Factory

Created using the most advanced equipment, of German origin, and rigorously selected domestic and foreign raw materials, Costa Verde’s porcelain stands out for its high-quality index.

The factory has an impressive stock of machines:

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Automatic casting machine
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Decoration kiln with 60 meters
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Isostatic presses
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Glaze firing kilns of 60 and 75 meters
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50 and 65 metre biscuit firing kilns
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High pressure casting machines
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Roller machines

Energy efficiency

Costa Verde monitors the types of energy consumed by the different equipment. Hot air recovery systems have been installed, aiming to reduce CO2 emissions and 10% in energy costs.

In partnership with Helexia, 3,696 photovoltaic panels have been placed on the roof of Costa Verde’s facilities, giving rise to a power station with a capacity of 1,000 Kw.

The production of electricity for self-consumption resulted in multiple advantages:

  • 20% reduction in electricity costs;
  • 3,5% improvement in energy efficiency;
  • Clean, and 100% renewable, energy production (620 tonnes less CO2 emitted per year);
  • In-house production of 25% of consumed electricity;
  • Profitability of plant coverage.
Costa Verde has an energy management system (ISO 50001 certification). This is how we reduce energy consumption and our environmental footprint. ISO 50001 certified companies, ceramic companies with energy certification, companies with energy certification, sustainable companies

Projects

Cerwave

Cerwave

Focused on microwave-assisted porcelain firing, with the aim of reducing energy consumption, achieving shorter firing cycles and reducing CO2 emissions.

Robocer

Robocer

3D printing design on porcelain body.

Premicer

Premicer

An initiative developed in partnership with INL and CTCV, aiming to improve the product’s technical characteristics, through nanotechnology application.

Isostatic Cup Press

Prensa Isostática de Chávenas

The machine that allows the robotic gluing of handles, has allowed gains of 25%, in production cost, and an improvement of 31%, in quality.

Printcer3D

Printcer3D

3D inkjet printing solution on porcelain powder.

Kaizen

Kaizen

Through jobs’ restructuring and optimization, this project, launched in 2007, has improved productivity and product lead time. In a second phase, it was implemented in the administrative and commercial sectors, with the whole organization now under Kaizen System’s guidance.

FRHM – Fully Ready Handle Machine

FRHM – Fully Ready Handle Machine

A project, entirely developed by Costa Verde, that resulted in the creation of a high-pressure filling machine, applied to the production of ready-for-gluing handles. The equipment is marketed by the German factory SAMA.

Scanner 3D – Reverse Engineering

Scanner 3D – Reverse Engineering

It aims the immediate 3D scanning of each and every product, mould or object, by obtaining profiles and quotas in a very fast way and in colour.

MES – Manufacturing Execution System

MES – Manufacturing Execution System

A solution, developed by Critical Manufacturing, reads, in real-time, the data generated by intelligent equipment, such as automata, robots and sensors, and allows Costa Verde into achieving greater operational efficiency. Thus, customer orders are handled in the productive equipment, in direct communication with the ERP. The initiative explores some innovative conceptions, in the aim of Industry 4.0, by being Costa Verde prepared to extend the concept in the future.

Minimum

Minimum

Project to create ecological porcelain pieces developed by Costa Verde, in partnership with CTCV, CENCAL and LNEG. The use of recycled raw materials from the sludge of the water treatment plant results in a multifunctional and environmentally friendly kitchen set, resistant to microwave, oven, refrigerator, and freezer.