Acimac Handbooks - Edition 2014/2015

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IMA

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2014E D I T I O N

2015

HANDBOOKS

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IMA

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Digital Glazing

and Decoration of ceramic tiles

HANDBOOKS

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IMA

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© Copyright ACIMAC, Associazione Costruttori Italiani Macchine Attrezzature per Ceramica

Via Fossa Buracchione 84 • 41126 Baggiovara (MO) • Italy • Tel. +39 059 510 336 • www.acimac.it

Edito da S.A.L.A. srl • Via Fossa Buracchione 84 • 41126 Baggiovara (MO) • Italy • Tel. +39 059 510 108

In collaboration with:

Images from the conference Acimac/Tecnargilla "Digital Glazing and Decoration of Ceramic Tiles", Rimini (Italy)

2014E D I T I O N

2015

The series of Acimac Handbooks de-voted to digital decoration technolo-gies is being expanded this year with the fifth publication which focuses on the latest technological innova-tions introduced in this specific seg-ment.

Produced in cooperation with the magazine Ceramic World Review, this edition of the handbook will be available at all the leading tra-deshows for the sector in 2015 and can also be downloaded free of char-ge from the page devoted to Acimac technical manuals on the website www.tiledizioni.it.

The aim of the Acimac handbooks is to promote knowledge of technologi-cal and process aspects of the ce-ramic industry through publications that are straightforward and easy to read but at the same time offer exhaustive and detailed coverage of key issues. The ceramic technology supplier companies have supported us in the-

Introduction Fabio Tarozzi

se efforts by making their experti-se available and providing the texts.

Given the enormous interest in the theme of “Digital Decoration”, and today in the new field of Digital Glazing, right from the very first edition of the handbook in 2009 it was clear that we would have to provide an update at least every two years. In the end, the reality of the situa-tion has prompted us to make an-nual updates. There are two main reasons for this: firstly, ceramic digital technology is evolving at a rapid pace and has seen the emergence of new market players (machinery manufacturers, ink and service suppliers); secondly, the already large-scale use of ceramic digital printing systems in much of the world is forcing tile producers to broaden their knowledge of availa-ble technologies and of the poten-tial for further optimising digital

ceramic production. The enormous interest in these is-sues was much in evidence at the 6th Annual Meeting on Digital De-coration organised by Acimac and Tecnargilla in Rimini on 23 September 2014, which was attended by some 700 technicians and professionals from the worldwide ceramic industry.

This new Acimac Handbook contains several of the contributions presen-ted at the conference as well as fresh material provided directly by sector companies operating in the fields of colour management, digital glaze and ink supply and inkjet prin-ting machine construction. We feel certain that it will make an important contribution to the knowledge of industry professionals in Italy and abroad. We are also convinced that research in this field will continue steadily and will bring further advances in the ne-ar future.

Fabio TarozziAcimac Chairman

Fabio Tarozzi

Colorobbia Digital Space: digital evolution continues ............................................ pag. 2

Esmalglass-Itaca, new digital solutions for the ceramic market ............................ pag. 6

INCO Quick Stain Pigments for ceramic inks ........................................................ pag. 8

Diversa, a new concept in ceramic production ....................................................................pag. 12

The innovation of Durst digital decoration technology .......................................................pag. 16

Innovative solutions for rapid and cost-effective prototyping .........................................pag. 22

The infinite potential of the digital revolution ......................................................................pag. 28

Advanced colour management solutions for ceramic digital decoration ......................pag. 32

Breaking the paradigm of submicron ceramic pigment suspensions ...........................pag. 36

Contents

2 . Acimac handbooks - 2014 Edition

Colorobbia Digital Space: digital evolution continues

Space range.

Rather than just a range of materials for digital technology, Colorobbia Di-

At a time of continuous technologi-cal advances in the ceramic indust-ry, Colorobbia is unveiling the latest innovations in its Colorobbia Digital

gital Space is a series of integrated solutions incorporating concepts such as design, inks, glazes and technology.

by Fabio Avoni

vapour. This new range follows in the foot-

steps of the previous series (C-Inks, C-Glaze and C-Shine) while bringing this important additional benefit, which is particularly useful in cer-tain production conditions. Other factors such as gamut and stability of the material remain unchanged.

With these two series Colorobbia of-fers its customers a complete range of inkjet inks that above all guarantee the maximum performance in all pos-sible production conditions.

But the Colorobbia Digital Space ran-ge is far more than this. Unlike just 5 or 6 years ago, the be-nefits of digital decoration are now widely recognised. Exploiting the advantages of this technology, rese-arch efforts currently focus on the application of greater quantities of material than is possible with tradi-tional inkjet technology, the use of even more functional materials, grea-ter customisation of the finished pro-duct and optimisation and increased efficiency of the process. This may lead to complete digitalisation of the glazing line by combining both digital decoration and digital glazing.

What once might have been consi-dered a distant dream is now ever closer to becoming reality.

Colorobbia believes that this goal can be achieved through two complemen-tary solutions: low discharge glazing and high discharge glazing.

• EHP SERIES (Extended Hydrophi-lic Properties).

This well-established series has been on the market for several ye-ars and has enabled Colorobbia to secure a leading role as a supplier of materials for digital decoration. Its main characteristics are the extremely high stability of the ink system, the wide range of colours and the extremely high compati-bility between the ink and water, especially the water contained in the materials typically used on the line (engobe, glaze, etc.).

This characteristic of the EHP series avoids the many surface defects and application problems that may arise as a result of total incompatibility between water and a number of organic solvents.

The EHP series includes the C-Inks family (pigmented inks), the C-Gla-ze family (special effect inks such as matt, white and sink-in inks) and the C-Shine family (unconven-tional effects such as metallised inks).

• ETR SERIES (Extended Tempera-ture Range).

This new range was recently laun-ched onto the market as an inte-resting alternative to the previous series.

With this new range, Colorobbia offers its customers a series of inks that maintain high performan-ce and productivity even in critical process conditions such as high tile temperatures and the emis-sion of large quantities of water

• High discharge: pin this solution material can be deposited in quan-tities ranging from 300-400 g/m2 to 1 kg/m2 or more but with a lo-wer resolution than with conventio-nal inkjet printing.

The technology is suitable for both floor and wall tiles and is highly ver-satile in terms of its position within the ceramic production layout. In this case, the machine used for applying material can be positio-ned either before the colour inkjet printer (for example, to replicate a texture without the need for spe-cial moulds or to apply a full field of engobe/glaze) or after it (to depo-sit a sufficient quantity of material for subsequent honing or polishing operations).

• Low discharge: material can be de-posited in quantities ranging from a minimum of 30-40 g/m2 up to 200/300 g/m2 with high print re-solution.

Here too the application is suitable for both floor and wall tiles.

The machine can be positioned ei-ther before or after the inkjet prin-ter and can exploit the enormous potential for design synchronisa-tion offered by digital technology. This solution also offers unlimited potential for customisation as a re-sult of continuous dialogue betwe-en all the machines.

Based on this philosophy, Colorobbia has developed two new series of ma-terials to meet all the needs of its ceramic manufacturer customers: the HQ series and the SPS series.

THE COLOROBBIA DIGITAL SPACE RANGE CURRENTLY INCLUDES:

Acimac handbooks - 2014 Edition . 3

The HQ Series is intended mainly for high discharge applications and in-cludes water-based materials with a particle size that is smaller than that of conventional glazes but higher than that of digital inks. This series has a D100 below 20 mi-crons. Colorobbia’s current range consists of an engobe, a glaze-engo-be, a matt glaze, a transparent glaze, a super white glaze and a waxy glaze, as well as more sophisticated effects such as lustre and metallised effects. These materials were originally crea-ted for use on floor tiles but can also be developed in a version for wall tiles. Photos 1 and 2 show two products obtained with these materials.

Colorobbia would also like to clarify its position with regard to the definition of water-based materials. This term is widely used in our sector, but what does it really mean? A water-based material is a system

FIG. 1 - HQ series glaze-engobe for texture effect

FIG. 2 - HQ series matt glaze

containing a significant percentage of water, which in our sector can be defi-ned as around 30-40%. Materials with a smaller percenta-ge of water or which do not contain water at all but are compatible with water cannot be described as water based. Conversely, in the accepted meaning of the term a water-based material does not necessarily contain 100% water as the solvent.

For low-weight glazing, Colorobbia is proposing its new SPS series. This series meets printhead manufac-turers’ requirements for application of low-weight materials.It consists of solvent-based materials with a new and innovative particle size distribution. This particle size distribution makes it possible to obtain more intense sha-des of notoriously pale colours such as yellow and pink and above all allows

for the use of materials that can pro-vide depth and thickness rather than just colour, achieving surface effects and textures that were previously unimaginable with digital technology. Colorobbia can already supply colours such as yellow and pink as well as ef-fects such as matt and transparent glaze. If these effects are applied using a double bar, they can create a ceramic surface that is equal if not superior in functional terms to con-ventional glazes. Photos 3 and 4 show two products created using some of these mate-

rials.

