Porcelanosa uses Sacmi technology to expand its large tile and slab plant

For the expansion of Plant 4, Sacmi has supplied a second Continua+ line, a dryer and a Maestro kiln, as well as advanced logistics systems with automatic stackers, LGVs and digital tracking.

Three years after starting up Plant 4, dedicated to the manufacture of large porcelain stoneware tiles and slabs, Porcelanosa has recently completed its expansion with Sacmi technology. Now, a complete production line has been launched, duplicating and developing the initial investment.

It consists of a forming line with a PCR2180 compactor from the Continua+ family, an E7P200 multi-layer dryer and a next-gen FMA217 Maestro kiln. Porcelanosa has thus raised plant output capacity from the current 1,300,000 m² to 2,400,000 m².

Installation of the third line takes the total surface area of Plant 4 to over 48,000 m². In addition to the 36,000 m² occupied by the first two lines, a further 12,000 m² has been obtained from the adjacent warehouse that houses Logistics Center 2.

Expansion hasn’t just raised production volumes: Sacmi-supplied automated handling and logistics systems have also delivered greater industrial versatility. Combined, these solutions allow Porcelanosa to adapt its production set-up quickly and respond to market trends more effectively.

In addition to Continua+, the global benchmark for slab and sub-size manufacturing, the project also saw Porcelanosa make a giant leap forward in terms of plant automation and logistics. In parallel with the expansion, Sacmi worked with Porcelanosa to develop a comprehensive automation project for fired product handling and storage, ensuring flexible control of deliveries to the warehouse and/or finishing facilities. Sacmi supplied 5 specially configured LGVs capable of stacking and storing slabs - anywhere in the factory - to an above-ground height of up to 7 meters, without any need for supports.

Sacmi also designed and provided the plant’s new tracking and supervision system. Each slab leaving the plant is marked with a Data Matrix code and tracked continuously, regardless of the required type of processing or reprocessing. This means each individual phase can be traced and ensures continuity of tracking in the various storage locations and after sorting.

With this project, Sacmi confirms its status as a crucial ceramic industry partner, both as a provider of complete slab and sub-size production solutions and as a leading proponent of cutting-edge plant logistics systems, from automatic flow/handling control to digital tracking (ID-Tiles).