaters are more shocking. With the improvement of consumers' living standards, "big and simple" "It is a young lifestyle that is both grand and elegant at the same time. This trend has also been extended to the ceramic industry. Nowadays, ordinary ceramic tiles can no longer meet the consumption upgrade needs of high-end consumer groups. In order to fill the gap in consumer demand and follow the trend of the times, the industry has developed the new specification of "ceramic large slabs" Ceramic tiles came into being and quickly became popular all over the world.
Although "big" is good, it has a series of production problems derived from it. At this Guangzhou Ceramics Industry Exhibition, when Zhongtaojun visited the exhibition, he discovered many upstream ceramic production companies that were solving the problem of ceramic large plate production lines. They were all innovating products for better development of the industry and developing new products that are suitable for ceramics. Machinery and equipment for large panel production (plan).
1. Xinpeng Industrial
A variety of molds were displayed at the Xinpeng booth. Among them, the "Four Great Inventions Born for Ceramic Large Slabs" and the equipment developed around ceramic large slab molds are even more new. One of the highlights of Peng’s booth.
Large-tonnage press mold: Rapid mold forming, the mold size can be customized according to the needs of ceramic large plates to meet the required size of the large plates. At the same time, its processing machine tools are large, The large working surface poses a very high challenge to the processing technology of large slabs.
High-efficiency and low-carbon molding system: It can also be called an exhaust system. Since the large plate mold is different from the ordinary ceramic tile mold, the mold exhaust is more difficult than the ordinary ceramic tile exhaust. The high-efficiency and low-carbon molding system improves the press efficiency. , the excellent rate is increased by 3% on average and at the same time, energy is saved. The unit area of tiles saves more than 30% of the electricity used by the press, which can effectively solve the exhaust problem of the previous large panels.
Split assembly: In the past, ordinary ceramic tiles needed to be assembled in layers. However, due to the large volume and heavy tonnage of ceramic tiles, installation, disassembly and assembly are very difficult. Replacing the entire set is a big problem, and the split assembly system is split. One part is fixed and only the other part that needs to be replaced is disassembled and assembled. It is easy to operate and saves time and effort.
Hydraulic mold loading truck: The size of the large plate mold is too large, and it is difficult to transport the mold truck smoothly and conveniently in the workshop. The hydraulic mold loading truck developed for this point, As a necessary auxiliary equipment for installation and disassembly, it makes the transfer of large plate molds more convenient.
2. SACMI - Centuries of ingenuity, innovation
The Sacmi Pavilion, located in the International Pavilion No. 3, is one of the pavilions that cannot be underestimated in the International Pavilion. It mainly displays products in continuous Forming process - large plate production line.
Continua+ continuous molding process is the industry technical benchmark for producing flat plates and large tiles of various sizes and thicknesses, and can produce excellent ceramic tiles and large plates. It is reported that this revolutionary pressing technology overcomes the limitations of large-size production, allowing manufacturers to naturally obtain more diverse aesthetic decorative effects and providing a large number of options for customer customization. The main features of its continuous molding process are: APB delivers a layer of single-color powder, APB-M delivers a mixed layer of colored powder (up to four layers), DDD digital printing system (for surface decoration using toner), PCR powder layer can Large ceramic plates that are continuously pressed directly on the conveyor belt and TPV pressed can be cut while moving.
Continua+ perfectly combines the overall decorative effect of the powder molding stage with the subsequent digital surface decoration of powder and ink. It can also produce large panels with structural surfaces and relief patterns. product.
3.Nade
Approaching Nader’s booth, a piece of equipment whose size and texture cannot be ignored came into view—a smart polishing machine for large ceramic plates.
Ceramic large plate intelligent polishing machine equipment. The grinding head can be equipped with a high-efficiency synchronous energy-saving motor, which can save more than 10% of energy. It is equipped with an automatic avoidance function for broken bricks and has a high degree of automation. . Its electronic ruler abrasive detection system can automatically alarm when the grinding head runs out of abrasive and remind the operator to replace the abrasive in time, which is highly intelligent. At the same time, the optional remote fault diagnosis system makes operation and maintenance more convenient.
This set of equipment is specially customized for the thickness-fixed polishing production line process of large plates: automatic loading → bottom surface scraping → plate flipping → front-side thickness setting → plate trimming → Plate surface polishing → Plate nano-polishing → Plate air drying → Large plate quality inspection → Plate film application → Unloading → Large plate storage.
