industrial experimental plant - 1icscm
TRANSCRIPT
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INDUSTRIAL EXPERIMENTAL PLANTINDUSTRIAL EXPERIMENTAL PLANTINDUSTRIAL EXPERIMENTAL PLANTINDUSTRIAL EXPERIMENTAL PLANT
Sandra Lpez Molina Industrial Management EngineerIndustrial Management EngineerIndustrial Management EngineerIndustrial Management Engineer
Alfonso Corts Izurdiaga Process EngineerProcess EngineerProcess EngineerProcess Engineer
Technologies for R&D in the stone industryTechnologies for R&D in the stone industryTechnologies for R&D in the stone industryTechnologies for R&D in the stone industry
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General SummaryGeneral SummaryGeneral SummaryGeneral Summary
1. CTAP Introduction
2. Industrial Experimental Plant
i. What is the Industrial Experimental Plant?
0Summary
ii. Industrial Experimental Plant valuesiii. Industrial Experimental Plant Technologies
3. Successful Projects
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Introduction
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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, develo in our activities at a national and
01CTAP Introduction
ctap
international level.
Mission:
Our missionmissionmissionmission is to improveimproveimproveimprove thethethethe competitivenesscompetitivenesscompetitivenesscompetitiveness of businesses in
the sector, through the generation and transfer of knowledge
and the implementation of new business models.
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Areas of workAreas of workAreas of workAreas 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.
01CTAP Introduction
Each working area has its own differentiated lines of
work and in turn carries out successful projects, which
are transferred and implemented within businesses.
-TheTheTheThe R&DR&DR&DR&D WorkingWorkingWorkingWorking AreaAreaAreaArea
-EcoEcoEcoEco----sustainabilitysustainabilitysustainabilitysustainability
-BusinessesBusinessesBusinessesBusinesses andandandand competitivenesscompetitivenesscompetitivenesscompetitiveness
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Technological Centres, Institutes and Universities
TECHNOLOGICALTECHNOLOGICALTECHNOLOGICALTECHNOLOGICAL
01CTAP Introduction
CENTRESCENTRESCENTRESCENTRESSpanish TCSpanish TCSpanish TCSpanish TC
CTMNCCTMNCCTMNCCTMNC, France, France, France, France
CTPCTPCTPCTP,,,, BelgiumBelgiumBelgiumBelgium
ESBULCO, BulgaryESBULCO, BulgaryESBULCO, BulgaryESBULCO, Bulgary
CETEMCOCETEMCOCETEMCOCETEMCO,,,, MoroccoMoroccoMoroccoMorocco
CETEMAGCETEMAGCETEMAGCETEMAG,,,, BrazilBrazilBrazilBrazil
MQTCMQTCMQTCMQTC,,,, EgyptEgyptEgyptEgypt
CVALORCVALORCVALORCVALOR, Portugal, Portugal, Portugal, Portugal
UNIVERSITIES:UNIVERSITIES:UNIVERSITIES:UNIVERSITIES:
School of Mechanical Ingenieers of Metz (France)School of Mechanical Ingenieers of Metz (France)School of Mechanical Ingenieers of Metz (France)School of Mechanical Ingenieers of Metz (France)
University of Gante (The Netherlands)University of Gante (The Netherlands)University of Gante (The Netherlands)University of Gante (The Netherlands)
Spanish and Andalucian UniversitiesSpanish and Andalucian UniversitiesSpanish and Andalucian UniversitiesSpanish and Andalucian Universities
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Enterprises
01CTAP Introduction
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Ctap grows with the industryCtap grows with the industryCtap grows with the industryCtap grows with the industry
624624624624 ClientsClientsClientsClients
70707070 private projects since 2007private projects since 2007private projects since 2007private projects since 2007
21212121 internal R&D projects since 2007internal R&D projects since 2007internal R&D projects since 2007internal R&D projects since 2007
9.849.280,159.849.280,159.849.280,159.849.280,15 of investment in equipment and technological
infrastructure since 2002.