FIG. 3 -SPS series matt glaze on glossy base

FIG. 4 - Interlocking matt glaze and gloss finish, both SPS series


THE RANGE OF COLOROBBIA PRODUCTS IS SHOWN IN THE TABLE

All digital products supplied by Colo-robbia are fully tested and approved by most major machine and printhead manufacturers. As a result of this extensive ongoing collaboration with the leading OEMs, Colorobbia has already performed in-dustrial testing on SPS series pro-ducts at the facility of a leading Italian ceramic company, which has produced various models of tiles on an industrial scale exploiting the unlimited deco-rative opportunities offered by digital application technology.

In view of the advantages of digital technology, Colorobbia believes it will be possible to obtain a finished tile that is completely glazed and decora-ted using digital applications. For this purpose, Colorobbia offers hi-ghly functional materials which when

combined interact in a sequence of layers to produce an innovative and entirely digital tile. These materials are highly functional due to interaction between the se-quence of layers deposited on the ce-ramic surface. This interaction makes it possible to use a smaller application weight than would be necessary with a conventio-nal process, allowing for effects and textures that would not otherwise be achievable.

Another functional material capable of producing effects that would not be possible with traditional techniques is the patented C-Shine series, unveiled by Colorobbia at the ACIMAC conferen-ce on digital decoration technologies held in November 2012. By applying an interphase using one of the two inks in

the range (“gold” effect or “silver” ef-fect), it is possible to achieve innovati-ve optical interference effects such as metallised or terracotta. Highly versatile effects and colours can be obtained by varying the mate-rial application weight. This versatility also brings significant benefits in terms of costs as Colo-robbia is able to innovate its products simply by using a material like C-Shine ink.

While waiting to see a fully digital pro-duction line installed in a factory, Co-lorobbia has developed a wide range of materials to meet the technological needs of end customers and is con-tinuing its R&D efforts at its various laboratories. These materials are shown in the fol-lowing diagram.


NOTES

CONCLUSIONS

Colorobbia Digital Space offers much more than a simple colour chart or a single test run of a digi-tal effect/glaze. Colorobbia Digital Space brings cu-stomers a series of essential cha-racteristics based on its 90 years of experience: reliability of mate-

rials, safety before and after the process to protect personnel and the environment, a worldwi-de technical service with unrival-led speed and quality and bran-ches located in all existing and newly emerging ceramic produc-tion areas, proprietary know-how

of all production processes, and teams of technicians specialising in basic product research and fini-shed projects. These key values have one thing in common: the commitment of em-ployees to the company and above all to customers.


Esmalglass-Itaca digital solutions

for the ceramic market

by Armando Meletti, Alessandro Ferrari

portunity to create an entirely digital process.

The “Digital Effects” series consists of submicron products suitable for use with today’s printheads, nano-metre-scale particles whose particle size distribution ensures excellent physical stability along with optimum performance. This category compri-ses materials that complement the decoration and create special ef-fects. These include: a white effect used for decoration or as a base for digital inks; a transparent shiny ef-fect designed to create contrasting matte-gloss areas; and a transpa-rent matte glaze that creates small variations of level in the base glaze, resulting in micro-reliefs.

The “Digital Material” series con-sists of micron products designed for use with the new high-discharge printheads. They allow for material application weights well above 100 g/m2 and as high as 1 kg/m2 or more. They are water-based materials with a particle size greater than 3 mi-crons. This larger particle size with respect to submicron materials has a direct influence on the ceramic ef-fect, resulting in digitally deposited application weights that are compa-rable with the quantities currently

The digital revolution in the ceramic industry that began with pigmented inks now offers enormous production and economic benefits for ceramic floor and wall tile manufacturers.

But why consider only the advanta-ges of digital decoration when cera-mic is far more than this? Ceramic is a combination of textures, con-trasts, brightness and different sur-faces that are achieved through the application of material. And if this material can be applied using a digital system capable of performing deco-ration and glazing simultaneously and in a synchronized manner, this will bring further benefits alongside the many advantages already offered by digital technology.This is why Esmalglass-Itaca set its sights on developing materials for di-gital application. After many years of research and experimentation, it has finally developed two new groups of products that can be applied to cera-mic surfaces using digital systems: Digital Effects and Digital Materials. These two families complement the already wide “Digitalinks” range of digital inks that our customers have been using to decorate their pro-ducts for years.These two families of products are designed to give customers the op-

deposited by bells, flat screen prin-ting machines, rollers and fumés. These products also have a signifi-cantly lower price than submicron materials, which is essential for in-dustrial operation with high applica-tion weights. These two factors have made a key contribution to the feasi-bility of a fully digital ceramic produc-tion process.

The Digital Material family includes: matte white, transparent white, transparent matte satin, crystal and metallic for monoporosa tiles and porcelain, and a lustre. These pro-ducts can be applied full field in thick layers, before or after decoration, or as clearly defined designs synchro-nized with the rest of the process to create thickness effects, as with screen printing or rollers. They can even be used to create reliefs, an operation that is currently only pos-sible with a press mould. They allow for the same kinds of applications as existing methods but with all the productivity advantages of digital technology.

Esmalglass-Itaca has been studying and developing these kinds of ma-terials for a number of years; they first came to public notice when the company won the Alfa de Oro award

ADVANCED DIGITAL TECHNOLOGY FOR MATERIAL APPLICATION


NOTES

at Cevisama 2011 and consequently patented its high discharge digital micron glazes.Both type of materials, micron and sub-micron, are designed for applica-tion on all kinds of tiles: monoporosa, porcelain, stoneware, double-firing, etc. All compositions have been optimized to meet the aesthetic and techni-cal characteristics required by to-day’s ceramic industry while main-taining the high colour performance of Esmalglass-Itaca pigmented inkjet inks.

Using a fully digital process with the materials that Esmalglass-Itaca is offering the market brings countless advantages, including improvements to products and benefits in terms of the production process and ma-nagement. Aesthetic advantages include new finishes and structures and a simpler development process. The benefits regarding production and management include a shorter production line, faster new product development times, reduction or eli-mination of the expendable supplies of traditional decorations, greater flexibility and speed in model chan-geover and a smaller number of co-

lour tones, resulting in simpler wa-rehousing operations.

Last but not least, the Digital So-lutions family from Esmalglass-Itaca consist of more than just digital co-lour – they decorate tiles by actually applying a layer of material. This gi-ves tile manufactures and designers the opportunity to create products that are clearly differentiated and are manufactured using a fully digi-tal process.

In its renovated showroom in Vil-larreal, Esmalglass-Itaca Group is also presenting an exclusive display area for large-format tiles, from 240x120 cm up to 320x160 cm or larger, with a variety of sizes obtai-ned by cutting the large panels. De-coration can be performed before or after compaction, for which purpo-se Esmalglass-Itaca offers a highly comprehensive range of products: from the colours to be applied to the earths, atomized glaze and flakes to produce a richly coloured body; to the above-mentioned inks, digital effects and materials, up to glazes, colours, grits and granules to obtain extremely natural looking or highly polished finishes.

8 . Acimac handbooks - 2014 edition

INCO Quick Stain Pigments for ceramic inks

INCO Industria Colori has developed a specific range of ceramic pig-ments for ink production with ex-ceptional technical characteristics.These products are aimed at ce-ramic glaze and colour producers and ceramic tile manufacturers in-terested in starting up their own independent production of pigment-ed inks.The technical characteristics are a result of complete pigment refor-mulation, meticulous selection of the raw materials and a thorough review of the production process.

ment particle size (a “top down” pro-cess) through high-energy grinding in special mills with grinding chambers filled with microspheres of diameter of 0.3-0.4 mm (Photo 1).During the process, a homogeneous mixture of solvent and pigment is circulated for several hours through the grinding chamber, while a special rotor imparts a high peripheral ve-locity, and hence high energy, to the spheres. This continues until the in-organic pigment has an average par-ticle size of 250-350 nm and a d99 of 0.8-1.3µm (Photo 1b).

by Daniele Verucchi, Angelo Lami, Maurizio Cavedoni

This completely new range of dedi-cated pigments is already used in the production of INCO INX and can pro-duce excellent quality inks quickly and with considerable savings.For this reason the range has been named QUICK STAIN.

Pigmented ceramic inks are disper-sions of a solid inorganic pigment phase in a liquid phase (solvents with varying degrees of polarity, disper-sants, rheology modifiers).The production of these inks is based on a process of reducing the pig-

FIG. 1 - Ink Mill

FIG. 1B - Ink Mill FIG. 1C - Ink Mill

CHARACTERISTICS OF CERAMIC PIGMENTS

Unlike the organic pigments used for production of inks for printing on pa-per and fabrics, inorganic pigments have a high Mohs hardness (>6-7) and a high specific gravity (>4 g/cm3) (Photo 2).This high degree of hardness means that a lot of energy (2-4 kWh/kg) and long milling times are needed to achieve the requisite ink particle siz-es. This results in low levels of plant productivity, high energy costs of production and considerable wear of the grinding spheres and mill cham-ber components.Due to the high specific weight of the pigment and the larger particle size with respect to other types of inks, ceramic pigmented inks are more

FIG. 2 - Properties of inorganic pigments

Acimac handbooks - 2014 edition . 9

FIG. 4 - Yellow pigment milled with Jet Mill technologyB Y P Rb G

susceptible to sedimentation.The properties of the inorganic pig-ment play a key role in the design of a high-quality ink.In particular, the particle size distri-

bution, morphology and homogeneity of the particles have a significant in-fluence on the end characteristics of the ink in terms of colour gamut, fil-terability and sedimentation.