4.Monte.Bianco Benlang
Nowadays, ceramic slabs are very "hot", but making ceramic slabs is not "easy". Among them, polishing tools and polishing toolsThe perfect combination of light technology is a key technical difficulty in the processing of ceramic large plates. Benlang's ceramic large plate processing adopts a "mixed and matched use scheme of rigid grinding blocks and flexible grinding blocks". It conducts in-depth research, optimization and improvement of the polishing process to achieve an overall improvement of the polishing effect from quantitative change to qualitative change, and perfectly solves the problem of water ripples and grinding plates. The surface gloss is uniform, flat and transparent, thus presenting a perfect effect.
5. Engineering and Electrical Engineering
Gongke Electromechanical has developed a circulation mill waxing machine and a circulation grinding polishing machine for ceramic large slabs. The circulation mill waxing machine can meet the requirements of brightening and waxing products with a diameter of 1800mm. It uses nano-liquid to fill the pores after polishing the surface of the plate and repair micro-cracks, so that the surface has strong anti-fouling properties and uniform gloss. The circulating flow grinding and polishing machine has now launched a large-sized series of 1600*3200mm, which can meet the surface polishing treatment of large-sized ceramic and stone products. The structural design of the circulating flow mill can save raw materials for enterprises, and at the same time, it is efficient and high-quality. Complete the waxing machine casting process.
Flags of environmental protection, energy saving, automation and intelligence are flying
Environmental protection, energy saving, automation and intelligence are still the main words of many exhibitors at this Guangzhou Industrial Exhibition. Next, let us take a look at them. Enterprises bring us surprises in these aspects.
Keyword 1: Environmental protection, energy saving
1. Huanglong Environmental Protection: A company specializing in environmental protection equipment, it demonstrated a one-stop solution for waste gas on site.
2. Green Star Environmental Protection: A company specializing in the development of high-efficiency, energy-saving solid-liquid separation and environmental protection equipment and sewage sludge treatment recycling systems. According to on-site staff, the molecular membrane dehydrator displayed on site has the advantages of high automation, energy saving and consumption reduction, cleanliness and environmental protection, and resource reuse, and has obtained a number of invention and utility model patents.
3. Aigao air compressor: According to the staff, the improved compression permanent magnet frequency conversion screw air compressor developed by Aigao Equipment Machine, it can achieve energy saving of more than 30%, the noise becomes smaller and the life span is longer.
4. Qihao Machinery: Qihao mainly displays energy-saving light wave rapid heating machines, which are mainly suitable for polished glazed tiles, marble tiles, Large tiles, etc. as well as daily porcelain industry, glass processing industry, powder drying industry.
Keyword 2: intelligence, automation
New Jingtai Booth
5. New Jingtai: Glazing line industrial 4.0 system, central control system, cloud data management platform, glazing line, water jet spray Glaze machine, linear glaze spraying, Inkjet machine control. The new Jingtai Glaze Line Industrial Cloud Platform remotely controls machinery and equipment in different places, enabling remote monitoring of HMI human-machine interfaces and remote penetration of PLC controllers to complete status monitoring and program updates.
6. Guanghua Intelligent:The AGV robot exhibited by Guanghua Intelligent is suitable for transfer work between various processes in the ceramic production line. It has been successfully Used in many ceramic companies such as Marco Polo, AGV storage and transportation from the baler to the temporary storage area solves the automation problem of the last 100 meters of the ceramic tile production line. The application of Guanghua AGV fully automatic storage and transportation system will promote intelligent production and take a big step towards the goal of building an unmanned factory.
7. Ribo Mechanical and Electrical: The fully automatic intelligent billet storage system behind the kiln adopts low-voltage power supply mode and wireless full coverage control. The process of unloading bricks from the end of the kiln, sorting and unloading bricks, transferring and sorting bricks on shuttle buses, and loading bricks before polishing and grinding are all controlled by an automated, intelligent, and manual interactive control system. It solves the damage, air pollution, multiple numbering of wall and floor tiles, and energy loss of motorized forklifts caused by the traditional upper and lower brick technology.
8. Bohui Electromechanical: The large-scale digital fabric was displayed on site, which exactly matches the ceramic large-scale products that are currently sought after in the ceramic industry.
9. Huibo Robot: Displayed intelligent products such as ceramic bathroom robots.
10. Basel Electromechanical: Exhibited a dry edge grinding automatic production line and a new blank polishing machine.
11. Haofeng Heavy Industry: On-site demonstration of high-efficiency and energy-saving pre-crushing system, dry direct entry combined segmented continuous ball mill system, environmentally friendly low-temperature spray drying tower, energy-saving gas burner, glaze fully automatic distribution system and other ceramic raw material workshop line technologies.
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The above are the latest equipment, materials and technologies at the Guangzhou Ceramics Industry Exhibition that Zhongtaojun and his friends have collected for you through in-depth and extensive visits in the past few days. information.
