REFRESH, UPGRADE, PERFORM · REFRESH, UPGRADE, PERFORM SACMI provides a wide range of burners, suitable for all fuel types, specially developed for ceramic products. The burner families

REFRESH, UPGRADE, PERFORMRevamping Kits and Digital Solutions for quality improvement and energy savings

REFRESH, UPGRADE, PERFORM

Optimized consumption management

YOUR ADVANTAGES

• Broad working range

• More stable flame detection

• Better flame speed

• Compatibility with all burner block types

• Burner body suitable for use with hot air

• Simple head cleaning

BURNERSSacmi for energy savings

Complete range of burners for all fuel types.

Heads specially designed for different capacities ensureoptimal combustion in all working ranges.


SACMI provides a wide range of burners, suitable for all fuel types, specially developed for ceramic products.

The burner families most commonly used with gaseous fuels are:• PLC 50 kW series• PL7 25 - 50 kW series. This series also includes a version with calibrated diaphragms (for precision control of air

and gas flows) mounted directly on the burner body

Sacmi Forni also provides a kit for converting existing PL7 APG, PRO or DUAL burners into PL7 L030 burners. The kit was designed in order to maintain the existing burner body and therefore contain the cost of conversion.

• PLS 30 and 75 kW series• PL8 65, 90, 130 kW series. This series also includes a version with calibrated diaphragms (for precision control

of air and gas flows) mounted directly on the burner body• PL9 300 kW series

Lean gas:• PLP 50 kW series

For liquid or dual (liquid + gaseous) fuels we provide the following series:• BBH 40kW series• RPR and RFI 80 and 90 kW series (used on heavy clay kiln roofs)

BURNERSTechnical features



YOUR ADVANTAGES

RECOVERY SYSTEMSacmi for energy savings

Final cooling air retrieved for use as combustion air.

Air is filtered and sent to the combustion air fan before being heated further via an exchanger in the fast cooling zone, reaching a temperature of between 150°C and 250°C.

• Immediate savings of up to 10%

• Simple installation

• Combustion air temperature up to 250°C


Cooling air may have a temperature that ranges from 120°C in the case of cooling with a single chimney to 250°C in the caseofdualcoolingcircuits.Airisdrawndownstreamfromthefanandsenttoafilterbeforebeingmadeavailabletothe combustion air fan.

If the air temperature exceeds 150°C it is necessary to check that fan and burners are suitable for high temperature use.

Ifthekilnhasonlyasinglefananewonecanbeinserted,thusseparatingthefirsthightemperatureextractionhoodsfromthemaincircuitandfromthefinallowtemperatureones.

RECOVERY SYSTEMTechnical features



YOUR ADVANTAGES

CONSUMPTIONMONITORING KITSacmi for energy savings

Device for real-time reading of gas consumption.

The data is shown on the operator control panel.

• Can be installed on dryers and kilns

• Real-time gas consumption monitoring

• Instantaneous pressure and temperature readings

• Easy calibration


The kit consists of gas pressure and temperature control devices. The connection kit lets users monitor real-time consumption on the kiln control panel.

CONSUMPTION MONITORING KITTechnical features



YOUR ADVANTAGES

• Flexibility: volumes can be set according to the product

• Consumption optimisation

• Reduced consumption if there is a gap in production

• 3 independent macro-zones

CONTROLLED-AIR KILNSacmi for energy savings

The combustion system is divided into 3 macro-zones, each of which supplies a specific kiln zone: pre-heating, pre-firing and firing. The operator panel can be used to adjust air flow to burners in specific zones according to recipe, product and kiln conditions.

Maximum efficiency is obtained by combining this modification with the oxygen analyser to optimise combustion air under all conditions and, consequently, optimise product quality and consumption.


SERVE FOTO

CONTROLLED-AIR KILNTechnical features

The combustion air circuit is modified to create 3 fuel feed macro-zones. Each macro-zone is, in turn, sub-divided into an upper branch and a lower one and each branch has a motorized valve connected to a pressure transducer. The system is completed by installation of an inverter on the fan and a pressure transducer on the main duct to keep circuit pressure stable under all operating conditions.

