System Ceramics to build Delta Group's new Industry 4.0 factory

The plant will be equipped with four Superfast presses with a total production capacity of 66,000 sqm/day. System Ceramics will also supply the four glazing and decoration lines, the sorting, storage and handling equipment and Prime software

The new factory owned by the Delta Group of Rio Claro (Sao Paulo), one of Brazil’s leading porcelain floor and wall tile manufacturers and a major player in Latin America, will be built by System Ceramics. The plant is due to start up in 2022 and will be one of the most advanced facilities anywhere in South America. It will be equipped with latest-generation Industry 4.0 technologies capable of combining maximum production efficiency with the most innovative, large-format materials, thereby expanding the Delta Group’s portfolio and strengthening its leadership in the high-end segment.

The new factory will be centred around the Superfast mouldless pressing technology from System Ceramics. It will have two complete lines equipped with 4 Superfast presses with a total production capacity of 66,000 sqm/day. The machines feature a scrap recovery system and complete dryer loading and unloading management and also guarantee significant energy savings.

For the glazing and decoration department, System Ceramics will supply four complete lines, each equipped with a Creadigit XXL digital printer and a Check Point inspection unit for unfired tile quality control.

System Ceramics will also supply the end-of-line equipment, including four sorting lines and two Maxi Compensers custom-designed for Delta (super king size), as well as the automatic fired product handling system based on AGVs.

The Delta Group’s new plant will also be a fully integrated and connected ultra-modern smart factory equipped with the Prime software services platform, the system developed by System Ceramics to organise the information flows of entire plants and monitor the energy consumption of the various departments. The Prime software can be used to digitalise a ceramic manufacturer’s production environment by providing a complete overview of production processes, an essential requirement for guiding operators’ decision-making processes and constantly improving production performance.

For System Ceramics, this latest challenging project for Gruppo Delta consolidates a partnership between the two companies that has been in place for several years now, thanks to the Italian group’s ability to act as a reliable supplier renowned for its constant commitment to product and process innovation. The System Brasil subsidiary located in Rio Claro has also been providing a timely service to Brazilian customers for many years.