PRODUCTION OF CERAMIC PIGMENTS FOR INKS

The inorganic pigments used in ce-ramics are synthetic products ob-tain from a high-temperature (1000-1400°C) solid-state reac-tion of mixtures of transition met-al precursors (Fe, Cr, Ni, Co, Mn, Zr, etc.). This high-temperature process produces coloured crys-talline structures (spinels, zircons, sphene, etc.) that can be used for colouring ceramic glazes or as a solid component for the production of inks.The pigments used for ink produc-tion must have very specific char-acteristics:

1) Low percentage of salts: a washing process is therefore required.

2) High colour intensity: a limited quantity of pigment can be in-troduced as solid phase.

3) Colour gamut: each pigment must produce the maximum specific colour range.

4) A narrow particle size distribu-tion: the narrower the particle size distribution at the entrance to the grinding mill, the narrow-er the distribution curve in the final ink.

This is preferable as it allows for the production of inks with su-perior colorimetric properties and stability.

Pigments for ink production cur-rently undergo a dry pre-milling pro-cess using Jet Mills. These consist of compressed air counter-jet mills (up to 6 atmos-pheres) in which the grinding action is achieved by impact between the particles. The narrow and fine distribution of the particles is guaranteed by a

classifier that rotates at different speeds according to the desired particle size (Photo 3).This grinding technology has certain particle size limitations in terms of the coarse fraction, especially as regards the particle fineness spec-ifications required for ink produc-tion. Laser diffractometer measure-ments of the particle size distribu-tion of products obtained from Jet Mills reveal values of d50=2-3 µm and d99=5-7 µm, which are certain-ly very good values.

However, if we analyse the particle size distribution in greater detail, we find that d100 can reach values as high as 10-14 µm, revealing the presence of a grinding tail consist-ing of coarser particles which are sometimes not detected by the in-strument.

The situation proves to be even worse when analysing the pigment under the scanning electron micro-scope (SEM), which is capable of measuring the real size of the parti-cles as well as analysing their mor-phology.Photo 4 shows the particle size dis-tribution of a yellow pigment milled in a Jet Mill as measured using a la-ser diffractometer. Although 100% of the particles would appear to be smaller than 10 micron, this is simply not the case.Analysing the photo taken under the scanning electron microscope, we find particles larger than 10 mi-crons and with dimensions as large as 25-30 micron. Furthermore, the pigment displays a significant degree of nonuniform-ity in terms of particle size and shape. Although these particles are not

FIG. 3 - Jet Mill


large in number, their presence can nonetheless create problems during the submicronic milling process.According to milling theories, these larger size crystals would require grinding spheres of diameter 1.0-1.5 mm, which are too large to produce the required ink particle sizes of 0.2-0.3µm. These particle size values can be ob-tained using spheres of diameter 0.3-0.5 mm.

With these sphere dimensions it takes a very long time to reduce the size of the large particles and these long milling times have the negative consequence of creating a fine parti-cle size tail in the final ink. These particles result in a loss of col-our in the ink and rheological prob-lems.

Exploiting its more than 25 years of experience in the field of inorgan-ic pigments, INCO has conducted a study aimed at developing a new se-ries of pigments with significantly im-proved particle size and morpholog-ical properties compared to those produced in a conventional Jet Mill.

FIG. 5A - Comparing particle size distributions. Standard yellow Jet Mill pigment (left) compared with yellow Quick Stain (right)

FIG. 5B - Yellow Quick Stain pigment

FIG. 5C - Comparing particle size distributions. Standard brown Jet Mill pigment (left) compared with brown Quick Stain (right)

The Quick Stain pigments have a particle size distribution with an av-erage value of 0.7-0.9 µm and a re-al d100 of below 3 micron measured from images made with a scanning electron microscope, as well as par-ticles with more uniform shape and size.Photos 5a and 5c compare pigments obtained with Jet Mill grinding tech-nology (left) with Quick pigments (right).As can clearly be seen in the pho-tos, the Quick series pigment parti-cles are considerably finer and more uniform (Photos 5a, 5b, 5c).These properties of Quick pigments result in an ink with a narrower par-ticle size distribution than a pigment deriving from a Jet Mill process, as can be seen in Chart 6.The image for Quick Yellow ICQ 10/Q110 appears to show a fused, spongy, almost sintered mass. In re-ality, as can be seen in the following image taken at a larger magnifica-tion, it is an aggregation of prima-ry particles created by electrostatic attraction between very fine parti-cles, with average particle size val-ues of around 600-700 nm.

THE ADVANTAGES OF QUICK

Due to their finer size and narrower particle size distribution, Quick tech-nology pigments are most suited for the production of high-quality ceram-ic inks (Chart 6).

They give the following advantages:

1) More intense colour. Narrowing the Gaussian grinding

curve reduces the quantities of the finest and coarsest particles, automatically increasing colour in-tensity.

2) Lower sedimentation and creaming. A more uniform particle size re-

sults in a reduction in sedimen-tation and creaming.

The product remains rheologi-cally stable for a longer period of time.

3) Greater colour stability. More uniform particles result in

production batches with more consistent colour while main-taining the same fire resist-


ance. 4) Improved filterability. Quick pigments have a more reg-

ular shape, which is maintained even after Ink Mill grinding. The particles therefore always have the same size at the filter.

Other kinds of pigments are lia-ble to create inks with lenticular shaped particles and thereby give rise to problems of filterability on decorating machines.

This brings savings of at least 30% for ink producers.

5) Energy saving during grinding. Due to the very fine particle size,

the narrow Gaussian curve and the controlled shape of the parti-cles, it is possible to reduce the grinding times by 30-40%.

6) Reduction in wear of grinding media.

The expensive grinding media (spheres) are used for less time.

7) Reduction in mill wear.

FIG. 6

The expensive internal lining of the mill is used for a shorter time.

8) Smaller plant investment. All the above-mentioned savings

lead to a reduction in investments in milling machinery as a result of the considerable increase in pro-duction capacity.

THE QUICK RANGE

The Quick Stain range consists of 14 high-saturation pigments with a par-ticle size below 3 microns. They cover a wide gamut and enable ink manufac-turers to offer a wide range of col-ours.In keeping with the INCO tradition (Sarti del colore dal 1988 - Colour tai-lors since 1988), specific colours can naturally be developed to order using Quick technology.

Inject high quality into your ink sys-tem!

FIG. 7 - The Quick range


Diversa, a new concept in ceramic production

Digital technology has revolutionised tile production and digital printers are now widely used both in Italy and abroad.

In ceramic factories in the past, spe-cialist female workers would pour the glaze over the flat ceramic surface from wooden bowls to avoid contami-nating the glaze. This was the first surface glazing process. Step by step this led to curtain coaters and bell applicators. Now that many of the processes have been digitalised, it is only natu-ral that this stage of tile decoration cannot continue to be performed an-alogically. For this purpose, System’s latest invention - called “Diversa” - rev-olutionises the decoration depart-ment, converting what has always been considered a harsh and difficult environment into an almost aseptic workplace.

The Diversa glazing and decoration process uses water-based materi-als and inks with a low environmen-tal impact. All the decoration stations (up to 36 applications) are concentrated in a space of just 25 linear metres com-pared to the 130 metres occupied on average by current glazing lines. Diversa will therefore bring consider-able savings in terms of space. The use of the future tense here is ob-ligatory because System’s invention is ahead of its time, and like all great

In theory, inkjet printing is a simple process: a printhead deposits drops of product onto a substrate. But in practice, this technology is complex and requires multidiscipli-nary expertise to implement. To be performed correctly, the entire decoration process must be metic-ulously designed, implemented and managed, taking all factors into con-sideration. But if it is so complex, why is the ceramic industry choosing to adopt the inkjet process for decoration? The first reason is that inkjet is much more than a simple printing technique. It can be used for apply-ing coatings, for depositing specif-ic quantities of material with a high degree of precision and for creating microstructures. Inkjet technology would appear to have unlimited uses and offers numerous advantages: a major reduction in production costs; higher quality; a reduction in ware-house stock; the ability to work on large surface areas; complete cus-tomisation of the product; rapid pro-totyping and just-in-time production. The introduction of inkjet technolo-gy to the ceramic tile industry may bring just minor improvements or it may prove revolutionary, but in any case the commercial benefits are generally very significant.

Inkjet technology is now a reality in many different sectors, ceramics be-ing one of the industries that has benefited the most.

ideas will require a period of time to be accepted by industrialists before it is installed in factories. It will take foresight to choose to adopt this new process. “We are a research company,” notes Franco Stefani. “You can’t keep research on the back burner. You have to document it and present it to the market to make it the benchmark and to initiate a pro-cess of debate and discussion with customers.”

