Creating Solid Colour with digital printing or traditional methods has highlighted issues that include the so-called "orange peel" effect, or the "television" effect. To avoid these, we have conducted research to establish a Solid Colour application technique that:
- greatly reduces costs
- improves quality
- enhances the colour gamut
- increases flexibility and productivity
While this technique should not be considered for flooring, it is an excellent solution for decorating any other ceramic surface. The process can be illustrated in 3 stages:
- application of a colour coating
- application of a protective layer
- application of the finished effect
Starting with the colour coating, after an optional primer, the colour gamut is vast and because application is performed at low temperatures, the colour chosen is not affected by a high-temperature process. Colours of any RAL or Pantone are reproduced faithfully.
Application is performed using any of three methods: spray, roller or curtain coating, all of which based on technologies designed, developed and fine-tuned in our LAB. In fact, the choice will depend precisely on further tests we can run to adapt the equipment to the lacquer used, the size and shape of the ceramic piece and the quantity of lacquer to be applied.
The second stage in the process regards the application of layers to protect the coloured coating applied initially. It involves a series of coating phases, performed on roller coaters where lacquer consumption can be carefully controlled to avoid waste. The result of this stage is the quality of the surface layer, surface resistance and colours which are true to the desired result.
Finally, the desired finished effect is obtained using integrated technologies to achieve an over 90 high-gloss or below 5 gloss deep-matt finish.
Each of the technologies implemented, from coating to curing, are the result of decades of research and innovation which have led to the benefits mentioned above.
How do they improve quality?
Each coating solution that can be implemented for the Solid Colour application technique has been perfected to ensure consistent, repeatable coating uniformity. Each machine enables full control over the operating parameters and can be accompanied by software solutions to maintain top performance. Booth pressurisation avoids dust entering the spraying cavity, increasing the quality of the process.
How do they reduce costs?
A host of devices and patented systems all contribute in different ways to increasing transfer efficiency, for example specially conceived coating enclosures (plenums), thereby reducing lacquer consumption. Patented cleaning systems retrieve excess lacquer during the coating process and recycle it to minimise waste.
How do they increase productivity?
Highly flexible, high-speed colour changeover is possible thanks to the patented Just in Time system. Recently developed devices applied to specific spray coaters also allow for on-the-go colour changeovers avoiding machine downtime. The scalability of the solutions allows coating to be performed on more than one product simultaneously. Overall costs are thereby reduced even further.