1. The Industrial Experimental Plant is a facility that allows knowledge agents, enterprises, and technology developers to collaborate on developing new products, processes, and technologies for the natural and artificial stone sector. 2. The plant has three technology areas - traditional stone processes, quality control processes, and confidential R&D processes. It aims to develop knowledge of stone transformation, train industry professionals, create collaboration spaces for enterprises, and transfer technologies to companies. 3. The plant has technologies for surface chemical treatment, mechanical treatment and texturing, stone block sawing, and composites formulation to further process and material development with a focus on parameter control and optimization. It has supported many successful collaborative projects.

2. INDUSTRIAL EXPERIMENTAL PLANT
Technologies for R&D in the stone industry
Sandra López Molina – Industrial Management Engineer
Alfonso Cortés Izurdiaga – Process Engineer

3. Summary
General Summary
1. CTAP Introduction
2. Industrial Experimental Plant
i. What is the Industrial Experimental Plant?
ii. Industrial Experimental Plant values
iii. Industrial Experimental Plant Technologies
3. Successful Projects

4. Introduction

5. CTAP Introduction
The Technological centre for stone is a private foundation created
in 2002 with thanks to entrepreneurial drive and the collaboration
of The Economic, Innovation and Science Council.
Occupying a position within the Andalusian system of knowledge
and as a National Technological Centre approved by The Ministry
of Science and Innovation, developing our activities at a national
and international level.
Mission:
Our mission is to improve the competitiveness of
businesses in the sector, through the generation and
transfer of knowledge and the implementation of new
ctap
business models.

6. CTAP Introduction
Areas of work
The activity in Ctap is organised into three
interrelated working areas.
The working areas are composed of highly
specialised professionals in different disciplines,
investigational departments and strategy experts.
Each working area has its own differentiated lines
of work and in turn carries out successful projects,
which are transferred and implemented within
businesses.
-The R&D Working Area
-Eco-sustainability
-Businesses and
competitiveness

7. Technological Centres, Institutes and CTAP Introduction
Universities

8. Enterprises CTAP Introduction

9. CTAP Introduction
Ctap grows with the industry
624 Clients
70 private projects since 2007
21 internal R&D projects since 2007
€ 9.849.280,15 of investment in equipment and technological
infrastructure since 2002.
4 known patents
5 patents on course
R&D Laboratory for resins and polymers
CTAP is a member of Fedit (The Spanish Federation of
Technology Centres).
ctap

10. Industrial Experimental Plant

11. Industrial Experimental Plant
1. What is the Industrial Experimental
Plant?
2. Objectives and values of the Industrial
Experimental Plant
3. Industrial Experimental Plant
Technologies for R&D

12. What is the industrial experimental plant? Industrial Experimental Plant
1. WHAT IS THE INDUSTRIAL EXPERIMENTAL PLANT?
The Industrial Experimental Plant is the best place where Knowledge Agents, Enterprises and
Technology Developers can join and work togehter for the development of new products, new
processes and new technologies for the natural and artificial stone sector.
The Industrial Experimental Plant is not a production factory!

13. Objetives and values of the Industrial Experimental Plant Industrial Experimental Plant
2. OBJECTIVES AND VALUES OF THE INDUSTRIAL EXPERIMENTAL PLANT
FIGURES: 3 DISTINCT AREAS
•Installed in 100% business •Traditional stone processes
environment •Quality and Production control
•Accounting for 10.000 m2 of buildings processes
•More than 22.960 m2 of land •Confidential R&D processes
•Investment of 7.5 M € in High
Technology

14. Objetives and values of the Industrial Experimental Plant Industrial Experimental Plant
TARGET 1: To deeply develop knowledge of the stone
transformation process.
Deepen knowledge in stone processing
TARGET 2: To become a training centre of excellence for human
resources in the sector.
The human factor: from Operator to Stone Specialist
TARGET 3: To create a common space where enterprises have the
possibility to improve their productive processes and generate new
uses.
Up to date technologies for Stone Innovation

