STC 4.0 HP – New Generation of Stoneware Tableware in Ceramic 4.0 via High Pressure Casting Robot Work Cell
The STC 4.0 HP project – to be carried out in consortium by Grestel, the Polytechnic Institute of Bragança, and the Polytechnic Institute of Leiria, with the partnership of Limerick Institute of Technology (Ireland) – aims to develop a new generation of single-firing fine stoneware tableware designed to exploit the full potential of the Ceramic 4.0 paradigm.
Until now, it was inconceivable to produce thin-walled pieces (4 mm – fine dinnerware) due to existing forming technologies and the handling involved. The implementation of Industry 4.0 technologies (robotization, cloud computing, machine vision, ubiquitous computing, artificial intelligence, and computer vision) in high-pressure forming and subsequent finishing of fine stoneware pieces addresses previously unthinkable challenges and opportunities.
The traditional stigma of the ceramic industry as outdated and artisanal has been challenged by Grestel through the development of innovative designs and unique decorations, as well as R&D for environmental improvements (energy efficiency and waste valorization), new products (flameware and induction-compatible clay bodies), and process innovations (glazing, digital decoration, and laser firing).
The STC 4.0 HP project represents a major leap in adopting Industry 4.0, with the robotization of high-pressure demolding, finishing, and digital visual quality control. It will enable unmatched productivity gains and resource optimization, allowing employees currently performing repetitive and monotonous tasks to be redeployed to higher value-added activities, while facilitating global market penetration in specific niches (hospitality). Removing the human factor from monotonous tasks such as handling and subjective quality control, and eliminating handling that can introduce defects, will significantly contribute to disruptive quality levels.
This project will introduce disruptive methodologies into the current fine stoneware tableware industry paradigm, marking a decisive step toward a Ceramic 4.0 industry that is versatile, highly productive, high-quality, greener, and more human capital-oriented.
Specific Results:
Among the most significant results achieved to date are the work carried out by IPB, which led to the development of the first prototype for automatic finishing of green stoneware pieces, and the work by IPL on the early detection of defects occurring during the forming stage through a machine vision system.
