CONTINUA+ compaction technology for slabs and tiles

The benchmark technology for variable-size, variable-thickness slab and tile manufacturing.

WHY CHOOSE CONTINUA+?

More Productive

CONTINUA+ is the most efficient, highest-productivity technology for the accurately managed manufacture of ceramic slabs and tiles, also producible with traditional bodies. The slabs are, in fact, formed without using a traditional press or mould, ensuring maximum flexibility in terms of size and thickness. Scrap is always below 3% and recyclability is 100%. CONTINUA+ seamlessly integrates the powder forming phase and subsequent digital decoration. The key strengths of this exclusive process are high quality texturing and unrivalled surface shine.
 

More Connected

CONTINUA+ is natively connected to H.E.R.E (Human Expertise for Reactive Engineering), the information flow organisation system that provides a comprehensive overview of ceramic plant production processes, maximising Digital Manufacturing 4.0 potential.
What’s more, CONTINUA+ is equipped with COMPUTER VISION systems that optimise surface decoration downstream from forming (SVV), making on-slab details even sharper.

More Sustainable

Another key CONTINUA+ advantage is certified sustainability: installed electrical power requirements can be cut by a factor of six (the SACMI PCR2000 runs on just 80 kW), effectively containing CO2 emissions and related costs. In addition to energy savings, very little hydraulic oil is consumed, ensuring further maintenance and waste disposal savings.
Furthermore, CONTINUA+ needs no foundations for its installation and is, when running, silent, vibration-free and dust-free, features that make this technology ground-breaking also in terms of environmental friendliness.
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MAIN TECHNICAL FEATURES

TECHNICAL FEATURES PCR 2120 PCR 2000 PCR 2180 PCR 3000
Width (fired) - mm 750 - 1200 900 - 1600 1000 - 1800 1000 - 1800
Thickness (fired) - mm 3-20 3-20 3-20 3-30
Maximum productivity (fired) - m²/day (*)
16000 19100 21500 21500
Pre-press applications - n° 1-5 1-6 1-5 2-5
power consumption - kWh/m² 0,06 0,06 0,06 0,06
PCR: installed power - kW 80 80 (**) 105 87
PCR: upper belt changeover time - min <30 <30 <30 <30
PCR: oil quantity - l 120 120 200 200
TPV: minimum longitudinal dimension - mm 300 300 300 400
TPV: minimum crossways dimension - mm 300 300 300 400

(*) fired values, shrinkage 8%, the machine runs at max. speed 24/7, using its entire effective width (without considering any downstream bottlenecks)

(**) Productivity attainable with the high speed kit: 9m/min (optional)

SACMI technology for ceramic trends

APC

APC

CONTINUOUS POWDER FEEDER

The APC is installed in the initial section of the Continua+ line. This unit lets manufacturers create products with effects that reproduce the layers, veins, stains and sedimentation patterns seen in natural stone and marble. It does so by making use of the separation, overlap and flow of materials of different colors and/or types; the latter are deposited on a belt in the upper part of the machine and subsequently fed into a vertical hopper. The unit is also used to create through-body veining effects.

APB

APB

POWDER-ON-BELT DEPOSIT SYSTEM

This device deposits a layer of powder on the main belt of the CONTINUA+ line. It can be used to deposit the base powder. However, if installed downstream from another feeder, it can deposit a layer of material different from the one deposited upstream. The APB is fed with plain color powder while the APBM variant also has a device that can mix 4 colors. It can be used to deposit both a full-body layer or a surface layer.

DMS

DMS

MICRONIZED POWDER, GLAZE AND FLAKE DOSING UNIT

The DMS can apply ceramic materials such as micronized powders, glazes or flakes over the entire slab surface. Positioned upstream from the PCR, it applies a layer of material on the powder base that moves along the conveyor. The machine is designed to produce slabs and tiles decorated with differently colored grains, flakes and micronized powders.

DDD

DDD

DIGITAL DECORATION SYSTEM

A digital decoration system for controlled surface application of powders on the CONTINUA+ line, this unit lets manufacturers apply different types of ceramic powder without any restrictions on particle size distribution or color. It combines the flexibility typical of digital systems with the freedom to use the materials typically used by the ceramic industry. The DDD lets manufacturers create a broad range of graphic effects, hues and decorations that enhance ceramic surfaces and thus boost the aesthetic quality of the finished products.

PCR

PCR

ROLLER COMPACTOR PRESS

The PCR is the core machine of the system: it performs continuous compaction of the incoming powder layer, using two motorised belts with converging axes and a set of intermediate drive rollers. The belts are driven by electronic speed control and have adjustable compaction geometry. The compactor body is set up to facilitate the replacement of the upper belt, by opening one side of the machine and some pneumatic cylinders, which lift the belt and move it in the suitable position.

TPV

TPV

ON-THE-FLY TRANSVERSE CUTTING MACHINE

Located downstream from the CONTINUA+ line compactor, this unit performs on-the-fly transverse slab cutting (i.e. without having to change the feed rate of the compacted unfired slab). It can also cut the slab longitudinally. Thanks to highly versatile configuration of the number of cutting heads, this machine lets producers create a wide range of unfired sub-sizes. Control is fully digital and done via the on-panel recipe.

RRS

RRS

SCRAP SHREDDER ROLLER UNIT

The RRS machine conveys slabs/tiles exiting the TPV towards the downstream line. It shreds the very small quantities of material trimmed off by the TPV and makes them available for transfer to the various recycling systems.

MDX

MDX

X-RAY DENSITY MEASURING DEVICE

The MDX is a process control system that performs real-time data measurements on just-formed, unfired slabs and tiles. It lets manufacturers obtain the correct slab/tile density quickly at the start of a batch. As production continues it executes real-time monitoring of thickness and density at various points on the slab/tile, allowing fast detection of any deviations. It does so by continuously measuring (without stopping production or damaging the slab) compacted slab density and thickness with a low-power X-ray system. MDX offers excellent reading accuracy and reading repeatability and has very low X-ray emissions.

SVV

CERAMIC SLAB THROUGH-BODY VEINING INSPECTION SYSTEM

Integrated on the Continua+ slab manufacturing line, the SVV vein 'vision' system performs a complete inspection of the surface of every single slab to obtain detailed information on the decoration. The SVV system is particularly effective when used in the process that forms slabs with through-body veining. With this type of decoration the system detects the exact position of the veins and sends the information to the digital decoration unit; the latter then self-adjusts to ensure continuity between the veining on the upper surface and that which runs through the body of the slab.

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