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New clean technology for the decoration of all kinds of ceramic surfaces, whether flat or textured, with a minimal use of raw noble materials (EWG)
Start date: Oct 1, 2004, End date: Sep 30, 2007 PROJECT  FINISHED 

Background Present technologies allow machine decoration of ceramics only for flat surfaces. Haut and bas-relief decoration is handmade, resulting in the exposure of the artisan to enamels and solvent fumes. Serigraph and air-brush technologies can only be used on simple surfaces and for simple decoration models. They also produce large volumes of waste - 100 litres of enamel waste for each colour used. Objectives The project explored a new technology to limit and even eliminate waste from the process of decorating ceramics. New equipment should allow the glazing of flat and textured surfaces using the minimum necessary quantity of glaze, eliminating dispersion of waste oxides and pigments, whilst producing a faultless result. It was expected that glazes used per product unit can be substantially reduced. Energy consumption was meant to be reduced by 20-30%, and exhaustible raw material consumption proportionately. The technology should also offer the potential for excellent, high definition results on non-flat surfaces, as well as painting of much larger pieces. Results The EWG (End Waste Glaze) project successfully implemented a pilot plant for glazing special tiles. The plant features a system that can automatically decorate non-planar surfaces of special tiles using a soft roll able to adapt itself to the surface's shape, thanks to a specific software for modifying and managing the images to be applied. This kind of operation could previously only be done by hand. The final tests carried out confirmed that the project objectives foreseen in the proposal were reached, and in some cases even exceeded. The results of a comparative study of a traditional glazing line and the new EWG line were as follows: the reduction in wasted glazes, estimated in the proposal at 95%, corresponding to about 1 200 tonnes/yr, actually amounts to 98%. the reduction in waste caused by printing faults, estimated at 5% corresponding to some 270 tonnes/yr, actually amounts to some 8%, or approximately 390 tonnes/yr; the glaze saving for deposition of constant thickness layers, estimated at 5-40%, actually amounts to some 73%; the reduction in direct energy consumption by the production line, estimated at 20-30%, actually amounts to up to 76% (depending to the images to be applied), even if the EWG machine requires a higher power installation; the reduction in indirect energy consumption, for the reduced enamels production, estimated at 95%, was actually some 80-90%; the saving in raw materials for producing ceramic glazes amounts to some 80% and the water saving to 80-90%.A technical solution has been found for 89 types of tiles decorated by the beneficiary. Product quality is comparable to tiles produced by the handmade technique, while the operating costs of the EWG line are lower than those of a traditional line. The plant is now working all day long and decorates 4 – 5 kinds of tile surfaces every day. The project will continue for three years after LIFE funding ends. Disclaimer : This « results » section should be considered as a draft until the Commission has completed its evaluation .
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