Gruppo B&T and Riwal collaborate on a sustainability project

Nuova Riwal Ceramiche has installed a new complete line at its Roteglia facility, with Gruppo B&T supplying state-of-the-art technology for the key stages of the process.

Energy efficiency and sustainability continue to play a pivotal role in the Italian ceramic industry’s development policies, with companies now needing to avoid fluctuations in gas costs and to comply with EU regulations on the circular economy and energy efficiency.

Against this backdrop, Gruppo B&T acts as a strategic partner in the construction of efficient and sustainable hi-tech plants based on a combination of raw material recovery systems and the use of hydrogen-methane blends to reduce CO₂ emissions.

The objective of maximum process sustainability featured prominently in the project recently undertaken for Nuova Riwal Ceramiche (Casalgrande Padana Group). For its facility in Roteglia (RE), the ceramic company commissioned Gruppo B&T to supply a complete porcelain stoneware production line featuring state-of-the-art pressing, drying, firing, finishing and automatic storage equipment.

Product forming is performed by SUPERA® Rapida, the high-speed, mouldless on-belt pressing technology which in the 18,000-ton version produces sizes from 60x60 cm up to 120x240 cm and thicknesses up to 20 mm. This line is also designed for the production of traditional sizes and achieves unique results in terms of high performance and reduced consumption and costs. For this purpose, Nuova Riwal Ceramiche has equipped SUPERA® Rapida with the patented Start&Stop® system, an innovative hydraulic control unit with pumps that can be adjusted according to the pressing cycle. This ensures very low levels of power consumption, resulting in a 50% energy saving compared to conventional presses.

SUPERA® Rapida uses an easily storable upper punch coated with extra-hard resin, enhanced by a patented perimeter containment system. This eliminates the need to trim the tile after pressing, resulting in the loss of only 1-2% of the weight of the tile, which in turn is fully recycled back into the process. By means of the Green Cut process developed by Ancora (the group company specialising in finishing technology), SUPERA® Rapida guarantees maximum flexibility and versatility in terms of product sizes and thicknesses while completely eliminating unfired waste.

Downstream of the press, Gruppo B&T supplied a 7-layer horizontal dryer, while the firing department was equipped with a Titanium®H2 single-layer roller kiln. With a combustion system based on a hydrogen-methane blend of up to 30% by volume, the kiln allows for a significant reduction in CO₂ emissions.

Located at the kiln exit is the TORNADO dry squaring line developed by Ancora. This technology also allows for a significant improvement in process efficiency and greatly reduces operating costs. It has a productivity of up to 20,000 sqm/day and is fully automated thanks to the new laser system that measures the removal process in real time and self-adjusts continuously.

“This partnership demonstrates our desire to steer the ceramic industry towards increasingly smart, sustainable and energy-saving solutions,” said Fabio Tarozzi, Chairman and CEO of Gruppo B&T. “This project for Nuova Riwal rewards our vision for a green, efficient ceramic production facility with low production costs. It incorporates all our latest technologies and sets a new standard in ceramic production.”