Production processes

Production Processes

Every production process pursues manufacture of a specific product at the lowest cost, highest quality, and in the most sustainable possible form. ITC has the relevant capabilities, both in human resources and in technical means, to enable ceramic companies to optimise their processes. Companies can thus lower production costs and raise profits, without losing sight of process sustainability.

1.

CONSULTANCY SERVICES AND TECHNICAL AUDIT

Technology consulting on issues raised by companies relating to their production process. In addition, technical audits in which the work methodologies in the different sections and laboratories of the production process are evaluated to detect company strengths and weaknesses and to draw up an improvement plan to resolve the detected problems.

2.

PROCESS IMPROVEMENT

Improved performance in the different production process stages (milling, pressing, extrusion, slip casting, drying, decoration, and firing). Remedying manufacturing defects (fractures, cracks, curvatures, surface defects, etc.).

3.

INDUSTRIAL PROCESS CONTROL AND OPTIMISATION

Continuous measurement, monitoring, and analysis of industrial variables (density, moisture content, thermal cycles, temperature differences in kilns and dryers, surface thermography, etc.) and automatic control of different manufacturing stages.

4.

EQUIPMENT DESIGN AND CONTROL

Design and construction of industrial equipment (scanner for non-destructive measurement of tile bulk density distribution, powder friction feeder in pre-formers, continuous kiln for curing brake pads, etc.). Design of facilities (silos) for handling particulate solids (avoiding arching and segregation).

INDUSTRIAL PROCESS SIMULATION

5.

INDUSTRIAL PROCESS SIMULATION

Predicción del funcionamiento de procesos y prototipado virtual de nuevos equipos. Simulación de sistemas en varios escenarios y análisis de los posibles cambios y sus consecuencias. Aplicable a equipamiento y procesos de conformado, secado, impresión por chorro de tinta, cocción, pulido, etc.

6.

PILOT PLANT

600 m2 of facilities and equipment for pre-industrial assessment of improvements in materials and compositions, and optimisation of manufacturing processes, aimed at verifying the feasibility of their implementation, minimising any reduction in production capacity.

7.

ADDITIVE MANUFACTURING

Consultancy services and development of projects for ceramics manufacture by additive manufacturing, colloquially known as 3D printing.
Adjusting materials, modelling, adaptation, and configuration of the design for the available techniques.

INDUSTRY 4.0

8.

INDUSTRY 4.0

Implementation of projects for transformation towards Industry 4.0. Consultancy services and accompaniment from the earliest stages, in which companies need to analyse their processes and infrastructures to assure data collection, to the most advanced stages, in which the use of tools and advanced systems enables information to be generated that will help improving and automating decision-making processes.