Moisture cracks
Sporadic cracks visible only on the fired product leaving the kiln.
Analytical Case Study
DRYDECT: in-line residual moisture detection on tiles.
How a leading manufacturer in the Sassuolo district cut fired-product scrap by 30% and lowered the dryer temperature by 15°C by introducing a new process control parameter.
Among the largest tile producers in Italy.
The customer (one of the largest tile producers in Italy) authorized us to share this case history without revealing their identity. A company highly attentive to innovation, equally selective and demanding.
Until our implementation, tile moisture measurement was carried out at defined intervals via laboratory staff. The control was later moved in-line, managed directly by an operator to reduce reaction times. But it remained a destructive, sample-based test, consuming time and resources.
A destructive sample-based test, with resource consumption and slow reaction times, remained the weak link in in-line quality control.
Manual, obsolete, destructive sample-based process.
Manual sample-based measurement was not enough to intercept residual moisture reliably. Defects emerged at later stages (when the product was already fired) generating scrap, kiln explosions, and gas overconsumption in the dryer kept at over-temperature.
A hidden cost, spread across quality, energy and plant reliability.
Kiln explosions
Lost production, material contamination, significant damage on slabs and thick formats.
High gas consumption
Dryer kept over-temperature to offset uncertainty on real moisture.
The conditions for real-time measurement.
The customer identified a line with significant conditions to install our in-line, real-time moisture measurement system. During the plant visit we analyzed key parameters: format, throughput, thickness, target moisture at dryer exit, fired/green scrap percentages, downtime causes, operator workstations.
Outcome: working conditions are clear and there’s room to meet the customer’s need with an automatic solution.
| Parameter | Previous solution | New solution |
|---|---|---|
| Measurement mode | Manual, sample-based | In-line, real-time |
| Reaction time | Long | Immediate (40 readings/sec) |
| Test type | Destructive | Non-invasive |
| Resources | Dedicated operator | Automatic |
| Traceability | Limited | Continuous, archived charts |
DRYDECT: in-line measurement with magnetic-field sensor.
DRYDECT is an intelligent system for real-time moisture control of tiles passing on the glazing line.
The magnetic-field sensor delivers up to 40 readings per second, suitable even for very high throughput. It stands out for easy calibration and configuration across thicknesses and formats via dedicated recipes. Precise and reliable, a fundamental condition to turn data into operational action. The device can provide an output contact to manage automatic in-line rejection systems.
The DRYDECT control panel handles up to 4 sensors.
-
Real-time
Continuous measurement via magnetic-field sensor, data always available.
-
40 readings/sec
Suitable for very high production rates, no bottleneck.
-
Easy calibration
Dedicated recipes for different thicknesses and formats, fast setup.
-
Automatic rejection
Output contact for in-line rejection systems, no human intervention.
Three measurement points to find the optimal position.
The conditions and measurement points were defined for a data-collection phase. The customer’s challenge: measure at 3 specific points, to determine (based on data) the most effective and definitive position:
- Dryer exit, checks dryer performance on all levels and load zones.
- After the first glaze/engobe applications, intercepts dryer differences and rejects pieces stuck under applications.
- End of line / before kiln, intercepts defects from the last application and rejects material exceeding the moisture threshold.
After a few months of production, the final configuration adopted for the other lines is 2 sensors per line: one after the first glaze application, one at end-of-line before kiln.
In the Field
Photo gallery of the project
Humidity measurement process automation.
Before
Sample-based, destructive
Moisture measurement
After
Real-time, accurate
Moisture measurement
After months of operation, the numbers proved satisfactory in terms of data reliability and accuracy, enough to launch the real project on the plant's other 5 lines. In-line measurement has become a fundamental process control parameter.
| Metric | Result | Impact |
|---|---|---|
| Fired scrap | -30% | Direct reduction of returns/disposal |
| Kiln explosions | Zeroed | No damage, no material contamination |
| Dryer temperature | Up to -15°C | Gas savings on some zones |
| Rollout | +5 lines | After pilot, scaled across the plant |
What this case demonstrates
The DRYDECT case shows that the ceramic production process is a complex system in which every variable affects the final quality. Even "minor" parameters like residual moisture, when managed with reliable and continuous data, transform control approach from reactive to predictive.
01
Reliable data, operational decision
Data reliability is what turns measurement into decision: anticipate deviations, identify oscillations, intervene before defects occur.
02
Eliminate manual
Manual processes without added value must be progressively eliminated. The destructive sample test is one of them.
03
Traceability = competitiveness
Data collection and traceability improve control and management. Even undervalued processes can carry significant weight for competitiveness.
Next step
Got a similar situation?
In the ceramic industry, making data collection and analysis easier is the foundation for efficient, stable, quality-oriented production. DRYDECT turns a hidden cost into a competitive advantage.
More success stories
See all →
07 Let's talk
Want to optimize your production line performance?
30 years in the ceramic industry. From diagnosis to solution, a single point of contact.