Have you ever wondered what separates a premium ceramic tile that lasts a lifetime from a mediocre one that fades in a year? In the high-stakes world of ceramic manufacturing, the margin for error is zero. Imagine a production line where a single misaligned pixel can result in thousands of dollars in wasted materials. This is the nightmare that top-tier manufacturers like Porcelanosa face daily. For decades, the industry struggled with color inconsistency and mechanical downtime, but a recent shift has changed the game. Porcelanosa, a global leader in luxury surfaces, recently made a strategic move that sent ripples through the industry: they fully integrated the Projecta Ikon Plus digital printing system into their production workflow.
This isn’t just a story about buying a new machine; it is a blueprint for the future of industrial manufacturing. Whether you are a factory manager in Spain or an operations director at a growing tile plant in Yazd, Iran, understanding the “why” and “how” behind this selection is crucial. In this comprehensive guide, we will break down the technical superiority of the Ikon Plus, the operational shifts required to implement it, and how this partnership solves the most “unsolvable” problems in ceramic printing. By the end of this article, you will have a clear roadmap for achieving Porcelanosa-level quality in your own production environment.
۱. The Technological Leap: Understanding the Ikon Plus Architecture
The decision by Porcelanosa to adopt the Ikon Plus from Projecta (a SITI B&T Group company) wasn’t based on brand loyalty alone; it was a calculated move based on hardware architecture. The Ikon Plus represents the pinnacle of “Drop-on-Demand” (DoD) inkjet technology.
Advanced Printhead Integration
Unlike older models that suffer from “banding” (visible lines on the tile), the Ikon Plus utilizes a modular printhead system that allows for seamless overlapping of ink droplets. For an operator, this means you can achieve a native resolution that mimics natural stone or high-end wood grain with 100% accuracy.
Operational Insight: The “Plug-and-Play” Reality
One of the most operational advantages of the Ikon Plus is its electronic waveform management. Each ink type has a different viscosity. The Ikon Plus allows operators to adjust the “push” of the printhead electronically.
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Actionable Tip: If you are switching from a matte glaze to a high-gloss ink, do not manually prime the heads. Use the Ikon Plus software to adjust the pulse width of the waveform to prevent clogging and ensure consistent droplet size.
۲. Solving the Color Consistency Crisis
The biggest headache in ceramic production is “shading.” A batch of tiles produced in the morning might look slightly different from a batch produced in the afternoon due to temperature shifts. Porcelanosa required a solution that guaranteed color uniformity across millions of square meters.
Real-Time Color Management
The Ikon Plus features an integrated Color-Matrix system. This software communicates directly with the ink tanks to monitor temperature and flow rate in real-time. If the ambient temperature in the factory rises, the machine automatically recalibrates the ink delivery to maintain the same saturation.
| Feature | Legacy Systems | Projecta Ikon Plus |
| Color Recalibration | Manual (Hours) | Automatic (Seconds) |
| Ink Circulation | Partial | Total (End-to-End) |
| Gradient Smoothness | Visible Stepping | Photorealistic |
Operational Strategy: The “Golden Sample” Method
To maximize the Ikon Plus’s potential, Porcelanosa utilizes a “Golden Sample” workflow.
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Print a master tile at the start of the week.
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Use the Ikon Plus’s onboard optical sensors to scan subsequent tiles.
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The system alerts the operator if the Delta-E (color difference) exceeds 0.5.
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Actionable Tip: Set your threshold to a Delta-E of 0.7 for standard runs and 0.4 for premium luxury lines to balance speed and perfection.
۳. Maximizing Throughput: Speed Without Compromise
In the industrial sector, speed is often the enemy of quality. However, Porcelanosa’s throughput requirements are massive. The Ikon Plus was chosen because it maintains high-definition (HD) printing even at line speeds exceeding 60 meters per minute.
High-Frequency Internal Electronics
The “Plus” in Ikon Plus refers to the upgraded electronic backbone. It can process massive image files (GBs of data) without lagging. This is essential for large-format slabs, which are currently the most profitable segment of the market.
