Easymud – efficient and cost saving production of soft mud products

Easymud, Capaccioli‘s fully automated production line for the forming of bricks, floor tile, roof tiles, brickslips and special pieces in soft mud, is a line production and a method patented by Capaccioli since 1997 with substantial innovations to create soft-mud products on an industrial level so as to ensure the transition from one product to another in a short time. As Capacioli shares, over the past two years, Easymud has been the subject of a thorough renovation that led it to unique performance in its sector, according to the company.

The extensive use of robot-based technology has led to new important results. The current machine allows the forming of brickslips and other decorative materials of small dimensions with roughness similar to those of bricks. This type of brickslips, a high demanding product, is commonly produced by cutting two external sides of the fired bricks, discarding the central part with a great material waste and consequent production inefficiency. Producing strips with Easymud means to have no more product waste as well as considerable energy savings.

Significant energy savings possible

The new Easymud production system also guarantees an accurate surface finish of the mortar or glue application face, allowing it to be applied with glues requiring tolerances in the order of tenths of mm.

Another interesting feature of Easymud is the forming of corners, or special pieces, to be applied on the corners of the walls. These are usually made by forming whole bricks, firing and then cutting them. This procedure involves a large amount of waste. The Easymud system allows the realization of corners of various sizes, formed without waste. The robotic shaving process ensures the desired surface accuracy. The shaving trimming is reintroduced into the working cycle.

The wide use of robotic technology has led to a significant progress in the principles of lean manufacturing. The use of mobile parts as well as special machines has been reduced to a minimum, with benefits on reliability, time management of the plant and maintenance times. The latest changes have also made it possible to reduce format change times even more, integrating every aspect of this function, including the management of mould sets, into the machine design.

Easymud system enables to simplify and reduce maintenance and production costs, to drastically reduce the consumption of raw material and consequently also the general consumption of energy, both compared to previous machines and compared to the current technology on the soft mud production.