Returning to the technological sys-tem presented by System, Diversa incorporates all the stations that make up a ceramic decoration pro-cess. The first station is glazing, fol-lowed by the liquid decoration stages (pigmented inks and new-generation materials), then a second glazing station for protection and finishing, and finally dry decoration.

Encouraged by the success of the Creadigit printer, System began de-veloping a system that would be ca-pable of performing digital glazing us-ing piezoelectric DOD technology, the same technology that is successfully used on what are now standard dec-orating machines. A simply engineered head with recir-culation was chosen to enable wa-ter-based products with a particle size of 6 µm to be used. The result-ant machine, called Layerdigit, is able to load a maximum of 4 different products and deposit up to 400 g/m2 of material per application.

by Rita Cagnoli


LAYERDIGIT

Layerdigit is the first station in the ceramic production line of the future, called Diversa. By using digital technology, this line will be capable of glazing, decorat-ing, creating effects and reliefs and depositing protective layers on the tile – all in a space of just 25 metres. The Layerdigit philosophy involves depositing a sufficient quantity of material on the tile to ensure total coverage with maximum uniformity and absorption of the deposited ma-terial. The 360 dpi resolution is im-portant in order to achieve perfect-ly uniform product application and to completely close the surface poros-ity. Given the large quantities of product deposited on the tile, it is essential to develop materials that have a high

percentage of water along with the solid component and organic phase to avoid burning large quantities of solvents. System is currently working closely with Italian ceramic glaze and col-our producers to develop products and raw materials that can be used with this technology to achieve very high yields.

It will be possible to install high-res-olution (400 dpi) and low-resolution (200 dpi) decoration stations on the line to attain the highest degree of production flexibility. The entire line will be equipped with a single high-precision conveyor belt to ensure perfect synchronisation be-tween all the printing stations. With applications that include glaze-en-

gobes, glazes, coloured, gloss and matt effects, colour designs (up to 16 colours), metallic effects, protec-tive layers and powder applications with Windpowder etc., the new line will combine cutting-edge technolo-gy with outstanding scope for crea-tivity. The large printing width (mini-mum 1200 mm) together with a belt speed of 10 m/min. will ensure the same levels of productivity as narrow high-speed lines. This means that the line will be able to work simultane-ously on different sizes with different applications loaded on the machine bars. The System machine used for dry decoration is Windpowder, which combines the effectiveness and inno-vation of digital technology with the potential for decorative and material effects offered by powders.

WATER-BASED INKS

Standard water-compatible inks are being developed to harmonise the line’s applications and guarantee the maximum compatibility between one decoration station and another.Solvent-based inks are the most widely used products on inkjet ma-

chines due to their good printing quality, the stability of their formu-lation, the range of compatible pro-cesses and their good functionality inside printers. Water-based or water-compatible inks have the advantage of being rel-

atively inexpensive and environmen-tally friendly, but industrial take-up has been slow and the ceramic in-dustry has only just begun to adopt them. On its printers System has chosen to use printheads that can operate

with both solvent-based (non-polar) and water-based (polar) systems.

The water-based inks currently be-ing studied by System are synony-mous with quality, eco-sustaina-bility, technological innovation and cost-effectiveness. One of the most important fac-tors behind the decision to change course and consider water-based inkjet systems for the ceramic in-dustry is the environment. Water-based inks guarantee a sig-nificant reduction in polluting emis-sions along the entire production chain. They contain about 50% less organ-ic chemical components and produce far fewer combustion products with

a low odour threshold (VOCs, Vol-atile Organic Compounds); energy consumption for ink production is reduced (water makes the grinding process more effective); solvents do not need to be used for washing the production plants as everything can be washed with water; the en-ergy used for disposing of the wash-ing solvents and containers used for storage is reduced (all materi-als can be released to wastewater without the need for special treat-ments).The technological innovations in-clude the total absence of wa-ter-repellence with respect to glaze applications before and after deco-ration, compatibility with water va-pour present in the tiles passing

underneath the digital printer, fast-er drying on the ceramic tiles com-pared to solvent-based inks, re-duction in surface defects caused by combustion of organic chemical components, and ease of washing of the circuits and external parts of the printer.

Diversa is built entirely by System. This includes hardware (mechani-cal design, manufacture of compo-nents, design of hydraulic system and study of materials), software, electronics, image processing and formulation of the inks and products used. All machines in the Diversa system are fully integrated and syn-chronised.

SYSTEM ELECTRONICS: THE ADVANTAGE OF SIMPLICITY


System itself designs and builds not only the mechanical parts of the au-tomations but also all the electron-ics. System Electronics is the compa-ny business unit devoted to the de-velopment of software and hardware solutions.“Exploiting the experience we had gained with the Creadigit digital printer, we developed a new elec-tronic system that could deliver the

high performance required by Diver-sa. First and foremost this means more processing power,” explains Alessandro Benassi, division manag-er at System Electronics. “From the dual core processor of Creadigit, we proceeded to the quad core + GPU of Diversa. The capacity for communication with the printheads has increased four-fold, making it possible to control multiple heads and therefore deco-

rate large format tiles without any loss in performance.”

Printhead synchronisation on Diver-sa is performed virtually by means of Ethercat, allowing different types of bars to be managed in complete free-dom regardless of their position. The new decoration process present-ed by System takes place in a space less than 30 metres in length incor-porating all the various tasks.


The specially developed electronic platform can be dynamically recon-figured to meet the multiple task requirements of Diversa, includ-ing the application of glaze, colours, powders and glassy coatings – op-erations that use different kinds of heads.The entire electronic system has been integrated into the colour bar, considerably simplifying the machine and reducing overall dimensions. The printheads are managed by means of a high-speed bus with the

possibility of operating at up to 4 Gbit. In this configuration, a single ca-ble carries all the printing informa-tion regarding both images (what to print) and synchronisation (when to print). This does not impose limita-tions on the width of the printing ar-ea, resolution or line speed.The upgraded Coredigit, the core of the colour bar’s processing unit, is able to handle large image areas and to load new graphic designs at the same time without interfering with

normal production.The new electronic equipment devel-oped for Diversa also includes the Copilot 21.5’, a latest generation touch screen developed as an opera-tor interface by System Electronics. Copilot is equipped with a low-pow-er processor with a wide operat-ing temperature range and full HD high-definition retro-projected ca-pacitive touchscreen. The bluetooth interface enables it to recognise users authorised to per-form advanced operations.

NOTES


The innovation of Durst digital decoration technology

high-performance digital printer for industrial ceramic tile decoration de-signed for pigmented ceramic inks. This machine marked the first step in the digital revolution in ceramic tile decoration and production. Since then, Durst has continued to make major innovations in close coop-eration with its customers, contrib-uting to the success of many leading ceramic tile manufacturers around the world.

Durst, the industrial inkjet specialist, is the most successful printing ma-chine manufacturer for digital deco-ration of ceramic tiles with over 500 installations worldwide. Customers choose Durst Gamma inkjet printers for their high print quality, productiv-ity and reliability. Durst Single Pass Technology for ce-ramic tile decoration began its de-velopment in 2003. In 2004 Durst presented Gamma, the world’s first

As a result, Durst Gamma inkjet printers have quickly become the in-dustry standard for print quality with high uniformity and strong colours, flexibility, productivity and reliability.

At Tecnargilla 2014, Durst once again demonstrated its ability to in-novate with the launch of the new Gamma XD Series and the introduc-tion of the new Digital Glaze Line concept.

by Norbert von Aufschnaiter

from left:FIG. 1 - Image courtesy of Ceramica

Sant’Agostino, ItalyFIG. 2 - New Durst Gamma XD Series

FIG. 3 - Durst milestones in the ceramic digital sector


NEW DURST GAMMA XD SERIES

The Gamma XD Series is Durst’s new-generation 8-colour ceram-ic inkjet printer platform designed for long-term high-precision print-ing with ultimate colour stability and print uniformity. Alongside technological innovations, the machines have sophisticated new features including modularity and an integrated self-maintenance capability. The Gamma XD platform is the basis for different printer versions to meet the requirements for current and fu-ture tile sizes. The Gamma XD Series is equipped with the latest Durst High Defini-tion Printhead Technology with dual ink circulation and can be configured

with up to 8 printing bars (photo 4).

The new Gamma XD Series deco-rates tiles with a native resolution of 300 dpi combined with the innovative Adaptive Dot Placement Technology. It prints with 4 greyscale levels and drop sizes up to 90 pl. For special effects such as glossy, matt, lustre and metallic inks, print-heads with drop sizes of up to 320pl are optionally available. An intelligent Electronic Printhead Alignment System combined with the Adaptive Dot Placement Technol-ogy guarantees banding-free printing for high image quality and colour ho-mogeneity across the entire printing width.

A new printhead cleaning and ink fil-tration system with almost no loss of ink guarantees consistent print results and a long life cycle for the printheads with long maintenance in-tervals and avoids purging the ink on the transport belt. The entire belt transport assem-bly can easily be cleaned without the need for consumables (brushes or liquids). The new ink filtration sys-tem avoids nozzle blockages and as-sures high printer reliability and up-times. The integrated main ink tanks are protected against dust and wa-ter by swing doors. The Durst proprietary Ink Cubitainer System with rapid connector enables spill-free and safe ink refills.

