In the intelligent production base of Guangdong Jianyi (Group) Ceramics Co., Ltd. (hereinafter referred to as "Jianyi Company"), the production line is working in an orderly manner. There are only a few workers in the workshop busy on the automated assembly line... "The company adopts The digital intelligent management system enables full-process intelligent manufacturing, greatly improving production efficiency and reducing labor costs," said Huang Shanping, general manager of Jianyi Company's intelligent production base.
Jianyi Company was established in 2002. It is an enterprise focusing on the research and development, production and sales of ceramic tiles. Since its establishment, the company has always focused on intelligent manufacturing, technological innovation, and green production, focusing on building an intelligent production base, and continuously polishing products with ingenuity. At present, the company has been rated as a national high-tech enterprise and a national green factory. Li Zhilin, chairman of Jianyi Company, said that the company hopes to use technological innovation to "intelligently manufacture" green ceramic products and replace natural stone with industrial "intelligent products" to reduce mining and better protect the environment.
Focus on intelligent production
Jianyi Company vigorously develops intelligent manufacturing and promotes intelligent production, which not only greatly improves production efficiency, but also fully meets the individual needs of consumers, taking the initiative in market competition.
Huang Shanping said: "The total investment in the intelligent production base of Jianyi Company is nearly 3 billion yuan. The production base has a total of 9 intelligent production lines, each of which is equipped with a glazing line of more than 500 meters long to automatically apply glaze to the ceramic body. Each production line is equipped with a glazing line of more than 500 meters long. The glaze assembly line is equipped with 36 digital printing machines, which can print on any relatively flat material such as ceramics. The registration accuracy error is less than 0.1 mm. The company uses advanced intelligent manufacturing technology, combined with inkjet and screen technology, to present the result. The exquisite texture of marble. "At present, the intelligent production base of Jianyi Company has an annual output of more than 23 million square meters of high-end marble tiles, with an annual output value of over 4.5 billion yuan.
Jianyi Company applies intelligent production methods to all aspects of ceramic tile production and manufacturing. Huang Shanping introduced that the material selection link is very critical for ceramic tile manufacturing. The raw materials for making ceramic tiles are mainly mineral raw materials, and the performance of each batch of raw materials fluctuates greatly. Therefore, ensuring the stability of raw material performance determines the quality of ceramic tiles. "The company applies the ridge material homogenization system and the plastic material slurry system to the intelligent production line, which not only greatly improves the stability of the raw materials, but also improves the production efficiency." Huang Shanping said.
In the ceramic tile firing process, whether the firing temperature can be accurately controlled often determines the final quality of the ceramic tile. In order to ensure the quality of ceramic tile firing, the "intelligent roller kiln" introduced by the company applies a digital intelligent control system throughout the entire process to control the temperature in the kiln and the sintering status of the ceramic tiles in real time, so that each ceramic tile can meet the standards set by the company. The flatness of intelligently produced ceramic tiles is controlled within 0.2 mm, the dimensional error is within 0.3 mm, and the water absorption rate is controlled within 0.1%.
ItemCurrently, Jianyi Company has implemented digital control from raw material processing to finished product delivery, established an industry-leading AGV (automatic guided vehicle) unmanned intelligent warehousing center, and achieved a high degree of automation in the production process through data analysis and intelligent management. At the same time, the company's intelligent production system can also adjust the production line in time according to the individual needs of consumers to achieve small batch and diversified production.
Committed to innovative technology
In the exhibition hall of Jianyi Company's company headquarters located in Chancheng District, Foshan City, Guangdong, various marble tiles with textures like landscape oil paintings come into view. Among them, a kind of marble tile called "Bihai Jialan" looks like a whole piece of natural stone from a distance after being laid, giving people a sense of natural atmosphere - this is the result of the "close joint paving technology" innovatively developed by Jianyi Company one.
Huang Haifa, the R&D director of Jianyi Company, said that traditional ceramic tile paving often faces problems such as tile hollowing, warping, and stretched porcelain (irregular cracks in the surface glaze layer). And it is easy to harbor dirt and evil people and practices. In order to solve these problems, the company pioneered the "tight seam joint paving technology" in 2018, changing the traditional seam paving to dense seam paving. On the premise of retaining the connection of the tile texture, the gap between the tiles is controlled to 0.5 Within millimeters. After using this technology, no matter how many pieces of tiles are laid, they will look like one piece, presenting a different aesthetic.