01CTAP Introduction
ctap
4444 known patentsknown patentsknown patentsknown patents5555 patents on coursepatents on coursepatents on coursepatents on course
R&D Laboratory for resins and polymersR&D Laboratory for resins and polymersR&D Laboratory for resins and polymersR&D Laboratory for resins and polymers
CTAPCTAPCTAPCTAP is a member of Fedit (The Spanish Federation of TechnologyFedit (The Spanish Federation of TechnologyFedit (The Spanish Federation of TechnologyFedit (The Spanish Federation of Technology
Centres).Centres).Centres).Centres).
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Industrial Experimental Plant
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021111.... WhatWhatWhatWhat isisisis thethethethe IndustrialIndustrialIndustrialIndustrial ExperimentalExperimentalExperimentalExperimental Plant?Plant?Plant?Plant?
2222.... ObjectivesObjectivesObjectivesObjectives andandandand valuesvaluesvaluesvalues of ofofof thethethethe IndustrialIndustrialIndustrialIndustrial
Industrial Experimental Plant
ExperimentalExperimentalExperimentalExperimental PlantPlantPlantPlant
3333.... IndustrialIndustrialIndustrialIndustrial ExperimentalExperimentalExperimentalExperimental PlantPlantPlantPlant TechnologiesTechnologiesTechnologiesTechnologies forforforfor
R&DR&DR&DR&D
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What is the industrial experimental plant?
1. WHAT IS THE INDUSTRIAL EXPERIMENTAL PLANT?1. WHAT IS THE INDUSTRIAL EXPERIMENTAL PLANT?1. WHAT IS THE INDUSTRIAL EXPERIMENTAL PLANT?1. WHAT IS THE INDUSTRIAL EXPERIMENTAL PLANT?
The Industrial Experimental Plant is the best placeplaceplaceplace where Knowledge Agents, Enterprises and Technology
Developers can joinjoinjoinjoin andandandand workworkworkwork togehtertogehtertogehtertogehter for the development of new products, new processes and new
technologies for the natural and artificial stone sector.
02Industrial Experimental Plant
The Industrial Experimental Plant is not a production factory!The Industrial Experimental Plant is not a production factory!The Industrial Experimental Plant is not a production factory!The Industrial Experimental Plant is not a production factory!
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2.2.2.2. OBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL PLANTOBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL PLANTOBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL PLANTOBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL PLANT
Objetives and values of the Industrial Experimental Plant
02Industrial Experimental Plant
FIGURES:FIGURES:FIGURES:FIGURES:
Installed in 100% business environment100% business environment100% business environment100% business environment
Accounting for 10.000 m2 of buildings10.000 m2 of buildings10.000 m2 of buildings10.000 m2 of buildings
More than 22.960 m2 of land22.960 m2 of land22.960 m2 of land22.960 m2 of land
Investment of7.5 M7.5 M7.5 M7.5 M in High Technologyin High Technologyin High Technologyin High Technology
3 DISTINCT AREAS3 DISTINCT AREAS3 DISTINCT AREAS3 DISTINCT AREAS
Traditional stone processesQuality and Production control processes
Confidential R&D processes
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Objetives and values of the Industrial Experimental Plant
02TARGETTARGETTARGETTARGET 1111:::: To deeply develop knowledge of the stone transformationprocess.Deepen knowledge in stone processingDeepen knowledge in stone processingDeepen knowledge in stone processingDeepen knowledge in stone processing
TARGET 2:TARGET 2:TARGET 2:TARGET 2: To become a training centre of excellence for human
resources in the sector.
Industrial Experimental Plant
The human factor: from Operator to Stone SpecialistThe human factor: from Operator to Stone SpecialistThe human factor: from Operator to Stone SpecialistThe human factor: from Operator to Stone Specialist
TARGET 3:TARGET 3:TARGET 3: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 InnovationUp to date technologies for Stone InnovationUp to date technologies for Stone InnovationUp to date technologies for Stone Innovation
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Objetives and values of the Industrial Experimental Plant
TARGETTARGETTARGETTARGET 4444:::: To be the major shuttle of industrial development projects
Technology transfer to companies as the final purposeTechnology transfer to companies as the final purposeTechnology transfer to companies as the final purposeTechnology transfer to companies as the final purpose
TARGETTARGETTARGETTARGET 5555:::: To establish a culture of cooperation between public and private agents and
businesses.