FIG. 4 e 5 - Durst Gamma XD: ergo-nomic control panel with adjustable height

SAFETY

The Durst Gamma XD Series include several features for all-round op-

erator safety, including fully closed printer design, efficient ink evapo-

ration and aerosol extraction, ink certification geared to maximum op-

EASY AND QUICK PRINTHEAD REPLACEMENT


The new printheads are also de-signed in such a way that they can easily be replaced and re-adjusted by the operator within a very short time so as to minimize downtimes. The new Gamma XD printers are equipped with Remote Diagnostics Technology and enable customers to

perform all regular maintenance and service work themselves, including printhead replacement, without the need for Durst assistance. The machines provide easy service access from both sides and guid-ed procedures for fast and easy re-placements and alignments (photos

8 and 9).The new printer design of the XD Se-ries incorporates the optimization of the machine’s ergonomics to further improve the work process. The con-trol panel can be adjusted in height, rotated and easily adjusted on site for left or right handed operation.

FIG. 8 - Easy service access from both sides

FIG. 9 - Easy printhead replacement (patented)

FIG. 6 - Durst-GammaXD, ease of access and protection FIG. 7 - Durst-GammaXD, safety in production

erator safety and printer reliability/performance (photo 6). An automat-

ic tile thickness/profile scanning system and print engine control as-

sures non-stop printing to avoid un-necessary line stoppages (photo 7).


THE BEST RATED PRINTER SOFTWARE FOR HIGH PRODUCTION EFFICIENCY

The Gamma XD Series is equipped with the best-rated multilingual printer software (64-bit Linux) for easy and fast operations. The operator can choose between many languages to customize the user interface. The software provides high flexi-bility and various new features to optimize the digital workflow, e.g. the unique Durst Autostructure function for automatic structure creation when using special effect inks such as lustre, sink-in ink, etc. (photo 10).

FIG. 10 - Printer management software

DURST DIGITAL GLAZE LINE

With the new Digital Glaze Line con-cept, Durst is introducing an inno-vation that will revolutionise ceramic tile production through synchroni-sation of the digital glazing, printing

and finishing processes (photo 11). This will allow for greater creativi-ty, efficiency and precision, resulting in true on-demand production with-out the need for further production

stages, from the computer through to the finished product. The Digital Glaze Technology will allow ceramic tile companies to apply glazes with full or partial coverage, to create

FIG. 11 - Durst Digital Glaze Line


FIG. 12 - Digital Glaze technology

FIG. 13 - Digital Glaze technology

PARTNERSHIPS

Durst offers leading industrial print-er technology with the highest in-stalled base (over 5,000 indus-

trial printers installed worldwide). Durst’s experienced staff provides high level support, knowhow and ex-

perience in digital imaging to assure successful production start-up and operation.

structures that are aligned perfect-ly with the design and to offer new design possibilities that could not be achieved with traditional glazing technologies.For example, wood decorations can be produced with the same wood grain or in random mode. Alongside its precision, the Durst Digital Glazing Technology also offers the advantage of being able to pro-duce an unlimited number of different structures. Today, a maximum of 4 different structures can be produced with a

printer depending on the design and tile size.

Digital Glaze technology can be in-stalled before the current digital decoration printer to glaze tiles with flat or textured surfaces, or after the printer to apply special effects or crystalline, etc. (photos 12 and 13). The main advantage of this innova-tive technology compared to the oth-er solutions on the market is that it can jet large quantities of glazes with particle sizes close to those of traditional glazes, thereby achiev-

ing cost-effective applications with-out losing the real ceramic effects. This makes it possible to streamline the production process, increase ef-ficiency, reduce waste and minimise finishing costs.

The new Gamma XD series is already equipped with a software interface to synchronise with Digital Glaze technology. Durst is also planning to develop con-nections for third-party printers so as to offer the system as a stand-alone solution.


Durst also provides comprehensive factory and on-site training for ap-

plication, digital workflow and ser-vice/maintenance operations.

NOTE


Innovative solutions for rapid and cost-effective prototyping

ity to support multiple ink changes or simply because of quality issues deriving from the fixed transversal printhead resolution. For real prototyping or small just-in-time production runs, certain activi-ties need to be performed quickly, re-liably and cost-effectively:• Scanning of stone, wood and other

natural materials• Automatic colour management

Glaze and colour producers, third fire ceramic tile producers and labo-ratories are experiencing a growing need to perform tile prototyping as part of their R&D activities and for small special production runs, such as those with precious metals. For these kinds of activities, normal single-pass digital decoration print-ers are often not sufficiently versa-tile, either due to their limited abil-

• Plotter with quick ink change.Intesa’s solution consists of three devices that can be combined per-fectly to meet the needs of ceramic glaze and colour laboratories, third fire tile producers and companies wishing to prototype products with-out occupying lines and single-pass digital machines.

by Alessandro Beltrami

IMAGO – XL IMAGE SCANNER

tion systems. It was created by adapting one of the best commercial optical sys-tems on the market, produced by Seiko Epson, and fully exploits the system’s ability to acquire details and colours on smooth and slightly textured materials. With an optical density of 3.8 DMax it can detect contrast on the most strongly variegated stone, while the native colour depth is 48bit. This means that it can acquire al-most 300 trillion (3x1014) colour combinations compared to the 16 million colours of normal 8 bit per channel devices!

Ceramic producers often require a spectral scanner, so let’s look at

Imago is a photographic scanner that acquires images of stone, wood and other flat materials with-out the need to break them into small pieces. Imago uses 2,400 dpi autofocus optics and is designed to reproduce colours and details with a high degree of accuracy so that they can be replicated with Intesa digital printers with the aid of the Crono colour management system.Its solid structure enables it to easily handle ceramic panels up to 1x1.5 metres in size and weighing up to 150 kg. The project was developed by Inte-sa with the goal of obtaining a ro-bust and simple machine that would be easy to install and above all much less expensive than other acquisi-

why Imago may offer a valid alter-native. A spectral scanner normally consists of a high-resolution camera but with a lower DPI than the native 2,400 of Imago. Filters are used to split up light sole-ly across the visible spectrum (spec-tral scanner) or including part of the infrared and ultraviolet component (hyperspectral scanner). This means that the same device can acquire graphics and testcharts, whereas with an RGB scanner like Imago a spectrophotometer is re-quired. The list of the pros and cons of Ima-go compared to a spectral scanner shows that it is difficult to make a direct comparison between the two devices:

FIG. 1 - Imago - XL image scanner FIG. 2 - Imago - XL image scanner


Spectral scanner Imago

Pros Colorimetric precision

• The price is a fraction of that of a spectral scanner.• Maximum versatility and ease of use by any graphics operator.• High acquisition speed (typically 15 min/m2 for 600 DPI high-quality

scanning).• Optics and lights produced for more than 15 years by Seiko Epson,

which has customer support centres all over the world.• Standard Epson software for PC and OSX.

Cons

• Very high price.• Light/shadow contrast not optimal.• Low acquisition speed.• Optics and lights produced in small quantities and difficult to find on

the market.• Need for custom software

A spectrophotometer is required to complete the workflow

the same results were achieved as with the use of a spectral scanner. The ability to reproduce a materi-al with precision, which is the key strength of a spectral scanner, be-comes pointless if the designer has

From our experience at Intesa, we believe that a spectral scanner is not necessary in the ceramic indus-try. In all projects carried through using Imago (more than 100 in var-ious factories), in the worst cases

to make colour variations or per-form graphic design processing. In this case, because Imago is a tra-ditional RGB scanner it can gener-ate a more versatile if theoretically less precise input file.

CRONO DESKTOP 3 + SPECTROPRO – CERAMIC COLOUR MANAGEMENT

FIG. 3 - Crono

ly suitable for companies looking to start up digital ceramic production as it offers them a quick and simple way of achieving a good level of colour quality while minimising the number of trials required before commencing production. Crono manages ceram-ic colour in xCLR mode, so it is in-

Crono is a system developed by INTESA. Imaging since 2009 for col-our management in the pre-printing stages of the digital decoration pro-cess. Crono software facilitates the use of digital images and of design and production data in the various processing stages. It is particular-

dependent of the CMYK model. This enables it to handle digital configu-rations with multiple colours (up to 8 or more), independently managing similar shades of colour on the ma-chine. When interfaced with Imago and Colorscan 1010 it creates the ideal workflow for glaze and colour producers and for ceramic R&D lab-oratories.

Version 3 of the Crono system intro-duces an array of new features, all of which have been developed inter-nally by the Intesa Imaging research centre. The main changes come from the new Crono Image Library™ which forms the basis of all new Intesa software: Crono Desktop, Crono Production, Crono Cap and the operational soft-ware of DHD and DHW digital ma-chines. Crono Image Library™ allows images to be processed with state-of-the-art technology, using the mul-tithread and video card resources to


speed up all operations.

Improvements:• Up to three times faster over a

complete workflow compared to the previous version.

