Design of new industrial mould filling systems for the manufacture of ceramic tiles using a discrete element framework

The lack of orthogonality in the ceramic tiles is a common problem associated with the mould filling process during its manufacturing process. Unfortunately, the existing mould filling equipment have not undergone significant changes over the years. This paper studies alternatives to the traditional powder filling systems used in the ceramic tile manufacture industry. The new proposals are analysed via virtual prototyping using a simulation framework based on the Discrete Element Method (DEM). These new systems aim at improving the product quality and process sustainability and efficiency demanded by the ceramic industrial sector. The demanded requirements involve: (i) assessment of average powder compactness in the mould, (ii) quantification of the powder heterogeneity in the mould as a function of the filling system, (iii) characterization of the filling dynamics and (iv) evaluation of the powder wasted during the filling process. Compared to the traditional systems, the new designs substantially simplify the mould filling by using a single or double hopper. The results obtained with a single hopper system generates the highest and the most homogeneous powder mould filling. A double hopper system, which yielded similar mould compactness, revealed less sustainable compared to other systems due to wasted powder mass to complete a filling cycle, reaching up to 25%. DEM-based virtual prototyping proves to be a powerful tool to develop new equipment giving insightful information and helping to substantially reduce the high costs of physical prototypes construction and instrumentation.