15. Objetives and values of the Industrial Experimental Plant Industrial Experimental Plant
TARGET 4: To be the major shuttle of industrial development projects
Technology transfer to companies as the final purpose
TARGET 5: To establish a culture of cooperation between public and private agents
and businesses.
Together we can go further
TARGET 6: To attract investment for knowledge generation.
Future: the Industrial Experimental Plant as the hub of stone R&D

16. Industrial Experimental Plant Technologies Industrial Experimental Plant
3. INDUSTRIAL EXPERIMENTAL PLANT TECHNOLOGY SUMMARY
Surface Chemical Treatment
Technology
• Surface Mechanical Treatment
and Texturing Technology
• Stone Block Sawing Technology
• Industrial Mixing Laboratory for
Composites

17. Industrial Experimental Plant Technologies Industrial Experimental Plant
Machinery VS Technology concepts
• Maximum open operating parameters
• Whichever type of fungible and tools can be
used
• Tools change will be very simple both to
minimize time and procedures
• The machinery must be compatible with any
stone material or material derived from stone
(at least covering the largest possible range)
• Evolving Technologies: Machinery suppliers
must be open to further cooperation in order to
carry out modification / improvements to the
existing technologies
OPEN INNOVATION
PROCEDURE

18. Industrial Experimental Plant Technologies Industrial Experimental Plant
1. Surface Chemical Treatment Technology
Limitations of current technologies
• Actual chemical treatment lines are composed mainly by one or, at most, two curing systems.
Industrial application processes are defined based on laboratory tests and resin suppliers
recommendations.
• Limitations in Vertical Thermal Ovens:
• Just two independent sections, no matter the number of floors available: drying section and curing section.
• No air control (humidity and flow).
• Limitation of maximum operating temperature at 60ºC.
• There’s no scientific evidence to demonstrate the advantage provided by a vacuum unit.
• Dosage, mixture and application automated systems are not versatile (for fillers and resin
change).
• UV and IR ovens do not permit a wide range of parameterization.
• Process parameter definition and modification is hard with actual interfaces.

19. Industrial Experimental Plant Technologies Industrial Experimental Plant
Surface Chemical Treatment Technology
Selected supplier for technology:
Main characteristics:
• Three kinds of oven available: thermal, UV and IR
• Thermal oven with 8 independent sections (5 floor each). Temperature and air regulation (flow,
humidity and inversion period of circulation).
• Automated and versatile system for resin dosing, mixing and application (work in progress).
• Easy user interface for process cycles definition.

21. Industrial Experimental Plant Technologies Industrial Experimental Plant
PARAMETERS MAP

22. Industrial Experimental Plant Technologies Industrial Experimental Plant
2. Surface Mechanical Treatment and Texturing Technology
Limitations of current technologies
• Machines available are not versatile to work with both marble and granite (heads and
polishing systems are completely different).
• Individual pressure control available per head but always above the head weight (the
minimum pressure is the one caused by the head weight).
• Rotation speed of heads fixed.
• Refrigerating water flow completely uncontrolled and unmeasured.
• No slab thickness calibration system available for natural stone slabs.

23. Industrial Experimental Plant Technologies Industrial Experimental Plant
Surface Mechanical Treatment and Texturing Technology
Selected supplier for technology:
Main characteristics:
• Two kinds of head available: marble and granite type.
• Fast tool change for heads and abrasives.
• Control of main process parameters, including:
• Absolute pressure of the head on the stone slab
• Water flow per head (work in progress)
• Rotation speed per head (in both calibrating and polishing heads)
• Easy user interface for process cycles definition

25. Industrial Experimental Plant Technologies Industrial Experimental Plant
PARAMETERS MAP

26. Industrial Experimental Plant Technologies Industrial Experimental Plant
3. Stone Block Sawing Technology
Limitations of current technologies
• Sawing loom changing and distance regulation is very time consuming.
• The loom beats are unable to be controlled and also the frequency of the main motor.
• Block sawing process demands high energy consumption.
• Refrigerating water flow is completely uncontrolled and unmeasured.

