Beyond generic solutions, in today’s ceramics industry, competitiveness is defined by the ability to accurately manage complex and variable processes. Growing regulatory demands, increasingly stringent quality standards and the need to optimize resources have made digitization a fundamental operational requirement. However, implementing a generic MES system in a ceramics plant presents significant limitations that can compromise the expected results.
Traditional MES systems are designed to fit multiple industries, which implies a generalist approach that does not take into account the specifics of the ceramic process.
Control Ceramics the only MES System specifically for ceramics
Control Ceramics arose more than a decade ago from working directly with ceramic plants, where we have documented and understood the specific processes of the sector. This experience has allowed us to develop a system that not only records data, but also interprets the information in the correct context of the ceramic process.
During a recent customer review, two questions arose that illustrate this specialized approach. The first was about our knowledge of glaze formulations. The answer lies in our practical experience, we have worked with application technicians, we know how variations in composition affect the final result and we have developed modules that digitize recipes considering not only the proportions, but also the characteristics of each batch of raw materials, milling conditions and application parameters.
The second question concerned our mastery of quality processes. Our answer is based on the transformation we have achieved in the document management of ceramic quality. The system automatically integrates laboratory data with production information, generates reports that meet international standards specific to the ceramic industry, and structures the information in such a way that audits, which traditionally required weeks of preparation, can be resolved in a matter of hours with full access to the required traceability.
Ceramics-specific functionalities
Control Ceramics functions as an integration system that connects diverse equipment, from presses to kilns, glazes to sorting lines. The platform integrates with existing ERP systems while maintaining data consistency and provides complete traceability from raw material receipt to finished product.
Specific modules include advanced digitalization of ceramic recipes, with control of batch variations and monitoring of critical parameters. Energy control is adapted to the particularities of ceramic kilns, monitoring firing curves and specific consumption by product type. The automation of regulatory records takes into account the specific regulations of the sector, from emission standards to quality certifications for different markets.
The system provides real-time monitoring of each batch during the baking process, with automatic alerts when deviations in critical parameters such as temperature, oven atmosphere or cycle times are detected. This information allows immediate corrective interventions, reducing losses and maintaining product consistency.
Implementation and perspectives
Control Ceramics represents a solution specifically developed to meet the technical and operational challenges of the ceramic industry. Its implementation allows plants to optimize existing processes, improve traceability and facilitate regulatory compliance, which are essential elements to remain competitive in an increasingly demanding market.
Digitization specific to the ceramics sector is not a future advantage, but a present tool for plants seeking to optimize their operations with solutions designed for their particular needs.