The new Ceramica Artistica 3 plant in Prignano sul Secchia (Modena) came into operation in early 2024 and is dedicated to the production of large size tiles and slabs with dimensions up to 120×280 cm and thicknesses ranging from 6 to 20 mm. It is the latest industrial venture undertaken by the Pifferi family, a well-known name in the Italian ceramic industry since 1964 when Danilo Pifferi founded Ceramica Artistica Artigiana, famous for its trend-setting craquelé surfaces. Over the following years, the family continued to build its legacy with the founding of Ceramica Artistica Due by Danilo’s son William and subsequently Nuovocorso by his grandson David, the company’s current Vice Chairman.
“The Ceramica Artistica 3 project represents the evolution of Ceramica Artistica Due and aligns with our vision of the ceramic production process based on technological innovation and rigorous technical and aesthetic product research,” explains David Pifferi. “We use the latest available Italian technology to exploit the experience of the past while looking to the future.”
The new factory is a jewel of innovation equipped with the most advanced production technologies, from forming with the Continua+ line through to digital decoration, robotics, handling automation and product finishing. The finishing equipment was delivered entirely by BMR, a longstanding partner that has been supplying the ceramic company with lapping, finishing, cutting, grinding and other solutions for over ten years. The latest step in this partnership was the start-up of the new line for polishing ceramic slabs.
We visited the new department together with the Vice Chairman of Ceramica Artistica 3, David Pifferi, and BMR area manager Marco Sichi, who described the various technologies in operation.
CWR: Could you tell us about the latest addition to the production line, the LeviCompact?
David Pifferi: We use BMR’s LeviCompact, which represents the Sacmi Group’s most advanced technology in the field of polishing, to perform lapping, satin finishing and polishing of porcelain slabs. The slabs are also produced and decorated using Sacmi solutions. We chose this entirely new technology because it allows us to improve quality while reducing overall dimensions and machining times, all of which are key factors for maintaining product competitiveness.
CWR: Could you give us some more details about the system?
Pifferi: LeviCompact is the world’s first solution consisting of two parallel oscillating tables with 10 heads each. This set-up allows for greater speed and coverage compared to traditional designs, with the added benefit of improved uniformity. In practical terms, this means we can achieve optimal results while reducing the machine’s footprint by 45%. LeviCompact is a modular and flexible solution that is easy to integrate into the plant layout. It is also completely digital, allowing it to integrate and connect with all other applications. The interfaces enable us to monitor all parameters, including the pressure exerted on the surface of the slab, the quantity of material removed and the hours worked by the tools. This allows us to optimise operation and maintenance, resulting in significant savings in terms of energy consumption and waste.
CWR: The entire ceramic manufacturing process has undergone dramatic changes in recent years, and that includes the surface finishing stage.
Pifferi: That’s right. The so-called “end-of-line” stage is no longer just a step in the process but an entire production department in its own right, requiring maximum efficiency and versatility. Since production is now driven by market demands rather than warehouse stock, we need efficient, state-of-the-art technologies that provide the flexibility necessary to produce the desired product sizes.
CWR: Surface aesthetic research is one of the hallmarks of Ceramica Artistica 3. How do the finishing technologies you have adopted meet your requirements?
Pifferi: I can confirm that BMR’s SuperShine solution is unrivalled in terms of product aesthetics. We have installed a SuperShine Plus, the evolution of the well-known SuperShine. This advanced dry super-polishing machine enhances the tile’s digital graphics and guarantees a high-gloss, protected surface thanks to the dynamic interaction between the tool, the surface and the applied chemical. SuperShine integrates two functions: the aesthetic function of polishing based on the mechanical action of the tools, and the protective treatment resulting from the closure of the surface pores. This latest version offers superior levels of performance and digitalisation and is a highly interconnected machine with constant data sharing for process control.
CWR: On the subject of digitalisation, the plant installed at Ceramica Artistica 3 is one of the most innovative in the industry.
Pifferi: That’s right. Among other functions, this plant benefits from the i-Manager application, based on the iTools-Edge platform. This software interconnects data originating from the automation of our machines, allowing us to manage all processing operations, states of progress, recipes and production trends from a single access point. The platform is accessible from any connected device, paving the way for the implementation of further advanced process monitoring and control functions.
CWR: Could you tell us about the squaring line you have adopted?
Pifferi: The cutting and grinding areas are located in the second section of the plant, accessed via a tunnel. Here, the centrepiece of the line is the Squadra Vision with cameras, a direct evolution of BMR’s classic camera squaring machine. The main advantage of this system is its optimised management capabilities. Thanks to the cameras, wheel consumption is reduced by 40% compared to laser and similar technologies, with real-time parameter correction during feed. This solution is also designed for the optimal management of the large sizes we produce with Continua+, such as 1200×2800 mm and modular sub-sizes. In practical terms, this means ease of management, allowing us to quickly and intuitively change the degree of removal according to the configuration and type of tool.
CWR: Would you describe the partnership with Ceramica Artistica 3 as one of BMR’s most important collaborations?
Marco Sichi: Yes, the Ceramica Artistica 3 project is very important for us because it validates BMR’s approach to finishing, which involves the use of exclusive and patented solutions to ensure versatility, ease of use, reliability and performance optimisation, characteristics that have always been our hallmark.
In this plant, digitalisation enhances machine operation and maintenance management. Displays and digital tools allow for objective, real-time data analysis to ensure optimal settings and reduce waste. This is combined with innovative mechatronic solutions that are unique in the market. In this project, we have field-validated the new LeviCompact solution, which represents an utterly revolutionary technology. We believe it is an extremely effective solution for the Italian ceramic industry in terms of both its performance and its ease of integration into existing systems.
Learn more about lapping technology according to BMR: https://www.youtube.com/watch?v=le5U9qqYcDI