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Main Advantages of the Microwave Heating

  • Speeding up: minutes instead of hours!!
  • Volume Energy transmission - cold vessel
  • ENERGY Savings, Room Savings
  • Efficiency 70%
  • Automatization
  • Safety *
  • Environment *

Comparing to the processes using the combustion


REFERENCES

ECONOMY
  • saves time – minutes instead of hours
  • enables continuous manufacturing process
  • minimal space requirements
  • elimination of scrap
  • minimum heat loss  
 
DOZENS OF MICROWAVE DRYERS ROmiLL
are successfully deployed long-term in the ceramics
industry

MICROWAVE PRE-DRYING OF SANITARY CERAMICS


For the stabilization of freshly
cast pieces and complex shapes


THE PURPOSE OF PRE-DRYING
After being demoulded due to the relatively high moisture content the matter is still unstable. The semi-finished product is susceptible to various deformations which can occur during handling before the transport to the main tunnel dryer. Therefore it is important to reduce the plasticity by removing part of moisture. Since the whole depth of the wall is heated during the microwave pre-drying process, the pores open which helps the capillary forces push the water to the surface. This significantly speeds up the initial phases of drying and even the following main drying process.



MICROWAVE METHOD BY ROmiLL
Water unlike the ceramic matter, absorbs microwave energy. All of the water molecules are heated simultaneously and uniformly throughout the whole product. The increased temperature causes that all the water molecules are pushed to the area with lower pressure which forms on the cool surface because the surrounding air is not affected by microwaves. That grants the microwave pre-drying process the speed and effectivity which cannot be achieved by any other non-dielectric method. During the conventional means of heating, heat advances slowly from the surface to the core while the moisture is pushed in the opposite direction. Not only is that ineffective but also the whole material is heated which is a waste of energy.


 
THE CONVENTIONAL METHOD
The semi-finished products are stored in a closed, tempered and ventilated room where they are kept to pre-dry with the aid of controlled air circulation, temperature and humidity. This means an undesirable interim storage area is present where the products are loaded and unloaded in batches, which disrupts the continuity of the whole manufacturing process. This delay extends the whole production time which results in lower productivity. Not to mention the occupied space could have been used for other purposes or didn’t have to be built at all. Heating of the mentioned storage area causes energy losses since only a part of the energy used for heating the air is actually used to remove the moisture from the semi-finished product.

PRACTICE
The time needed for microwave pre-drying is identical with the time needed for casting - around 15 minutes. In various plants the time of casting differs because it depends on various factors: the raw material that the bidets and toilets are made of, the shape, the size of the product, the means of casting, manipulation and the initial and final moisture content. Microwaves shorten the process by an order of magnitude. Using a robotic hand for transport eliminates shaking with the fragile product and it can even be linked with the dryer to achieve automated operation.

OPERATION
The control system allows programming the drying modes according to the technologist´s requirements, it monitors faultless functionality, reports deviations and stores records. Operation can be managed by staff without qualifications. Control can be subordinated to a robot that is manipulating the semi-finished products. The device does not require special interventions. Consumable items are easily replaceable by an electrician. Even with the given information the manufacturer of course guarantees the post-warranty service.

INVESTMENT
Compared to the lengthy and inefficient hot air technologies, that apart from water unnecessarily heat the mass itself, where also the heat from the surface enters the core slowly, the cost of microwaves has no competition. The design and components used allow for longevity in continuous trouble-free operation. 

 PARAMETERS
 ROmiLL PRE DRYCER
 Length x width x height  2752 x 1731x 3008 mm
 Material  Stainless steel
 Output / Input (max)  8 / 10 kW
 Compressed air  5–8 bar
 Weight  1500 kg
 Certification   (or according to local legislation)
 Control system  Siemens Simatic S7 (or as required)