Deair technology Italy
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DEAIR TECHNOLOGY
Isostatic punch brand
DEAIR technology
The DEAIR isostatic brand pad was born from the need for a more effective deaeration of the ceramic mixture during the pressing phase.
This system introduces a series of relief valves distributed over the entire rubber surface.
The DEAIR system has multiple advantages under different aspects:
Increase in productivity: by eliminating or limiting the need for de-aeration phases, the press can work at a higher number of cycles / minute, we have obtained oscillating increases between 10% and 30% in the number of strokes per minute.
Longer life of pads and Iastrine: as already mentioned, thanks to the fact of distributing the expulsion of the gas during the deaeration phase in a more uniform way and on a higher vent surface, DEAIR isostatic punches have a duration of at least 50% longer. to the punches with simple perimeter vent. These advantages obviously also have an impact on the mold plates.
Energy saving: The press beam no longer has to make unnecessary up and down movements to obtain deaeration, significantly reducing the electrical energy consumption of the hydraulic unit as well as the overheating of the oil in the hydraulic circuit.
High resistance to bursting: The great accuracy of processing and the use of quality materials guarantee excellent anti-bursting qualities to the punches.
Flexibility in production: The time saved to carry out the pressing can possibly be exploited to optimize the mold loading / tile extraction phases.
Reduction of the migration of powders in pressing: Always taking advantage of the time saved to carry out the pressing, the speed of descent of the press crosspiece can be better modulated to reduce the flow of air from the center of the punches towards their perimeter, thus avoiding unwanted movements of the ceramic powders during the closing of the mould.
Reduction of defects due to incorrect deaeration (box effect, peeling).
Elimination of pre-compaction burrs.
DEAIR deaeration technology is patented on all major markets.
DEAIR and a registered lack.
|| DEAIR system is currently used and tested on any type of mold, both with re-entrant punches (brand above) and mirror or S.F.S (brand Below).
For its use on molds with re-entering punches (brand above) it does not require any modification for its functioning and its installation is easy and immediate as for the common isostatic punches normally used.
As regards the use on mirror systems or S.F.S (brand below) it is instead necessary to modify the mould by replacing the existing magnetic blocks with others suitable to allow the use of the DEAIR system.
We are therefore able to provide for the modification of any mirror / SFS mold in possession of our customers by equipping it with special magnetic blocks able to mount our punches. In this case, a hydraulic piston device is also added which facilitates the assembly / disassembly of the punches. This device is particularly useful in the case of moulds for large formats which involve the use of heavy weight pads.
Deair system
The DEAIR system has been designed to be easy to use as well as reliable.
In summary: the advantages:
The presence of numerous vent points, evenly distributed in the intersections of the isostatic chambers,
allows a rapid extraction of the air, with fewer or no presses of
deaeration, by means of a low pressure flow of just a few millimeters. It follows:
● The significant reduction of the air content in the tile before firing, and consequent
greater mechanical resistance.
● The elimination of laminations and cracks.
● Greater tolerance to variations in mix and humidity. (up to 1% more and less)
● The elimination of the migration of powders from the center towards the edges of the tile,
(especially with graphic applications in the press) and consequent absorption defects, e
● The elimination of lateral cracks during cutting.
● The reduction or elimination of dust pollution, in double loading.
● The longer life of pads and plates, due to the low deaeration pressure.
● Energy saving and less mechanical stress of the press, due to the lower number of
pressed per cycle.
● Less overheating of the press hydraulic circuit, and consequent savings
energy (in countries where the climate requires a cooling system)
And thanks to the elimination of deaeration:
● The elimination of defects due to the pressing of pre-compacting burrs. (in applications
on re-entering molds)
● if rubber springs are used, they can be removed as they are no longer necessary.
Versatility, you can use the time saved in pressing for:
● Increase the productivity of the press, we have obtained results ranging from 10% to
95% in the most difficult productions. (large dimensions and thicknesses, double loading, raw materials
first details ...)
● Take care of the loading of the powders, making it more homogeneous, and consequently
improving caliber, squareness and flatness, ensuring greater consistency, to the quality of
production.
Of course you can balance its use according to your needs, some of our customers use
DEAIR technology to obtain the same daily production, reducing costs
personnel and maintenance, and the waste of electricity, gas, and raw materials.
Other aspects appreciated by our customers are:
● The multiplied life of the lower brand plug in the SFS molds,
even 45 times normal, thanks to the detachment of the tile from the surface of the pad (carried out
from the pistons during the cleaning cycle), which allows post-expansion
before removal, the friction between it and the resin is almost eliminated.
● The high resistance to bursting of the pad.
● The increased time available for line maintenance.
● Reduced waste of raw materials and gas. (all our customers to date have reduced the
percentage of rejects and second choice due to defects in pressing, absorption,
handling, variations in humidity and characteristics of the dough)
● The speed and flexibility in reaching the production targets.
● The simplified use of dry grinding.
And, thanks to an improved use of gauge, flatness and square:
● Cost reduction of the squaring and sanding department
● Simplified warehouse and boxing logistics
● Reduced downtime in the sorting line.
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