At present, Jianyi Company's "close seam joint paving technology" has obtained the support of more than 40 patented technology matrices. Huang Haifa said: "After years of development, this technology has been upgraded to the standard of ultra-dense joints, and the minimum gap between ceramic tiles can be reduced to 0.05 mm. At present, this technology has been widely used in a variety of products produced by the company."
In order to promote the implementation of "close joint paving technology", Jianyi Company launched the finished product delivery service of this technology to provide consumers with a one-stop ceramic tile decoration solution. In addition, the company has established more than 20 finished product delivery centers to assist terminal store operations and ensure the delivery effect of products using "tight seam joint paving technology".
According to reports, Jianyi Company has integrated its R&D model, invested a large amount of R&D funds, and continuously launched new projects and developed new technologies in response to market demand. In recent years, the company has established provincial innovation platforms such as the Guangdong Province Doctoral Workstation, the Provincial Industrial Design Center, and the Guangdong Province Science and Technology Expert Workstation to continuously improve its technology research and development capabilities and levels. The company has also established long-term strategic cooperative relationships with universities and colleges, and has cooperated in new materials and process technology research, achievement transformation, talent training, etc., forming an industry-university-research collaboration integrating product development, scientific research, test verification, promotion and application. Combined technological innovation system.
According to statistics, as of the end of 2023, Jianyi Company has accumulated more than 240 patents, including more than 60 invention patents, more than 30 utility model patents, and more than 140 appearance patents. Huang Haifa said: "Only through technological and service innovation can we continue to promote brand development."
Adhere to green development
In the factory of Jianyi Company, there is neither scrap nor billowing smoke, and dust does not fall to the ground.
Huang Shanping introduced to reporters: "In recent years, the company has continued to increase investment in the development of green, low-carbon and circular economy, actively promote energy conservation and emission reduction, the use of renewable energy, resource recycling and environmental protection, and through the introduction of advanced environmental protection Technology and innovative production processes have significantly reduced energy consumption and environmental pollution, making the production process more environmentally friendly. ”
Currently, the intelligent production base of Jianyi Company adopts building integrated photovoltaic (BIPV) design for photovoltaic power generation. The average annual photovoltaic power generation of the base is nearly 60 million kilowatt-hours, with an average annual saving of nearly 20,000 tons of standard coal and a reduction of carbon dioxide emissions. Nearly 54,000 tons, sulfur dioxide emission reduction of nearly 160 tons, equivalent to planting more than 2 million trees.
According to statistics, about 50% of ceramic companies in the country currently use "natural gas" as the main fuel. However, many ceramic companies only realize "coal to gas" in the kiln firing process, and the spray tower pulverizing process uses powder. Coal still causes environmental pollution. Jianyi Company fully implements the concept of green and low-carbon development and uses clean energy in the entire production process, directly saving about 20% of energy and reducing carbon emissions by more than 40%. At the same time, in terms of industrial sewage treatment, the production base of Jianyi Company uses a fully automated tower sewage treatment system. The solid waste recycling rate reaches about 99%, and the industrial sewage achieves 100% recycling.
In addition to using clean energy, Jianyi Company also reduces mining excavation by replacing natural stone with industrial "intelligent products". Huang Shanping said: "The monthly production capacity of one of the company's production lines is more than 280,000 square meters. Calculated based on 11 months of production per year, the annual output exceeds 3 million square meters, which means that more than 3 million square meters of stone raw materials can be reduced in a year. Mining volume. It can be said that the company has truly protected the mines by improving the production line.”
Over the years, Jianyi Company has adhered to green development and promoted intelligent manufacturing. The energy consumption per unit output value and industrial added value have been reduced, while product quality has continued to improve. Huang Shanping said, "The company will continue to practice the concept of green development, actively promote the application of green energy, and make new contributions to building a beautiful China and protecting green waters and green mountains." (Economic Daily reporter Zhang Jianjun)