Together we can go furtherTogether we can go furtherTogether we can go furtherTogether we can go further
TARGET 6:TARGET 6:TARGET 6:TARGET 6: To attract investment for knowledge generation.
02Industrial Experimental Plant
Future: the Industrial Experimental Plant as the hub of stone R&DFuture: the Industrial Experimental Plant as the hub of stone R&DFuture: the Industrial Experimental Plant as the hub of stone R&DFuture: the Industrial Experimental Plant as the hub of stone R&D
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3.3.3.3. INDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY SUMMARYINDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY SUMMARYINDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY SUMMARYINDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY SUMMARY
Surface Chemical Treatment
Technology
Surface Mechanical Treatment and
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
extur ng ec no ogy
Stone Block Sawing Technology
Industrial Mixing Laboratory for
Composites
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MachineryMachineryMachineryMachinery VSVSVSVS TechnologyTechnologyTechnologyTechnology conceptsconceptsconceptsconcepts
Maximum openopenopenopen operatingoperatingoperatingoperating parametersparametersparametersparameters
Whichever type of fungiblefungiblefungiblefungible andandandand toolstoolstoolstools can be used
ToolsToolsToolsTools changechangechangechange will be very simple both to minimize
time and procedures
The machinery must be compatible with anyanyanyany stonestonestonestone
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
ma er ama er ama er ama er a orororor ma er ama er ama er ama er a er veer veer veer ve romromromrom s ones ones ones one a eas
covering the largest possible range)
EvolvingEvolvingEvolvingEvolving TechnologiesTechnologiesTechnologiesTechnologies: Machinery suppliers must
be open to further cooperation in order to carry out
modification / improvements to the existing
technologies
OPENOPENOPENOPEN INNOVATIONINNOVATIONINNOVATIONINNOVATION PROCEDUREPROCEDUREPROCEDUREPROCEDURE
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1. Surface Chemical Treatment Technology1. Surface Chemical Treatment Technology1. Surface Chemical Treatment Technology1. Surface Chemical Treatment Technology
Limitations of current technologiesLimitations of current technologiesLimitations of current technologiesLimitations of current technologies
Actual chemical treatment lines are composed mainly by oneoneoneone or, at most, twotwotwotwo curingcuringcuringcuring systemssystemssystemssystems. Industrial
application processes are defined based on laboratory tests and resin suppliers recommendations.
Limitations in Vertical Thermal Ovens:
Just twotwotwotwo independentindependentindependentindependent sectionssectionssectionssections, no matter the number of floors available: drying section and curing section.
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
NoNoNoNo airairairair controlcontrolcontrolcontrol (humidity and flow).
Limitation of maximummaximummaximummaximum operatingoperatingoperatingoperating temperaturetemperaturetemperaturetemperature atatatat 60606060CCCC.
Theres no scientific evidence to demonstrate the advantage provided by a vacuumvacuumvacuumvacuum unitunitunitunit.
Dosage,Dosage,Dosage,Dosage, mixturemixturemixturemixture andandandand applicationapplicationapplicationapplication automatedautomatedautomatedautomated systemssystemssystemssystems are not versatile (for fillers and resin change).
UVUVUVUV andandandand IRIRIRIR ovensovensovensovens do not permit a wide range of parameterization.
Process parameter definition and modification is hard with actualactualactualactual interfacesinterfacesinterfacesinterfaces.
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Surface Chemical Treatment TechnologySurface Chemical Treatment TechnologySurface Chemical Treatment TechnologySurface Chemical Treatment Technology
Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:
Main characteristics:Main characteristics:Main characteristics:Main characteristics:
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
,
Thermal oven with 8 independent sections8 independent sections8 independent sections8 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 applicationresin dosing, mixing and applicationresin dosing, mixing and applicationresin dosing, mixing and application (work in progress).
Easy user interfaceEasy user interfaceEasy user interfaceEasy user interface for process cycles definition.
