Introduction
In the field of sanitary ceramics manufacturing, many companies often fall into a misunderstanding: buying the world's most advanced high-pressure grouting equipment or energy-efficient kilns is equivalent to mastering the password for efficient production.
Sanitary ceramics manufacturing is essentially an extremely complex fluid rheology and thermal dynamic balance system.The whole plant planning of ceramic sanitary ware is not only the physical display of equipment, but also the core outline that determines the enterprise's production cost control, flexible release of production capacity, span of heat energy and power consumption, and intelligent expansion capability in the next five years. As a rare domestic closed-loop enterprise with "both high-end high-pressure equipment R & D and manufacturing capabilities and actual operation of a 1 million-piece sanitary ware factory,Based on decades of industry experience from TOTO and Huida's founding teams, Sunland will deeply deconstruct the whole factory planning for you to determine the next five years of modern sanitary ware factory.
I. Cost remodeling: eliminating "invisible logistics costs" and high finishing losses
In the traditional molding workshop,The unnecessary handling of unfired bodies is the core culprit of the waste of financial costs.
If the space layout between the grouting area, the finishing line, the glazing area and the drying kiln is crossed and repeatedly transported, the blank is prone to micro deformation and stress concentration invisible to the naked eye during repeated transportation. These defects cannot be detected before Plain firing or glaze firing,However, after the kiln will directly erupt into pinholes, cracks, resulting in scrap rate out of control.
Perfect whole plant planning realizes the one-way closed loop from mud input, compact forming, automatic glaze spraying robot to kiln entry by introducing the seamless connection between automatic conveying chain and high-pressure grouting line. Reduce the frequency of traditional manual handling by more than 70%,It not only maximizes the liberation of Labor, but also fundamentally reshapes the comprehensive cost advantage of the factory by controlling the tolerance of the finished product within the industry limit of 1%.
II. Capacity release: jump out of equipment stacking, pursue "de-technologization" and high system delivery stability rate.
Simple equipment buyers tend to calculate only the "nominal capacity" of a single machine ",The mature whole plant planners pay more attention to the stability rate of the comprehensive delivery period of the system.
The "barrel effect" kills the production capacity: If your molding end adopts high-efficiency high-pressure grouting, the single-piece molding time has been greatly reduced to 3-5 minutes; However, if the stability of the subsequent formula sizing agent, the speed of the vacuum degassing system or the drying kiln cannot be accurately aligned with the molding end in the whole plant planning,Efficient equipment will be reduced to expensive furnishings.
When planning the whole plant, Sunland will make accurate capacity equipment ratio according to the customer's order structure. For large-scale orders of millions of pieces, configure high-pressure grouting lines with long service life (more than 10000 times); For multi-variety, small-batch complex type or highly difficult intelligent toilet, split toilet, large-size FFC shower room base,It is recommended to mix the line with a more flexible, single-mode medium-pressure resin molding system that can be independently connected to the line. This kind of process complementarity can make new employees take up their posts quickly, get rid of the extreme dependence of traditional plaster molds on senior skilled workers, and realize the efficient release and flexible adjustment of workshop production capacity.
III. Spanning of Energy Consumption: Top-level Design of Kiln Waste Heat Recovery and Green Process
Sanitary ceramics manufacturing is a typical carbon-intensive industry,The fuel power consumption and energy consumption of the kiln directly determine the gross profit margin of the factory in the next five years.
The hard injury of energy waste: Modern tunnel kiln and shuttle kiln in the continuous firing process, will produce a large amount of high temperature flue gas and cooling zone waste heat. If the heat is not recovered by reasonable pipeline planning at the beginning of the whole plant, it is directly discharged into the atmosphere,It will not only cause a huge waste of resources, but also face increasingly stringent international green carbon tax penalties.
At the beginning of the layout design of the factory, we will write the waste heat preheating and comprehensive utilization system of the self-built kiln into the blueprint of the factory. Through the insulated pipeline, the cold air and flue gas waste heat extracted from the kiln firing zone is fed back to the high-solid slurry preheating system and the drying workshop,Supplemented by green auxiliary materials such as sodium-free debonding agent, the waste water discharge is reduced by 40%, and at the same time, it is easy to save hundreds of thousands of dollars of fuel expenses for the ceramic factory, which is directly converted into the net profit of the factory.
IV. Expansion Capability: Reserving Seamless Interface for "Intelligence and Category Switching" in the Next Five Years
The aesthetic and product categories of the global bathroom market (such as conjoined toilets, wall-hanging toilets, back-to-wall toilets, integrated Cabinet basins, etc.) are rapidly iterating.In the third year after the establishment of the factory, many factories fell into the embarrassing situation of "no change, no place to plug the machine", precisely because of the lack of forward-looking expansion capacity planning.
Long-term account reserved for extended interfaces: in the whole plant planning of Sunlets' digital design (CAD/CNC/3D scanning), the pipe diameter of each workshop span, strong and weak current route, gas path main pipeline,A surplus factor of 30%-50% will be reserved.
When the global market drifts to intelligent temperature-controlled toilets or large and difficult pots in the next five years, or when you need to upgrade manual glaze spraying to automatic glaze spraying robots, your factory does not need to stop production or break ground to destroy the factory structure.The sustainable evolution and rapid expansion of the plant can be achieved by seamlessly connecting new modules and new forming equipment to the reserved engineering interface.