industrial experimental plant 1 icscm
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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
Industrial Experimental Plant
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!
02Industrial Experimental Plant
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
02Industrial Experimental Plant
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
Industrial Experimental Plant
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
02Industrial Experimental Plant
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
Industrial Experimental Plant
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.
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
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.
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
PARAMETERS MAP:
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
2. Surface Mechanical Treatment and Texturing Technology
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.
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
Surface Mechanical Treatment and Texturing Technology
Selected supplier for technology:
Main characteristics:
• 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
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
PARAMETERS MAP:
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
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.
• Block sawing process demands high energy consumption.
• Refrigerating water flow is completely uncontrolled and unmeasured.
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
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)
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
4. Industrial Mixing Laboratory for
composites formulation
Selected supplier for technology:
Main characteristics:
• 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).
Industrial Experimental Plant Technologies 02Industrial Experimental Plant
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).
Successful projects New technologies in the stone industry
Tarsia
03
Successful projects New technologies in the stone industry
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!
Successful projects New technologies in the stone industry
Computer Vision and dimensional control 03
Successful projects New technologies in the stone industry
Computer Vision and dimensional control
A new concept for stone and arquitecture 03
THANKS FOR YOUR ATTENTION!
See you at the Industrial Experimental Plant!