Implementation Checklist for High-Speed Printing:
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[ ] Vibration Control: Ensure the conveyor belt is calibrated to ±۰.۱mm to avoid “ghosting” at high speeds.
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[ ] Ink Temperature: Maintain ink at exactly 38°C (100°F) for optimal fluidity.
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[ ] Static Management: Use de-ionizing bars before the tile enters the Ikon Plus to prevent dust attraction.
۴. Maintenance and Longevity: The “Zero-Downtime” Goal
Porcelanosa didn’t just want a fast printer; they wanted a durable one. The ceramic environment is brutal—dust, heat, and chemicals are everywhere. The Ikon Plus addresses this through its unbreakable ink circuit.
The “Total Circulation” System
Ink in the Ikon Plus never sits still. It circulates even when the machine is in standby. This prevents the heavy pigments used in ceramic inks from settling and clogging the expensive printheads.
Comparative Analysis: Maintenance Costs
Over a 3-year period, a standard printer might require 20% of its initial cost in replacement heads. Because of the self-cleaning cycles and internal filtration of the Ikon Plus, Porcelanosa has reported a significant reduction in “head strikes” and nozzle failures.
“Operational excellence isn’t about fixing things when they break; it’s about choosing a machine designed never to fail in the first place.” – A perspective shared by leading industrial engineers.
۵. Sustainability and Waste Reduction
In the modern market, being “Green” is a competitive advantage. Porcelanosa is committed to reducing its environmental footprint, and the Projecta Ikon Plus is a key ally in this mission.
Precision Dosing
Traditional printing methods often waste 10-15% of the ink during the purging process. The Ikon Plus uses a vacuum-assisted recovery system that captures purged ink, filters it, and returns it to the main tank.
Operational Step: Reducing Chemical Load
By using high-intensity inks compatible with the Ikon Plus, you can achieve the same color depth using 30% less fluid.
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Practical Example: In a typical Iranian factory producing 5,000 sqm/day, switching to precision dosing can save up to $12,000 a month in ink costs alone.
۶. Integrating Industry 4.0: The Digital Factory
Porcelanosa’s choice was heavily influenced by the SITI B&T “Digital Graphic Design” ecosystem. The Ikon Plus is not an island; it’s a connected node in a smart factory.
Remote Diagnostics and AI
The machine is equipped with sensors that predict part failure before it happens. If a motor is drawing more current than usual, the system sends an alert to the maintenance team’s smartphones.
How to Implement This in Your Plant:
If you are upgrading your facility, don’t just buy the printer. Ensure your IT infrastructure can handle OPC-UA protocols. This allows the Ikon Plus to “talk” to your kiln and your glazing line. If the kiln slows down, the Ikon Plus automatically adjusts its printing frequency to match the line speed, preventing pile-ups.
۷. Large Format Slabs: The New Frontier
The global trend is moving toward “Megaslabs”—tiles that are 120x240cm or larger. Printing on these surfaces is incredibly difficult because any misalignment is magnified.
Seamless Patterning
The Ikon Plus uses advanced stitching algorithms. When printing a marble pattern across multiple tiles to create a “bookmatch” effect, the software ensures the veins align perfectly to the millimeter.
Operational Tip for Large Formats:
When running large slabs, increase the “Drying Time” parameters in your workflow. The Ikon Plus deposits a higher volume of ink for these formats, and failing to dry properly before the next stage can lead to “bleeding” or surface defects.
۸. From Spain to the World: Localizing the Success
While Porcelanosa is a Spanish giant, their logic applies to manufacturers everywhere. In regions like Isfahan and Yazd (Iran), where the ceramic industry is a pillar of the economy, the shift toward European technology like the Ikon Plus is a bridge to international markets.
Adapting to Local Raw Materials
One unique challenge in different regions is the clay composition. The Ikon Plus is versatile enough to handle different tile “biscuits” (the base material).
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The Iranian Context: Local clays in Iran often have a higher iron content, which can affect the final color after firing. By using the Ikon Plus’s on-the-fly color correction, manufacturers can compensate for the “yellowing” of local clay by subtly increasing the blue/cyan channels in the print file.
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