Process instability
Risk of final-product quality instability with technologies not field-tested.
Analytical Case Study
Proven technology or cheaper alternative? The strategic screening choice.
For its new production expansion, Jaquar Group weighed whether to continue with Virto Ceramics by MLT Cuccolini Srl screening technology or switch to cheaper local solutions. Process stability drove the decision.
A sanitaryware leader expanding toward international markets
Jaquar Group is a leading reference player in India’s sanitaryware production, with continuous growth supported by significant investments in Italian and international technologies.
The goal is clear: increase efficiency and production capacity while maintaining high quality standards and a premium design aimed at international markets.
Screening is often considered a secondary process, but it actually has a direct impact on production stability and overall plant efficiency: the quality of the sieving and the screen’s ability to maintain high performance over time are decisive.
Achieving consistent performance over time requires far more than simply installing a machine: it takes application experience, the ability to test real performance, and know-how in managing process variables.
Proven technology or a more attractive local alternative?
Jaquar was preparing for a major new refurbishing and production-expansion investment. Automation for the casting lines had already been defined, with the goal of making a historically labour-intensive process more efficient, not to cut staff, but to increase production capacity by valuing the resources already in place.
To date, all screening departments used Italian Virto-Cuccolini technology, chosen over the years for reliability, performance and operational continuity. With the new expansion, however, a strategic assessment was launched: continue with the proven technology or consider more competitively priced local or Asian solutions.
Particle size fluctuations
Variations in particle granulometry within the slip, with a direct impact on quality.
Hidden maintenance costs
Increased maintenance costs where performance is not consistent over time.
More machines ≠ more output
Adding units to cover inefficiency multiplies maintenance, operating costs and management complexity.
The diagnosis: analysing real productivity and efficiency
During the site visit, real operating conditions, production performance and line-staff feedback were analysed. The existing plant (supported by original spare parts and defined operating procedures) had maintained measurable production stability over time, in both qualitative and quantitative terms.
The analysis also highlighted a key point: seemingly similar machines do not necessarily guarantee the same operational performance. The difference is made by application experience and the ability to sustain consistent performance over time.
| Parameter | Previous solution | New solution |
|---|---|---|
| Process stability | Variable | Consistent and measurable |
| Particle size control | Fluctuating | Stable over time |
| Maintenance costs | Unpredictable | Reduced and plannable |
| Spare parts | Heterogeneous | Standardised plant-wide |
| Initial investment | Lower | Higher (amortised over time) |
| Operational continuity | At risk | Proven over the years |
Virto Ceramics by MLT Cuccolini Srl technology as the reference choice
For controlled, Lean production processes geared toward maximum operational efficiency, Virto Ceramics by MLT Cuccolini Srl technology continued to be the reference choice.
Over time, the higher initial investment is offset by operational stability, production continuity and the reduction of indirect costs linked to maintenance, downtime and process inefficiencies.
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Operating stability
High operational stability guaranteed over time, even on intensive production cycles.
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Consistent performance
Measurable, repeatable production performance with no decline over the long term.
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Less downtime, lower costs
Reduction of unexpected downtime and associated maintenance costs.
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Standardised spare parts
Components unified plant-wide: simpler inventory management and service.
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Process control
Greater control over final quality thanks to reliable, repeatable sieving.
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Screen mesh durability
Long-lasting screening meshes that respect the high declared capacities.
An already-validated architecture, extended to the new expansion
The configuration chosen for the new expansion confirmed the architecture already validated in the previous phase, based on Virto Ceramics by MLT Cuccolini Srl VLB 1200 2Y screens in various application configurations.
The decision was supported by concrete operational results, production continuity and reliability demonstrated over time, avoiding the introduction of critical variables into an increasingly automated process.
In the Field
Photo gallery of the project
Confirmation of the choice: the second-phase order
Before
Local alternative
Option evaluated
After
Virto-Cuccolini
Confirmed choice (2nd phase)
In December 2024, by issuing the order for the second phase of the investment, Jaquar Group confirmed its intention to continue with Virto Ceramics by MLT Cuccolini Srl technology for future expansions too. A choice born from the results achieved over the years and the will not to introduce critical operational variables into an increasingly automated, high-performance production process.
| Metric | Result | Impact |
|---|---|---|
| 2nd-phase order | Dec 2024 | Technology confirmed for future expansions |
| Operational continuity | High | Fast start-up and standardised process |
| Unexpected breakdowns | Eliminated | Reliability proven on existing departments |
| Maintenance labour | Reduced | Fewer resources dedicated to corrective maintenance |
| Spare parts | Unified | Standardisation across the entire plant |
What this case demonstrates
The Jaquar case demonstrates two fundamental principles in choosing a process technology: real value is measured over time, not just on the initial investment, and application experience makes the difference between seemingly similar machines.
01
Real value is measured over time
The difference in initial investment loses importance when the process guarantees reliability, lower indirect costs and production stability over the long term.
02
Application experience and know-how
Seemingly similar machines can generate very different results over the long term. Application experience and the ability to maintain stable performance become decisive factors in technology choice.
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