• Video preview and other opera-tions optimised for processing Sacmi Continua® and Continua+® line files.

• New CMYK and Multicolor profiler with proprietary mathematics and algorithms, compatible with 0/45° spectrophotometers (e.g. X-Rite EyeOne and Barbieri LFP) and d/8° sphere spectrophotometers (e.g. X-Rite SP62/64 and Konica Minol-ta CM 2500/2600d).

• The reliability and size limitations of the plug-in for Adobe Photo-shop™ for Windows have been im-proved.

• Improved connection with Tecno-grafica database.

• Improved HotFolder function with

halftoning capacity for complete automation of workflows with col-our management and screening.

• Crono Image Library™ allocates computer resources intelligent-ly to conserve RAM and to make maximum use of processors. Var-ious strategies are used for small images or large sheets, including images larger than the comput-er’s physical RAM.

• Auto Update function with auto-matic download and installation on request.

New functions:• Advanced Ink Saving workflow

compatible with large profiles, with preview of results and infor-mation on savings.

• Complete management of PSD/PSB and TIFF files with up to 11 alpha channels.

• Generation of test runs with au-tomatic notes written on the tile.

• New Layout section with rota-tion, size change, cut and panel-ling functions; it is now possible to import a complete sheet and cut the sizes directly with Crono.

• Option with SpectroPro™ auto-mated spectrophotometer to create perfect profiles on tex-tured surfaces (e.g. Continua+®) and tiles with finishing glazes and grits.

• Advanced manual change with In-tesa Tone Compensation™ func-tion and other utility tools.

• Plug-in for Adobe Photoshop™ for Apple OSX.

• Halftoning capacity with various algorithms and drop division pa-rameters.

• Management of “effects” and “white” with levels sent separate-ly to different machines (e.g. DH-D+DHW project in a single file).

• Creation of master files for Crono Production 3.

FIG. 5 - Crono: image acquisition of marble and stone

FIG. 6 - Crono, profiling and separation FIG. 7 - Crono, advanced manual changes FIG. 8 - Crono, production preview

FIG. 4 - Crono: image acquisition of marble and stone


FIG. 9 - Spectro Pro

COLORSCAN 1010 – CERAMIC PLOTTER

high-definition images to be printed in four-colour or multicolour mode. Colorscan 1010 can be equipped with a maximum of 8 colour modules with the option of a further 8 mod-ules on stand-by for rapid ink chang-ing. This means that up to 16 colour bars are available to simulate all the cus-tomer’s ink combinations with a high degree of precision. The bars can be interchanged to perform sequence tests to be replicated on the sin-gle pass printer. Colorscan 1010 can operate in “single pass emula-

Colorscan 1010 is a compact and versatile plotter, ideal for research, development and prototyping activi-ties in the ceramic sector. The automation system consists of a Cartesian robot movement and en-sures high printing precision. The movements of the X axis (car-riage movement) and of the Y axis (table movement) are powered by lin-ear motors. The Z axis movement (carriage up/down) is managed by a stepper mo-tor.The graphics program allows

tion” mode to reproduce the typi-cal discharges of Xaar GS6 or GS12 printheads with multiple passes and achieve perfect, defect-free pro-totypes. For third fire production, Colorscan 1010 operates in “high discharge” mode, using multiple passes to deposit a greater quantity of colour than is possible in a normal single pass. These modes are man-aged using a special version of Crono Production, the software that func-tions as an RIP and adapts perfectly to the Crono Desktop graphic design firm workflow.

FIG. 10 and 11 - Colorscan 1010

The Spectro Pro spectrophotome-ter is recommended for use in ce-ramic laboratories and glaze and col-our factories. When a ceramic surface consists of glossy glazes, textures or finishes such as grits or protective glazes, it is very difficult for a normal 0°/45° spectrophotometer to read the col-our accurately and repeatably. Incor-rect measurements are detrimental to the generation of ICC profiles and impact on the entire Crono workflow, nullifying the benefits of soft proof-ing and adversely affecting image contrast. Spectro Pro is a Crono

option for automat-ing integrating sphere spectrophotometers, which are normally used in ceramic laboratories for formulating colour-ed glazes and for read-ing linearisations and testcharts in difficult measurement condi-tions. Crono Desktop can make use of read-ings made by sphere spectrophotometers in both SPIN mode and SPEX mode.


GLAZING AND DECORATION IN THE DIGITAL AGE

The DHD series can be fitted with all types of Xaar 1002 printheads, in-cluding the brand new GS40 heads unveiled at Tecnargilla 2014. DHD printers offer a number of ma-jor improvements and innovations over previous versions of Intesa ma-chines. In particular, the ink circula-tion and feeding systems have been entirely redesigned to ensure a very high level of performance. The electronics are also complete-ly new. All Intesa machines now use proprietary electronics developed in-ternally by the Sacmi Group, which ensure very high performance in terms of data transmission rates,

Intesa is continuing along its path of technological development with the goal of complete digitalisation of the ceramic glazing and decoration pro-cesses. For this purpose, it is unveiling a completely new range of digital print-ers marketed under the Sacmi brand name, demonstrating how its opera-tions are becoming increasingly inte-grated with those of its Imola-based parent company. For inkjet printing, Intesa is propos-ing its DHD series of decorating ma-chines based on technology from Xaar, the world leader in inkjet tech-nology.

manufacturing flexibility and reliabil-ity, while at the same time allowing for perfect integration between the various digital applications that are to be found today on a ceramic glaz-ing and decoration line.Furthermore, the DHD printer man-agement software has a simple and intuitive graphic interface that is easy to use by operators.The DHD digital printer range com-prises models DHD708 (maxi-mum printing width of 697 mm), DHD1108 (maximum width 1120 mm) and DHD1308 (maximum width 1390 mm). Alongside these models, which can be used to decorate all sizes up to 1200 mm after firing, Intesa is al-so proposing a digital printer version that has been specially designed for decorating very large format ceramic panels and for installation on Sacmi’s Continua+ production lines. With its maximum printing width of 1882 mm and the possibility of installing up to 8 colour bars, the DHD 1808 has technical, construction and function-al characteristics that are intended specifically for integration with the Continua+ production cycle. Equipped with an individual cleaning system for each colour bar, the DHD 1808 can be programmed to per-


NOTES

form bar washing cycles in the time between the passage of one tile and the next, without the need to halt production.

In view of the extraordinary benefits that digital technology offers for the decoration stage, the entire ceram-ic sector is striving to expand digital applications. In particular, special materials are being used to bring new aesthetic possibilities to the traditional deco-ration process, including increasing-ly rich natural textures, colours and effects. However, as these materi-als are still solvent-based and have a sub-micron particle size, they often have the drawback of high costs and limited application potential.To be able to produce tiles with the

real material look and feel that can-not be achieved using inks alone, Intesa has developed the new HW printing technology for controlled application of ceramic glazes. HW technology can apply wa-ter-based glazes with particle siz-es greater than 3 microns (range 3 - 12 micron). It is capable of depositing glazes in quantities of between 200 and 1000 grams per square metre for either full-field applications (engobes, textures) or specific spot applications inte-grated with traditional ink decora-tion.Initially designed and developed in the Sacmi Group’s research lab-oratories, HW is now brought to the ceramic industry by Xaar with the brand new Xaar 001 print-

head, featured on Intesa’s Glaze-jet and DHW series digital printers. The Glazejet 330 laboratory plot-ter, complete with a printing sta-tion and DropWatcher system, has already been adopted by numerous glaze and colour producers for their glaze research and development ac-tivities. The Glazejet 1000 plotter is suit-able for prototyping and developing large-size products. During Tecnargilla 2014, Intesa al-so unveiled the DHW 700 digital printer, the first single-pass digital machine for operation in a continu-ous industrial process. DHW can be synchronised with conventional ink-jet printers and allows a fully dig-italised glazing and decoration line to be created.


The infinite potential of the digital revolution

not involve a loss of skills, which in-stead are simply shifted from the decoration line to the graphic de-sign studio. To create a unique and inimitable product, the graphic design studio plays a key role in providing the ini-tial input and giving an overall sha-pe to the project. The mission embraced by Projecta Engineering and Digital Design is to improve customers’ knowledge of digital technology and its potential

Projecta Engineering believes that digital decoration is very different from using a photocopier. The digital process is capable of much more than turning out stan-dardised products at competitive prices or producing aesthetically perfect copies of wood or marble that have limited added value. The digital revolution is so profound that a complete overhaul of the sy-stem is required. Importantly, this revolution does

and of the infinite range of deco-rative solutions that can be achie-ved. This is primarily a cultural ope-ration, an investment that the company has chosen to make to promote full awareness of the po-tential of digital decoration lines and their ability to improve com-petitiveness by delivering aesthe-tically high quality products at a moderate price and giving free rein to creativity.

by Vincenzo Palumbo

Projecta Engineering provides everything necessary to create an integrated digital decoration line, from graphic design and de-velopment of the original project through to the finished product. As a “digital native” company, Projecta Engineering not only sup-plies the machine but can also pro-vide support in designing and deve-loping a fully digital decoration line. The essence of Projecta Enginee-ring lies in its overall vision of the process. The advances in technology must be backed by a “digital culture” that is capable of determining the best use of new technology sui-ted to any kind of custom solution (glazing, application of special ma-terials, dry decoration, effects and complex processes).