The system is managed via a control panel, ensuring repeatability of settings and letting the user differentiate opening in the different zones according to production requirements. In the event of a gap in production valve aperture can be adjusted to a pre-defined setting.



YOUR ADVANTAGES

• Immediate savings

• Control system maximises the economic advantages

• Fast return on investment

• Complete integration with existing plants

• Suitable for all kilns and dryers, horizontal and vertical

• Minimal maintenance

RECOVERY FROM KILNTO DRYER (RVE)Sacmi for energy savings

Cooling air retrieved and then fed towards the dryers (RVE).

The retrieved air is used as drying air, providing immediate savings.


Theairisdrawnfromthefinalcoolingchimneybyafanandsentviaaninsulatedducttothedryers.Theboosterfan is equipped with an inverter and, thanks to the pressure transducer mounted on the duct downstream from the fan itself, the user can control transfer flows. The control panel is independent; this means the RVE system can be installed on any machine.

System parameters are monitored constantly by software to maximise savings without having to alter production cycles.

RECOVERY FROM KILN TO DRYER (RVE)Technical features



YOUR ADVANTAGES

• Inverter for every recirculation and fume fan

• Working frequency setting for every recipe

• Cycles controlled according to product size and thickness

• Energy consumption optimisation

• 20-30% less electricity consumption

ENERGY MANAGEMENTSYSTEM (SEM)Sacmi for energy savings

On horizontal dryers, inverters are installed on the recirculation and chimney fan motors to optimise energy consumption according to the production recipe.

Completing the system is a chimney humidity probe; this supplies a key adjustment parameter.


OPERATING POINT WITHOUT INVERTER

SHUTTERING WITH INVERTER-CONTROLLED ADJUSTMENT (40Hz)

RPM 1916 1531ABSORBED POWER (kW) 12.7 7.7WORKING TEMPERATURE (°C) 160 160

The SEM system consists of a set of additional adjustment components and functions that let you optimise dryer electricity consumption under different operating conditions. To make dryer operation more stable, the humidity probe is not placed in automatic adjustment mode; however, it is extremely useful in determining the correct operating point and thus optimising thermal consumption of the dryer.

Fan speed control is automatic and linked to the recipe, making the system highly flexible and allowing management of extremely different cycles according to size and thickness while optimising energy consumption at all times.

ENERGY MANAGEMENT SYSTEM (SEM)Technical features

EXAMPLE TABLE


Process consistencySelf-tuning

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YOUR ADVANTAGES

• complete control of piece planarity

• all parameters are set via recipe

• volume control if there is a gap in production

• flow control via fan inverter

• adjustment flexibility above and below the roller bed

FAST COOLINGMANAGEMENTSacmi for enhanced process control and quality

Modification of Fast Cooling by separating the upper and lower zones and making them independent, with the possibility of further separation into two distinct zones.

All Fast Cooling is controlled automatically via the operator control panel.


Intervention involves modification of the fast cooling duct by separating the upper and lower circuit; both circuits mount a motorized valve which is controlled via the operator panel.

Further modification to the duct can allow the creation of two separate fast cooling zones. Each zone has a general motorized valve which is controlled by a thermocouple; it also has two motorized valves with position control, one for the upper channel and one for the lower channel. To complete the system an inverter is fitted on the fan and a pressure transducer fitted on the main duct.

All regulators and valves are controlled via the operator panel.

FAST COOLING MANAGEMENTTechnical features



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YOUR ADVANTAGES

• temperature control under all conditions

• automatic burner on/off control

• complete control of piece size and planarity

• temperature uniformity over cross-section, even at low temperatures

• automatic control in the event of a gap in production

BURNER IN FAST AND INDIRECTCOOLING ZONESSacmi for enhanced process control and quality

Burners in fast cooling and indirect cooling to control temperature during transitory stages and in the event of a gap in production.


Modification involves installation of burners below the roller bed in the Fast Cooling and Indirect Cooling zones. Burners are controlled and switched on/off automatically. All parameters can be set via the operator panel.

The combustion system is modified by lengthening the burner service ducts.