27. Industrial Experimental Plant Technologies Industrial Experimental Plant
Selected supplier for
technology:
Main characteristics:
• Download speed of loom frame
variable between 0 – 100 cm/h.
• Two detachable loom frames.
• Fast loom frame change (under two
hours).
• Frequency variator for main engine
with two principal advantages:
• Number of frame beats
adjustable
• Recovery of connecting rod
dropping power, usable in the
connection rod rising (50% power
saving).
• Refrigerating water flow control
(work in progress)

28. Industrial Experimental Plant Technologies Industrial Experimental Plant
4. Industrial Mixing Laboratory for composites
formulation
Selected supplier for technology:
Main characteristics:
• Rotating and inclined mixing pan. This promotes material
transportation towards the center of the pan and the mixing tool.
• Excellent for powder and solid mixing. It also allows liquid
addition during the mixing process.
• Easy user interface for process cycle definition, including the
following parameters (work in progress):
• Rotating mixing tool speed
• Power consumption
• Automatic filler addition
• Compressing unit and molds for composite conforming (Work in
progress).

29. SUCCESFUL PROJECTS

30. Surface Chemical Treatment Technology Successful projects
P-201100470: APPLICATION
PROCESS FOR A BRAND
OR LOGO OVER NATURAL
OR ARTIFICIAL STONE
SURFACES
• Definition of the diamond tool and
the machining process
• Exclusive resin formulation for high
transparence and gloss
• Water proof
• Polishing process definition for a
two phase material (resin + stone)

31. Surface Mechanical Treatment and Texturing Technology Successful projects
Gutiérrez Mena
• Different surface finishes to define
a family of products derived from a
single and exclusive material
• Surface process treatment
definition: types of abrasives,
sequences of abrasives and
machine parameters
• Process optimization to minimize
operating costs
• Brand definition and market
positioning

32. Surface Chemical Treatment Technology Successful projects
Idispaces
• R&D + Design applied for spa and
wellbeing equipments made of
stone.
•Development of completely new
technologies for stone heating,
water flow system along stone
components and lighting stone
components.
• Chemical protections for water and
oil environments.
• Industrial protection pending for
every product and two patents for
the general technology.

34. Industrial Mixing Laboratory for Composites Successful projects
Industrial Wastes Reuse
P-201100356 y P-201100355
•Characterization and analysis of
industrial wastes from the
Andalusian Stone industry.
•Definition of a preparation method
for these wastes towards their reuse
in the formulation of new materials.
•Development of a new formulation
of bituminous materials including
these wastes (2 patents generated).

35. New technologies in the stone industry Successful projects
Indálica del Diamante
•Design and construction of pilot plant
for the production of electroplated
diamond tools.
•Process parameterization and
definition for each geometry and size.
•Development of all tools needed for the
processes (control systems for chemical
baths, piece holders and chemical
contacts, quality control systems based
on computer vision).
•Specific tool design for any need.

36. New technologies in the stone industry Successful projects
Tarsia
P-200502077: Stone mosaics automatic
manufacturing system.
•Automated manufacturing system based on multiple
piling up and stacking stages.
•Exclusive formulation for a high mechanical resistance
and waterproff adhesive.
•Use of stone industry by – products
•Robotization of stone processes (loading and piling up of
slabs and resine application).

37. New technologies in the stone industry Successful projects
P-201001319
Recognition
Computer Vision and dimensional control
System for natural
and artificial stone
tiles.
U201001042
Dimensional
Control Machine
New processes for
quality control for stone
products: computer
vision and automatic
measurement.
•Exclusive computer
operators to determine
main characteristics of
stone tiles.
•Identification VS
classification to give the
stone a unique visual
identity.
•Fully compatible with
current production
technologies.

38. New technologies in the stone industry Successful projects
New possibilities for stone classification and stone compositions
Computer Vision and dimensional control
Stone composition based on Computer Vision – every tile is
worth it!

39. New technologies in the stone industry Successful projects
A new concept for stone and arquitecture
Computer Vision and dimensional control

40. THANKS FOR YOUR ATTENTION!
See you at the Industrial Experimental
Plant!
acizurdiaga@ctap.es
sandralopez@ctap.es