With the digital process, a one-off plant investment can be optimised to obtain an unlimited range of pro-ducts. An innovative design idea immedia-tely becomes a real, concrete op-portunity, without additional costs and investments. The graphic design is always the main focus. Projecta Engineering is also able to steer the technologi-cal development of printheads and

printing inks in the short to me-dium term thanks to the electro-nic system and print management software developed and produced internally.

Thanks to its knowledge and tech-nical expertise, Projecta Enginee-ring is able to offer all the major technological solutions available on the digital decoration market. These include compact, modular machines with a large printing width that guarantee extremely high flexibility and rapid colour change, smart maintenance, cu-stom printers and printers spe-cially designed for decorating trim pieces.

Projecta Engineering’s decision to avoid pointless superstructures right from the design stage to-gether with its knowledge of the methods and needs of the target sector mean that its machines are extremely simple and user friendly. Tailored to the needs of a dynamic and rapidly developing sector, Evol-ve machines are designed and built with a view to the future and are therefore capable of incorporating the research work and innovative proposals of other players such as ink manufacturers.

THE DIGITAL DECORATION LINE

EvoMOVING


THE ADVANTAGES OF EVOLVE DECORATING MACHINES

Through a process of ongoing rese-arch, Projecta Engineering has tran-sformed decoration into an efficient, high-performance digital system that can be fully integrated into the pro-duction process. A design approach that aims to establish an effective dialogue between all stages of the glazing line has resulted in intelligent, fully automated lines centred around the graphic design project.

The use of cutting-edge solutions (Evolve, Evostore, Synchro 3D, Evo-vision) has already produced outstan-ding results in terms of maximum in-tegration of digital technologies into ceramic production lines. Following the addition of new models and acces-sories, the Evolve family is now the most complete and versatile range of decorating machines on the market.

The main advantages of Evolve digital decorating machines are:- compactness, ruggedness and ver-

satility;- ease of access and maintenance

thanks to the automatic cleaning system;

- powerful suction;

- machine parameter management from a single point;

- low installed power;- speed of loading images and chan-

ging graphic design;- fully interchangeable colour modu-

les;- modularity and scalability according

to customers’ requirements.

Evolve decorating machines have very small overall dimensions and class-lea-ding characteristics. Their proprietary hardware and software architecture allows for the use of a range of prin-theads. An open system of this kind brings significant benefits as there are no constraints on ink and printhe-ad purchasing, allowing for the utmost freedom of choice.

Projecta Engineering unveiled a num-ber of new products at Tecnargilla 2014 including the digital machine with the largest printing width in the world, which is already in operation at the facilities of two leading Italian ceramic manufacturers. In view of the market success of large format tiles and their growing use in unconventio-nal applications, Projecta Engineering

Another innovation is that of Evo-DRYFIX, a machine for dry powder application already in operation at several factories in the Sassuolo area. EvoDRYFIX is the first digital cera-mic printer to combine inkjet drop on demand technology with dry ap-plication technology. The system is able to apply grits in a range of particle sizes from 50 microns to 500 microns according to a preci-se digital design that can synchro-nise perfectly with the design of the decoration inks.

This means the system can per-form any kind of application, from high-definition, low-thickness ap-plications through to coarse, high-thickness applications. It guarantees maximum stability and repeatability of granule ap-plication. As with the entire Evol-ve family of decorating machines, the EvoDRYFIX stands out for its exceptional flexibility of use. The granules can be changed in a short space of time to allow for a rapid reconfiguration of the deco-ration line.

EVODRYFIX

EvoDRYFIX

decided to extend its already wide range of extra-large printers with the introduction of the new EVO 8, which has a printing width of 1890 mm. It is the first company in the sector to have introduced a machine capable of decorating such wide ceramic panels.

EVO 8


EVOstore

EVOstore is a wheel-mounted sto-rage unit containing from one to five colour trays, which are fed and managed by a dedicated electronic system in an air-conditioned envi-

ronment.It meets the need to enhance digi-tal tile decoration using the enti-re range of inks currently available on the market, no longer limited to the CMYK colours of the traditio-nal four-colour process but incre-asingly enhanced with new colour spots and material effects. Inside EVOstore the trays complete with printheads temporarily on standby are fed continuously and cleaned automatically. The colours they

EVOSTORE

contain are kept circulating ready for use at the required operating temperature.The system is ideal for storing trays containing spot colours that lie outside the four-colour range or material effects such as lustres, metallised, white and sink-in gla-zes, which can be used interchan-geably on different machines. Evo-store is the natural complement to the Evolve/Evolve Plus series digital decorating machines.

EVO7


NOTE


Advanced colour management solutions for ceramic

digital decoration

management requirements. The fol-lowing are the most significant:

1) The use of non-proprietary colour management software solutions that are not restricted to a spe-cific brand of printers.

2) Optimised printing for an incre-asingly varied collection of inks that are ever more distant from conventional four-colour printing, often in conjunction with coloured glazes.

3) The ability to print a product on lines equipped with different prin-ters and inks and adopting va-rious firing conditions but with the certainty that the same end result will be achieved.

4) To reduce research times by

The rapid growth of digital ceramic decoration technologies has brought considerable benefits for the tile pro-duction process worldwide.Because of their complexity, however, these technologies must be managed effectively in order to make best use of digital decoration systems and to optimise the timeframes and costs of research and production.The initial approach to colour mana-gement, which was derived from the paper printing sector and involved adapting graphic design applications and performing subsequent testing, is now obsolete.The availability of an ever wider range of printing systems and inks, the nu-merous variables associated with the greater number of printing bars and the introduction of coloured bases with decorative effects have brought major changes in terms of colour

using high-performance acquisi-tion systems and high-fidelity on-screen or printed previews to be able to determine the end results of image processing right from the outset.

To meet these needs, the Smaltochi-mica group’s subsidiary Colourser-vice has launched a hyperspectral scanner acquisition technology and a colour management software called ColourProfiler specially for the cera-mic industry.The hardware and software has been developed from scratch using solu-tions tailored specifically to the ce-ramic industry rather than trying to adapt systems originally designed for the paper or textiles sectors, which have a number of aspects in common with the ceramic industry but also many differences.

by Silvano Filippi

HARDWARE SOLUTIONS

Colourservice has further optimised its spectral acquisition system with the introduction of a new image ac-quisition system with large acqui-sition dimensions (up to 100x100

system based on sphere (or 0° dif-fused) measurement technology, a technique that has been used highly successfully in the ceramic sector and was originally introduced by the Smaltochimica group with its por-table spectrophotometers (SP62).This instrument, integrated with a colour matching system, has been used for reproducing models sin-ce the time of ceramic decoration with silicone rollers.The solution is designed for custo-mers wishing to develop graphic de-signs internally or who base most of their work on third party repro-ductions of existing projects.In a single acquisition, the spectral scanner is capable of obtaining not just the graphic file of the scanned object but also all the reflectance values of the various tones. Subse-quent processing can produce a profiled graphic design project re-ady for printing which can be pre-viewed on calibrated monitors.

FIG. 1 - Spectral scanner 1000

cm) and a range of resolutions ca-pable of meeting the everyday needs of the ceramic industry.The scanner is a full-scale spectral


A paper preview can also be made by calibrating a photographic prin-ter and integrating it into the co-lour management workflow.

All output devices and graphic profi-ling of files on these devices are ma-naged using our colour management solution.

SOFTWARE SOLUTIONS FOR COLOUR MANAGEMENT

in such a way as to correct designs that display variations during a pro-duction cycle.These functions can considerable re-duce the quantity of non-compliant products and production stoppages.

This software solution also improves planning and makes for better use of ceramic resources by helping the graphics laboratory transfer a pro-duct developed in one printing con-text to a different one (for example a different factory, a currently underu-tilised production line, a new printing system or a new set of inks).This function, known as “device link”, allows for considerable freedom of planning and avoids obligatory pro-duction choices.Colour Profiler can quickly and relia-

Our colour management solutions serve as the cornerstones of a digi-tal laboratory. They were developed by a team with extensive experience in the ceramic industry using constantly evolving proprietary algorithms to meet the current needs of the sector.The software can display and process graphic design projects and mathe-matical formulations developed ac-cording to the specific needs of the ceramic industry.Colour Profiler (photo 2) is a comple-te colour management system inten-ded to help ceramic sector graphic design technicians develop and cor-rect graphic design projects for in-kjet printing.Its ability to manage all printers, inks and coloured bases makes it the per-fect tool for profiling new designs, whether they are based on our pro-prietary acquisition system or other conventional systems (RGB scan-ners, cameras or camera backs) or were supplied by graphic design firms or glaze and colour producers.Colour Profiler achieves clear time savings right from the start.The possibility of previewing the final result on screen or on paper enor-mously reduces the number of tests needed to achieve a given result. This enables the ceramic graphics labo-ratory to focus its efforts solely on products that guarantee a finished result that will meet the needs of the market and satisfy the requests of the marketing department.

