Celima-Trebol once again chooses Sacmi-Gaiotto solutions

Celima-Trebol, one of the top South American manufacturers of ceramic tiles, porcelain sanitaryware, taps and accessories with more than 50 years of experience, has made new investments in the sanitaryware sector.

To raise output and boost quality at its plant in San Martin De Porres near the capital Lima, a facility that already has an annual production capacity of 3.5 million pieces/year, the Peruvian company has commissioned Sacmi to supply two twin automatic glazing lines with Gaiotto GA/OL robots.

Unlike the GA 2000 robotic glazing line installed in the same facility in 2014, these new lines are equipped with Gaiotto’s new 7WD offline programming software, a real innovation in terms of production efficiency and finished product quality. The software is able to process all glazing programs off-line, thus eliminating the downtimes associated with production testing and increasing the number of actual hours of production. It also guarantees precise control of the quantity and thickness of delivered glaze, thereby minimising overspray on the workpiece and/or the need for multiple passes over areas that have already been sprayed.

Another interesting aspect is the layout of the two glazing cells designed to optimise the production flow in keeping with the new principles of lean manufacturing. The lines are positioned close to the kiln car loading track by means of bar conveyors running parallel to the direction of travel of the cars. Each individual glazing line consists of a belt conveyor for manual or servo-assisted loading of inspected pieces and an angular transfer unit that loads the pieces on the carousel before being handled by a 9-axis robot. The order also includes an automatic foot cleaning system mounted directly on the belt conveyor, which in turn feeds the bar conveyor immediately prior to car loading in the kiln.

The integrated glazing stations are equipped with software that allows the robot to interface with the Ethernet and thereby make use of advanced Sacmi-Gaiotto tele-assistance services.