BURNER IN FAST AND INDIRECT COOLING ZONESTechnical features



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YOUR ADVANTAGES

• Process stabilization

• Automatic valve opening control

• Setting via recipe

• In-kiln stability at all times, even if there is a gap in production

RCC VALVE AUTOMATIONSacmi for enhanced process control and quality

Automation of the valve in the extraction hood located at the end of indirect cooling.

The valve is controlled via a pressure transducer positioned in indirect cooling.

YOUR ADVANTAGES


The valve positioned on the hoods at the end of indirect cooling is motorized to allow control of valve opening via a pressure transducer installed in Indirect Cooling.

The pressure setting is established in the recipe and opening is controlled by the PLC.

The system ensures in-kiln stability at all times.

RCC VALVE AUTOMATIONTechnical features



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YOUR ADVANTAGES

• Automatic blowing control

• Centre-to-wall temperature uniformity

• Planarity control over cross-section

• Parameters set via recipe

AUTOMATICCOOLING CONTROLSacmi for enhanced process control and quality

Automatic blowing control system in Fast Cooling.

Insertion of ceramic blowers in the roof and wall-mounted blowers beneath the roller bed allows correction of planarity differences between the middle of the kiln and the walls.

YOUR ADVANTAGES


The system involves installation - in the fast cooling zone - of ceramic ducts on the roof and blower pipes beneath the roller bed. Roof blowing focuses on the central section of the channel to cool the surface of centrally positioned tiles.

Side blowers are installed under the roller bed and have the purpose of cooling the undersides of tiles near the walls. The result is the evening out of temperature differences over the cross-section and correction of piece planarity differences from centre to sides.

The project mainly concerns wide-mouth single-layer tile kilns. Both roof ducts and wall blowers are fed with air from the fast cooling circuit: both feature a modulating valve through which air flow can be regulated. Both valves are positioned according to the recipe, thus ensuring the system starts automatically only when really needed.

AUTOMATIC COOLING CONTROLTechnical features



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YOUR ADVANTAGES

• Optimised combustion (thus avoiding operation with excessively high reduction parameters)

• Energy savings

• Improved manufacturing quality (especially with light coloured products or those sensitive to or influenced by

changes in oxygen content)

The oXIeye system is designed to be installed on all existing Sacmi Forni machines with EwS 600, EwS 114, EPCEBP Praktico Supervisors and Hercules.

The oXIeye System allows constant monitoring and recording of the percentage of oxygen in the roller kiln combustion chamber. The data is displayed on the existing Supervisor.

OXYGEN ANALYSERSacmi for enhanced process control and quality


OXYGEN ANALYSERTechnical features

Using O2analysers,theoXIeyesystemisinstalledalongthepre-heatandfiringzones.Theanalysers,inadditiontoa connection with the displays, are network-connected to the kiln control computer (integrated system) with self-regulating instruments. The O2valueismonitored,displayedandrecordedinthefieldandontheexistingSupervisorlike any other thermal adjustment/display zone. It can also be called up in the running, trend and recorder sections.

For O2 monitoring zones it’s possible to establish a set point and minimum/maximum alarm thresholds (% content) on the recipe. This allows comparison between detected value and set point to provide a visual cue for the operator.

The oXIeye System consists of the following equipment items:• Probes with Zirconium Oxide cell for oxygen content analysis directly in the combustion chamber• Field transmitters that convert signals from the probe and show them on the high-brightness LED display• Shielded connection lead• Materials for modifications to the existing electrical panel:• Set of materials to modify the electrical panel• Thermoregulators / PLC analogue cards - Software upgrade• Flash-USB for installation of modification on PC• Instrument power leads and shielded signal leads• Raceways



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YOUR ADVANTAGES

• Outgoing tile temperature reduced by up to 25 °C

FINAL COOLING BOOSTSacmi for enhanced process control and quality

Final cooling blowing circuit boosted to reduce the temperature of tiles exiting the kiln.


FINAL COOLING BOOSTTechnical features

The final cooling blow circuit is boosted by replacing existing blower pipes with dual-feed pipes and installing new lower and upper manifolds; flow rates of intake and blowing fans are checked to see if flow is sufficient or whether the fans need replacing.