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PARAMETERS MAPPARAMETERS MAPPARAMETERS MAPPARAMETERS MAP:
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
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2. Surface Mechanical Treatment and Texturing Technology2. Surface Mechanical Treatment and Texturing Technology2. Surface Mechanical Treatment and Texturing Technology2. Surface Mechanical Treatment and Texturing Technology
LimitationsLimitationsLimitationsLimitations ofofofof currentcurrentcurrentcurrent technologiestechnologiestechnologiestechnologies
Machines available are not versatile to work withwithwithwith bothbothbothboth marblemarblemarblemarble andandandand granitegranitegranitegranite (heads and polishing
systems are completely different).
Individual pressure control available per head but alwaysalwaysalwaysalways aboveaboveaboveabove thethethethe headheadheadhead weightweightweightweight (the minimum
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
pressure is the one caused by the head weight).
RotationRotationRotationRotation speedspeedspeedspeed of heads fixed.
RefrigeratingRefrigeratingRefrigeratingRefrigerating waterwaterwaterwater flowflowflowflow completely uncontrolled and unmeasured.
NoNoNoNo slabslabslabslab thicknessthicknessthicknessthickness calibrationcalibrationcalibrationcalibration systemsystemsystemsystem available for natural stone slabs.
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Surface Mechanical Treatment and Texturing TechnologySurface Mechanical Treatment and Texturing TechnologySurface Mechanical Treatment and Texturing TechnologySurface Mechanical Treatment and Texturing Technology
Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:
Main characteristics:Main characteristics:Main characteristics:Main characteristics:
Two kinds of head availableTwo kinds of head availableTwo kinds of head availableTwo kinds of head available: marble and granite type.
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
Fast tool changeFast tool changeFast tool changeFast tool change for heads and abrasives.
Control of main process parameters, including:
Absolute pressureAbsolute pressureAbsolute pressureAbsolute pressure of the head on the stone slab
Water flow per headWater flow per headWater flow per headWater flow per head (work in progress)
Rotation speed per headRotation speed per headRotation speed per headRotation speed per head (in both calibrating and polishing heads)
Easy user interfaceEasy user interfaceEasy user interfaceEasy user interface for process cycles definition
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PARAMETERS MAPPARAMETERS MAPPARAMETERS MAPPARAMETERS MAP:
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
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3. Stone Block Sawing Technology3. Stone Block Sawing Technology3. Stone Block Sawing Technology3. Stone Block Sawing Technology
Limitations of current technologiesLimitations of current technologiesLimitations of current technologiesLimitations of current technologies
SawingSawingSawingSawing loomloomloomloom changingchangingchangingchanging andandandand distancedistancedistancedistance regulationregulationregulationregulation is very time consuming.
The loomloomloomloom beatsbeatsbeatsbeats areareareare unableunableunableunable totototo bebebebe controlledcontrolledcontrolledcontrolled and also the frequency of the mainmainmainmain motormotormotormotor.
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
Block sawing process demands highhighhighhigh energyenergyenergyenergy consumptionconsumptionconsumptionconsumption.
RefrigeratingRefrigeratingRefrigeratingRefrigerating waterwaterwaterwater flowflowflowflow is completely uncontrolled and unmeasured.
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Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:
Main characteristics:Main characteristics:Main characteristics:Main characteristics:
DownloadDownloadDownloadDownload speedspeedspeedspeed ofofofof loomloomloomloom frameframeframeframe variable
between 0 100 cm/h.
TwoTwoTwoTwo detachabledetachabledetachabledetachable loomloomloomloom framesframesframesframes.
FastFastFastFast loomloomloomloom frameframeframeframe changechangechangechange (under two
hours).
Frequency variator for main engine with
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
two principal advantages:
NumberNumberNumberNumber ofofofof frameframeframeframe beatsbeatsbeatsbeats adjustableadjustableadjustableadjustable
RecoveryRecoveryRecoveryRecovery of ofofof connecting connectingconnectingconnecting rodrodrodrod
droppingdroppingdroppingdropping powerpowerpowerpower, usable in the
connection rod rising (50% power
saving). Refrigerating RefrigeratingRefrigeratingRefrigerating waterwaterwaterwater flowflowflowflow controlcontrolcontrolcontrol (work in
progress)
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4. Industrial Mixing Laboratory for composites4. Industrial Mixing Laboratory for composites4. Industrial Mixing Laboratory for composites4. Industrial Mixing Laboratory for composites
formulationformulationformulationformulation
Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:Selected supplier for technology:
Main characteristics:Main characteristics:Main characteristics:Main characteristics:
Rotating and inclined mixing panRotating and inclined mixing panRotating and inclined mixing panRotating and inclined mixing pan. This promotes material
transportation towards the center of the pan and the mixing tool.
