Process information
| Key Data Set Information | |||
| Location | GLO | ||
| Reference year | 2024 | ||
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| Use advice for data set | Scope: The EPD applies to 1m of glazed and unglazed porcelain tiles, produced by Revigrs, in its facilities located in Barr - gueda - Aveiro - Portugal. The results presented correspond to an average EPD of the Revigrs. System boundary: Type of the EPD: cradle to grave. | ||
| Technical purpose of product or process | Ceramic Porcelain tiles can be applied both indoor and outdoor areas: indoor/outdoor covering floor/wall covering commercial buildings residential buildings industrial buildings floors of outdoor facilities such as gardens, terraces, pool sides and recreational areas | ||
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| General comment on data set | The Revigrs glazed and unglazed porcelain tiles are produced combining technological innovation with good environmental practices. They are dry pressed and characterized by technical specifications (high mechanical strength and resistance to wear, chemical and stains), and it is fully vitrified (at temperature of over 1200 C) acquiring extremely low water absorption, no more than 0.5%, with consequently frost resistance, making it suitable for outdoor installation. In porcelain tiles, each series can have different dimensions, colours, textures and finishes: Edge: natural and rectified; Surface: such as matte, glossy, non-slip, softened and polished.and thanks to its superior technical characteristics, allows the Designer to satisfy all project requirements. | ||
| Copyright | Yes | ||
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| Data set valid until | 2029 | ||
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| Technology description including background system | The production process is dived into 2 major stages: - 1st stage: Consists in the preparation of the ceramic slips (turbo dilution, and continuous and discontinuous grinding), followed by the preparation of powders (atomization); - 2nd stage: Granulation of powders (power mix and micronization), pressing/drying, application of finishes, firing, sorting and packaging. 1st stage Preparation of ceramic slips The main raw materials (clay and hard raw materials) are supplied in bulk and stored in bins, while the remaining raw materials are supplied packed in big bags. The main raw materials are transferred from the storage area for storage silos and into the plant. The core operations involved in preparation of clay slips are turbo dilution, continuous grinding and discontinuous grinding: The turbo dilution consists in deflocculation of the clay and is used in clays suitably dosed with the goal of preparing a clay slip used to manufacture the basic clay slip. The continuous grinding, required for the particle size reduction and homogenization of raw materials will be applied to clay raw materials, hard materials and turbodilution prepared clay slip, which is the product with higher consumption. The discontinuous grinding is applied both to the manufacture of concentrated coloured clay slips or super white slips, taking into account the nature and formulation of raw materials used.After screening the slurries are stored in individual tanks. i) Preparation of powders The dosage of concentrated base clay slips and coloured slips will allow the manufacture of various types of coloured slips. ii) Granulation of powders After screening the coloured slips are atomized. With this process, it is obtained coloured base powders and special coloured powders, due to special dosage performed in the previous stage. The atomization of a super white slip will result in the super white powder for the manufacture of silk screened porcelain tiles. The atomization operation is required in order to dry the clay slip (the humidity of the material changes from 40% to 5-6%) and to obtain porcelain powders. It is also at this stage that the particle size and the percentage of moisture required is determined. 2nd stage i) Granulation of powders This stage can encompass two operations: powder mix in order to achieve certain patterns and micronization. ii) Pressing/Drying The atomized powders (mixed or micronized) obtained in the previous stage, and the granulated powder are dosed and conveyed to the pressing/drying lines formed by hydraulic presses coupled to dryers which require the use of natural gas as a heat source. These pressing/drying operations allow the production of raw mosaic with the desired size and a moisture content between 0,8% and 1,2%. iii) Finishing After pressing/drying the raw tiles are conveyed to the finishing stage which may include one or more of the following operations: Polishing, surface treatment on the crests of ridges to limit the wear of natural stones; Applications of glaze; Serigraph printing using screen inks; Serigraph printing using soluble salts; Scrape.The products obtained at the end of this stage are stored and transported automatically through a LGV (Laser Guide Vehicle) system. iv) Firing The firing stage begins with conveying the stored raw mosaics into the furnace using the same LGV system; the duration of this stage will depend on the type of mosaic and format. There are two monochannel type kilns(one hob). The kilnsconsist of the usual pre-heating zones, firing and cooling. Each kiln comprises, at the entrance, a pre-furnace, which is intended to carry out a pre-heating and drying of the material using recovered gas of the cooling zone. After passing through the kiln, the tiles are fired and automatically stored in wagons, which are then automatically distributed also to the sorting and packaging lines. v) Sorting Sorting stage starts with the visual control of the mosaics, which is performed by a person. Depending on the type of flaw, the selector will mark each tile with code traces that will be read by the photoelectric sensor of choice machine. The physical feature of the tiles such as flatness, rectangularity and the parallelism of the edges are checked by mechanical and opto electrical sensors. vi) Packaging This section consists in automatic packaging of mosaics in boxes. The boxes with the finished products from the automatic packaging lines are routed to an automatic palletizing and movement system. However some material that still has a final coating (chamfering, etc.) will not be palletized. This system includes fully automatic palletizing, shrink-wrapping, labelling and storage of pallets through automatic and autonomous vehicles. Technical data: The Revigrs porcelain tiles comply with requirements of standard of EN 14411:2012 Group Bla (dry-pressed with water absortion EISO 10545 standards For each product, the data provided in the Declaration of Performance applies. Most relevant technical characteristics: Declared unit: 1 m2 of glazed and unglazed porcelain tiles. | ||
Modelling and validation
| Subtype | average dataset | ||||
| LCA methodology report | |||||
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Nomenclature compliance
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Quality compliance
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| Compliance |
Compliance system name
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Approval of overall compliance
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Nomenclature compliance
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Methodological compliance
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Review compliance
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Documentation compliance
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Quality compliance
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Administrative information
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| Data generator | |
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| Time stamp (last saved) | 2024-03-22T00:00:00 |
| Data set format(s) | |
| Publication and ownership | |
| UUID | f838d722-4559-41e0-81a3-cc2214f2780f |
| Data set version | 00.02.000 |
| Registration authority | |
| Registration number | EPD-REV-20240006-CCC1-EN |
| Owner of data set | |
| Copyright | Yes |
| License type | Free of charge for all users and uses |
| Access and use restrictions | None |
Environmental indicators
Indicators of life cycle