But Colour Profiler can do more than create new files. It can also help the graphics labo-ratory alter an existing printing file

bly determine the feasibility of tran-sferring a graphic design project to a different printing context based so-lely on the source and target colour profiles.All processing operations allow the user considerable freedom of opera-tion while ensuring a high-quality end result and optimising consumptions due to the new individual and total ink limitation functions.The Colour Profiler software is not only associated with the hyperspec-tral scanner but can also be combi-ned with various commercial mea-suring instruments for measuring colour patches. This enables even small and medium-sized ceramic companies to adopt the most advanced complete co-lour management solutions in their FIG. 2 - Workflow with Colour Profiler


workflows.To be even more useful for the cera-mic industry, the software contains functions for comparing the colour profile (gamut) and individual inks so as to be able to evaluate and analyse them immediately.Although the software was developed specifically for the ceramic industry, it is compatible with the require-

ments of graphic arts, allowing it to create colour profiles (ICC) that can be used in graphics processing appli-cations such as Adobe Photoshop.The application can be installed on standard workstations, enabling the various databases to be saved on a shared platform and allowing many different users to work at the same time.

In traditional decoration systems, the storage of manufacturing da-ta and retrieval of a model for a new production run were never insur-mountable problems.

The storage systems themselves were relatively simple. New production runs could be start-ed up simply by using a technical da-ta sheet kept in the laboratory. Fol-

SOFTWARE SOLUTIONS FOR DATA STORAGE

The advent of digital decoration has changed all of this, focusing on an aspect that tended to be neglected in previous technologies: the volatile nature of projects.Graphic projects and their implemen-

tation now consist of a sequence of bits that are at risk of being lost, damaged or stolen.

If all the production data - including variants, modifications and opera-

tional sequences - are not stored ef-fectively, it becomes extremely diffi-cult to reproduce a standard model. And if the stored data is incomplete, a lot of work is needed to recover the original files (photo 4).

FIG. 3 - Traditional decoration: project management using physical printing templates

lowing a couple of trial runs and a few corrections, it was possible to reproduce the model based on the original standard with a high degree of precision (photo 3).

FIG. 4 - Digital decoration: project management using software solutions


The Smaltochimica group and Colourservice

The Smaltochimica group is a leading company with more than thirty years of experience in the ceramic chemicals sector and has branches in all the world’s major ceramic manufacturing areas.As part of its ongoing research and innovation efforts for the benefit of customers, Smaltochimica has set up Colourservice, a new company in the field of ceramic colour management which develops and uses unconventional technologies to help customers optimise and improve the efficiency of digital decoration.

www.smaltochimica.it www.colourservice.net

NOTES

To tackle this problem, Colourser-vice has partnered with a leading player in a non-ceramic sector to develop a ceramic version of its file storage application.This client/server solution provides the ceramic graphics laborato-ry with a precise storage system, which can be used to hold original

products along with all the vari-ations and corrections that have been made and information on which operator has created or mod-ified the designs and the sequence in which these modifications were made. The system provides a sim-ple backup of products and guaran-tees traceability, thus protecting

against the risk of loss, overwriting or incorrectly assigned changes.

Smaltochimica group believes that tools for controlling digital print-ing must become a top priority for ceramic companies as they enable digital technologies to be managed with ever greater autonomy.


Breaking the paradigm of submicron ceramic pigment suspensions

certain degree leading to the men-tioned paradigm of “ungrindibility” of ceramic pigments below 1 micron. The introduction of ceramic in-kjet using drop on demand printing technologies pushed the technolo-gic leading companies in the field of milling to develop a process, based on the optimal combination of Dry + Wet grinding techniques, to obtain suspensions of ceramic pigments in

During many years it was widely ac-cepted that ceramic pigments could not be ground into the submicron range (d99 < 1 µ) without a relevant loss of colorimetric and other physi-cal properties.The wide spread use of wet grinding technologies, lead to extremely long times before finer products were to be produced. During this long grinding process pigments were certainly damaged in

the sub-micron range (d50 0,15 µ - 0,3 µ / d99 0,6 µ - 0,8 µ). Over 45 Mio kgs of ceramic inks supplied and more than 3000 cera-mic digital printers worldwide con-firm that this goal was achieved successfully, breaking that para-digm and opening new and challen-ging fields for grinding ceramic raw materials, glazes and other related products.

NETZSCH SOLUTIONS FOR CERAMIC APPLICATIONS

Since the first batch was run on a LABSTAR laboratory mill in December 2005, NETZSCH has accompanied the development of inkjet technology and has been at the forefront of this technology. This is confirmed by the hundreds

ment processing, mixing, wet grinding, etc.) in the production of digital glazes and inks, ceramic pigments, InGlass ceramics inks, technical ceramics, minerals and raw materials and ceramic mas-ses.

WET GRINDING - ZETA® SYSTEM

product portfolio (horizontal disk mills, basket mills, vertical mills,

Among the nine wet grinding sy-stems available in the NETZSCH

etc.) ceramic inkjet pigments manu-facturers have chosen the ZETA® Sy-

of NETZSCH machines producing ceramic inks and other ceramic applications all over the world. Through its vast experience, NETZSCH is able to develop and select the best solution for every single step of the process (pig-

FIG. 1 - Zeta 400


DRY GRINDING

As for dry grinding, a correct formu-lation and fineness of the ceramic pigments is essential to achieving a color with a narrow, controlled par-ticle size distribution. NETZSCH of-fers two solutions:• CGS Fluidized bed jet mill with

ConVor® classifier wheel for nar-row particle size distribution to d97 <4 µ - 5 µ

• and S-JET® Steam Jet mill. The S-JET® Steam Jet mill techno-logy is an advanced development of the NETZSCH-CONDUX Mahltechnik Gmbh well known Air Jet mill, using high pressure overheated steam in-stead of air as grinding media. The use of steam offers a much higher impact velocity as well as a completely new possibilities in the classification process, leading to fi-neness never seen before in the ce-

pers of ceramic inkjet inks. The narrower pigment curve from the S-JET®, together with the shor-ter wet grinding times, results into a much narrower curve of the ink with less ultrafines and therefore color strength (especially in yellow and red brown inks). This will set new standards in the digital decoration of ceramic tiles.Cost reduction and increase of ink quality will give a competitive advan-tage to companies adopting the S-JET® dry grinding technology. On top of that, this new dry grinding technology has opened new manu-facturing possibilities in the field of tile manufacturing and decoration, such as digital glazing and “simulta-neous” drying and grinding of cera-mic slurries in the submicron range, etc.

ramic pigment industry (a very nar-row particle distribution curve down to d50 ≈ 0,45 µ / d97< 1 - 2 µ). The use of such fine and narrow distributed pigments into ceramic inkjet inks has a direct influence in very significant decrement of the wet grinding time. Apart from the obvious consequen-ces of optimizing the bottleneck of the process, and energy cost reduction, even more important advantages derive from the shor-ter wet process of the ink: It is a well-known that wet milling using micro-beads below 0.5 mm creates an increasing amount of ultrafine particles of pigment into the final ink, which has a very negative ef-fect in colorimetric, rheological and reactivity of the ink and has been a constant nuisance for the develo-

NETZSCH worldwide

NETZSCH operates, in the truest sense, in close proximity to its customers. Currently have production facilities in Germany, the USA, Brazil, Russia, India and China. There, where new markets are taking root, to ensure that customers receive support and guidance on the spot. In a globally-organized regional sales network, NETZSCH guarantees that you will always be working with highly-qualified NETZSCH specialists. This means that you will receive guidance and support locally from NETZSCH specialists in the areas of sales, service, design and process engineering.

Always a step ahead - for more than 100 yearsBusiness division Grinding & Dispersing is part of a strong, family-owned enterprise established in 1873, whose philosophy calls for quality leadership in every regard. All three business units of the NETZSCH Group - “Analyzing & Testing”, “Grinding & Dispersing”, “Pumps & Systems” - meet these requirements. Our customers have made us what we are today: internationally soughtafter specialists for everything related to the areas “wet and dry grinding”, “mixing and dispersing”, and “de-aeration and classifying”. Constantly changing demands have led not only to a comprehensive range of machines, but primarily to a unique pool of applications and processing knowledge. This puts us in the position to make the visions of our customers a reality - unbureaucratically, innovatively and economically on into the future. You set the specifications, we make the machines.

stem because it offers clear advan-tages: Very narrow particle size distribution that is easier to control (filtering capability, color intensity, etc.); highest level of productivity; total reproducibility of the results and fewer grinding beads required.

ZETA® System is designed with a smaller grinding chamber (about half the size of that of a disc mill, com-parable energy input), a model for circulation mode and agitator pegs for the greatest efficiency. Recently, NETZSCH has launched

the largest mill in recirculation ever built, capable of processing up to 10,000 liters batches. It completes the mill range as for chamber sizes, from the 0.62 lts LABSTAR laboratory mill to the 400 lts LMZ ZETA® 400.

Acimac Handbooks - Edition 2014/2015

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