VitrA Expands Bozüyük Sanitaryware Facility with Sacmi Equipment
This facility joins the three existing plants on the site, reportedly making it Europe’s largest sanitaryware production facility.
VitrA recently completed a major investment at its headquarters in Bozüyük, Turkey, with Sacmi supplying a complete fourth manufacturing plant. This facility joins the three existing plants on the site, reportedly making it Europe’s largest sanitaryware production facility. With an output of 5.2 million pieces/year in Bozüyük, VitrA exports over 75% of its output to 75 countries worldwide.
Begun in 2015 with the delivery of a casting cell (featuring two AVMs with robots, three dryers, two Gaiotto glazing units with GA2000 robots, and a Riedhammer shuttle kiln), the project is now nearing full capacity following the installation of eight new cells incorporating 16 AVM casting machines. Each cell is controlled by robots that, in addition to governing all of the casting, de-molding and handling tasks, load the pieces onto the Sacmi FPV pre-dryer. The FPV reportedly uses tangential ventilation to remove significant amounts of water from the pieces in 60 min (as opposed to the 8-12 hrs required with routine air drying).
Eager to achieve complete automation of the line, VitrA has ensured it’s ready for the future installation of automatic laser-guided handling vehicles. Ergonomic design criteria and total automation of de-molding, pre-drying and on-trolley piece set-down ensure workers no longer have to perform any manual piece handing. In addition to the new casting machines, which bring the total number of cells working at the plant to 12, the facility has seen the installation of a further six drying chambers, each of which can hold 12 loading trolleys. A 135-m Riedhammer tunnel kiln features the EMS system for fume control and heat management/retrieval.
This investment reportedly saw close collaboration with the Sacmi Sanitaryware technology team, which handled all plant flow design and engineering. Once the plant is running at full capacity, expected this year, VitrA will be able to manufacture new WCs for the medium/high-end international market at the rate of 1,000 a day.