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YOUR ADVANTAGES

• Temperature control in the pre-kiln

• Elimination of breakages at kiln infeed

MOTORIZED HOODIN THE PRE-KILNSacmi for enhanced process control and quality

A motor-powered extractor hood is installed on the pre-kiln roof and/or floor in the last low module to introduce ambient air into the kiln chamber.Valve opening is thermocouple-controlled.


A motor-powered extractor hood is installed in the last low module of the pre-kiln. Its opening is controlled by a thermocouple positioned in the initial kiln modules.

Introducing cool air into the channel lowers pre-kiln temperatures, thus preventing any bursting or lateral cracking that might be caused by residual moisture content in the tile.

It also results in lower temperatures at the chimney.

MOTORIZED HOOD IN THE PRE-KILNTechnical features



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YOUR ADVANTAGES

• Automatic temperature control

• Consistent outgoing piece temperature

• Controlled temperature also in the of event line stoppages

• Piece temperature suitable for digital decoration

• Versatile module: can also be used as a drying module

DRYER:STABILISATION MODULESacmi for enhanced process control and quality

The insertion of a new stabilisation zone in final drying modules ensures consistent outgoing material temperatures. The temperature is set via the software and controlled automatically; this ensures that pieces exiting the dryer are at a suitable temperature for subsequent stages. In the event of a line stoppage the temperature is kept constant.


Digital decoration requires temperature control of pieces leaving the dryer.Depending on the size of the plant, the stabilisation module can be obtained by modifying the existing dryer or inserting a new module.Transforming a dryer module into a stabilisation module involves modifying the fume expulsion circuit with the introduction of an independent chimney and modification and motorization of the exhaust air valve (controlled by a thermocouple positioned on the recirculation duct).

DRYER: STABILISATION MODULETechnical features



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YOUR ADVANTAGES

• Real-time sensor data

• Two warning threshold settings (pre-alarm and alarm)

• Activation of warning light and beeper if thresholds exceeded

• Line stoppage in the event a warning

• Compressed air self-cleaning system

• Process stabilization

MOISTURECONTENT SENSORSacmi for enhanced process control and quality

A radio frequency-based instrument ensures continuous reading of tile moisture content.

This sensor can be installed at any point on the line and comes complete with a PC that displays moisture content readings. Warning thresholds can be set.

The system can be supplied with a thermogravimetric analyser for calibration purposes.


MOISTURE CONTENT SENSORTechnical features

Measuring probe placed upstream from kiln load feed system. A small touch-screen PC is positioned alongside the probe for moisture content reading and control purposes. Moisture content probe electronics are located directly on board the machine near the touch-screen PC.

The detection system consists of:

• Moisture content control sensor• A support to attach the sensor to the line• Display with stand or support• Industrial PC• Cooling fans• A base module with warning beeper/light• Measurement synchronism photocells (on passage of the material)• Clamps, leads and wiring accessories


EasinessReal time info

YOUR ADVANTAGES

• Major plant modernisation thanks to integrated data collection and control systems

• Production and consumption data can be shared with company management systems

• Coordinated automation to plan production

• Remote/tele-assistance systems

• Productivity and plant problem analysis

4.0 SYSTEMSSacmi for easiness and real-time info

Industry 4.0 provides the perfect opportunity to make full use of our data control and management systems.

Our 4.0 systems are modern, compatible with the most widely used data platforms and ensure machines can be used flexibly; they also ensure excellent usability of collected data.


Our 4.0 systems provide:

• Network-connected PLC systems for automation and worker/machine safety

• A simple, user-friendly man-machine interface that can be used by workers in any situation (even when personal protection items need to be worn)

• Continuous monitoring of working conditions and process parameters via suitable data sensors

• Adaptive-behaviour system control in the event of any process drift

• Remote tele-assistance service (automatic or worker-supervised) allows modification of process parameters and updating of control software

• PC/SCADA (Supervisory Control And Data Acquisition) system allows control, monitoring and supervision of the machine via a connection network

• Complete, exhaustive production and consumption databases made available to corporate network and to management software via Modnet or Database SQL protocols

4.0 SYSTEMSTechnical features

Documents

REFRESH, UPGRADE, PERFORM · REFRESH, UPGRADE, PERFORM SACMI provides a wide range of burners, suitable for all fuel types, specially developed for ceramic products. The burner families