Industrial Experimental Plant - 1ICSCM

8/3/2019 Industrial Experimental Plant - 1ICSCM

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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


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


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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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.


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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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.


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


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



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.



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:



,

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:




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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



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



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



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:




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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.



Block sawing process demands highhighhighhigh energyenergyenergyenergy consumptionconsumptionconsumptionconsumption.

RefrigeratingRefrigeratingRefrigeratingRefrigerating waterwaterwaterwater flowflowflowflow is completely uncontrolled and unmeasured.


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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



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



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



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


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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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!


Computer Vision and dimensional control03


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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!

[email protected]

[email protected]

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Industrial Experimental Plant - 1ICSCM