DDG Doubled: New Opportunities for Sacmi’s “All-Digital” Printing Line

The capabilities of the new digital modules for applying dry and wet effects have been enhanced. The result: more opportunities to create 3D surface textures, with simultaneous alignment and digital tracking.

Sacmi has introduced a new application of its Digital Decoration & Glazing (DDG) series for the production of digitally glazed, decorated, and textured ceramic surfaces.

The main innovation in this all-digital configuration is the expanded functionality of DDG technology, which now goes beyond the selective application of grits, glues, and other dry or wet effects. By installing two DDG modules, one before and one after the digital inkjet machine, the system can now create realistic surface structure effects.

In practice, the first DDG module can be used to apply grits and glues to create textures resembling wood, natural stone, and other materials. It also has the capability to add structural inks for high-definition micro-textures. Performing multiple processes simultaneously in a single decoration module yields exceptionally realistic results.

In conjunction with the application of resistant inks and other effects by Sacmi’s DHD inkjet modules, the piece then passes through the second DDG module to apply further material effects and glazed surface finishes, such as a classic transparent coating.

This innovative configuration leverages the full potential of proprietary DDG technology within the Sacmi Deep Digital line, extending the concept of digital decoration and glazing into the realm of 3D surface decoration. The result is a more efficient process for managing small-scale productions, Just-in-Time manufacturing, and frequent changes in size and texture. Furthermore, this process is entirely free from mechanical limitations, providing maximum flexibility in managing complex production mixes with high aesthetic value.

 

Line Up and Line Manager

 

Alongside the development of its all-digital platform, Sacmi has developed two new systems, Line Up and Line Manager, to overcome the operational limitations of these types of lines and simplify their management. These systems manage the increasing complexity of multi-printer lines with the goal of improving the alignment and synchronization of the graphic and material layers that make up the final product.

Line Up is a graphic alignment system that utilizes optical vision devices. This system ensures precise registration of overlapping images printed by different digital machines. In combination with an intelligent tracking system, Line Up allows for automatic tile/slab identification, instructing printers on which image to print. This system sends and receives process data from various machines, ensuring full traceability at the end of the line.

Line Manager enables the management of sequential digital machines from a central point. The operator can manage the entire line from a single control center, viewing the machines as a single unit. The operator receives complete product files from the graphic design unit and sends them to the line via this center. The system then assigns the appropriate files to each printer without requiring individual file uploads.

From the same center, the operator can manage all graphic and print optimizations typically performed on each machine separately. Production reports are also always available and can be shared with workflow management systems.

 

Integration with the Forming Process for Cohesive Ceramic Aesthetics

 

By integrating additional digital devices into the line, such as powder dosing units placed before the forming stage (e.g., DGD for traditional PH presses or V-Nature for Continua+ lines), Sacmi offers a comprehensive and adaptable decoration ecosystem capable of managing all surface and deep finishes of ceramic tiles and slabs on a single, integrated platform.

The result is a cohesive overall design with harmonious 3D effects and a distinctive aesthetic that faithfully reproduces the look and feel of natural materials.