Excellent for powder and solid mixingpowder and solid mixingpowder and solid mixingpowder and solid mixing. It also allows liquid additionliquid additionliquid additionliquid addition
Industrial Experimental Plant Technologies
02Industrial Experimental Plant
during the mixing process.
Easy user interfaceEasy user interfaceEasy user interfaceEasy user interface for process cycle definition, including the
following parameters (work in progress):
Rotating mixing tool speedRotating mixing tool speedRotating mixing tool speedRotating mixing tool speed
Power consumptionPower consumptionPower consumptionPower consumption
Automatic filler additionAutomatic filler additionAutomatic filler additionAutomatic filler addition
Compressing unit and molds for composite conformingcomposite conformingcomposite conformingcomposite conforming (Work in
progress).
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SUCCESFUL PROJECTS
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PPPP----201100470201100470201100470201100470:::: APPLICATIONAPPLICATIONAPPLICATIONAPPLICATION
PROCESSPROCESSPROCESSPROCESS FORFORFORFOR AAAA BRANDBRANDBRANDBRAND OROROROR
LOGOLOGOLOGOLOGO OVEROVEROVEROVER NATURALNATURALNATURALNATURAL ORORORORARTIFICIALARTIFICIALARTIFICIALARTIFICIAL STONESTONESTONESTONE SURFACESSURFACESSURFACESSURFACES
Definition of the diamond tool and
03Successful projectsSurface Chemical Treatment Technology
the machining process
Exclusive resin formulation for high
transparence and gloss
Water proof
Polishing process definition for a
two phase material (resin + stone)
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Surface Mechanical Treatment and Texturing Technology Successful projects
Gutirrez Mena03
Different surface finishes to define
a family of products derived from asingle 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
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R&D + Design applied for spa and
Successful projectsSurface Chemical Treatment Technology
Idispaces03
.
Development of completely newtechnologies 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.
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PPPP----201100356201100356201100356201100356 yyyy PPPP----201100355201100355201100355201100355
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.
Successful projectsIndustrial Mixing Laboratory for Composites
Industrial Wastes Reuse03
Development of a new formulation
of bituminous materials includingthese wastes (2 patents generated).
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Design and construction of pilot plant
for the production of electroplated
Successful projectsNew technologies in the stone industry
Indlica del Diamante03
.
Process parameterization and definitionfor 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.
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PPPP----200502077200502077200502077200502077:::: StoneStoneStoneStone mosaicsmosaicsmosaicsmosaics automaticautomaticautomaticautomatic
Successful projectsNew technologies in the stone industry
Tarsia03
....
Automated manufacturing system based on multiple pilingup 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).
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Successful projectsNew technologies in the stone industry
Computer Vision and dimensional control
PPPP----201001319201001319201001319201001319
RecognitionRecognitionRecognitionRecognition SystemSystemSystemSystem
forforforfor naturalnaturalnaturalnatural andandandand
artificialartificialartificialartificial stonestonestonestone tilestilestilestiles....
UUUU201001042201001042201001042201001042
DimensionalDimensionalDimensionalDimensional ControlControlControlControlMachineMachineMachineMachineNew processes for quality
control for stone products:
computer vision and
03
automatic measurement.
Exclusive computeroperators to determine
main characteristics of
stone tiles.
Identification VS
classification to give the
stone a unique visual
identity.
Fully compatible with
current production
technologies.
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New possibilities for stone classification and stone compositions
Stone composition based on Computer Vision every tile is worth it!
Successful projectsNew technologies in the stone industry
Computer Vision and dimensional control03
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Successful projectsNew technologies in the stone industry
Computer Vision and dimensional control
A new concept for stone and arquitecture
03
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THANKS FOR YOUR ATTENTION!
See you at the Industrial Experimental Plant!