Today we want to tell you about Control Flux, one of the most advanced innovations developed by Air Power Group for ceramic glazing.
A system that addresses one of the most frequent and costly issues in the production process: partial or total obstruction of airless nozzles.
Why nozzle monitoring is strategic for ceramic companies
Nozzles are fundamental components within the glazing line. Even a minor variation in flow rate can compromise product quality, generating aesthetic defects, weight errors, waste, and resulting extra costs.
In a highly competitive sector like ceramics, minimizing these variables is essential not only to ensure high quality standards, but also to improve overall production efficiency.
Control Flux was created precisely for this purpose: to ensure constant monitoring of the flow rate of each individual nozzle in real time, eliminating instability and preventing errors before they turn into problems.
How Control Flux works
The system immediately detects anomalies in the flow of glazes and slips, signaling wear and obstructions. Every parameter is under control and usage thresholds are preset and customizable, so as to adapt to different production requirements.
Thanks to integration with Air Power’s Airless systems, Control Flux fits easily into existing lines, without requiring invasive or complex interventions on the line.
Main advantages for ceramic production
1. Flow rate control
- Flow stability for each individual nozzle
- Elimination of weight error
- Configurable usage thresholds for customized management
2. Wear monitoring
- Continuous monitoring of nozzle condition
- Immediate detection of partial or total obstructions
- Automatic line shutdown capability → zero waste
3. Preventive maintenance
- Accurate analysis of glaze and slip consumption
- Operator alerts with countdown (30/15/5 minutes) before replacement
- Immediate intervention in case of anomaly
In this way, the system not only prevents unexpected machine downtime, but also allows maintenance to be planned predictively, avoiding waste and optimizing resource utilization.
Concrete benefits
Implementing Control Flux on your glazing line means not only improving a technical aspect, but creating strategic value for the entire company.
The benefits are reflected on multiple levels:
- Waste reduction: fewer defects mean less wasted material and greater production yield.
- Cost optimization: monitoring enables more efficient management of glazes, slips, and maintenance time.
- Operational continuity: fewer unexpected interruptions, more stable line performance.
- Sustainability: a more precise process reduces consumption and waste, aligning with ESG objectives and international market demands.
This translates into greater competitiveness, faster return on investment, and consolidation of the company’s positioning as an advanced technology player.
Simple integration, immediate results
Control Flux can be installed as an integral part of the Slim Cover Fast system, or as an independent module for all Airless systems already in operation. This flexibility makes it a versatile solution, capable of adapting to both new lines and existing plants.
Conclusions: toward more efficient and sustainable ceramic production
The challenge for the ceramic industry today is to reconcile quality, productivity, and sustainability. Technologies like Control Flux represent a concrete step forward in this direction: real-time monitoring, preventive maintenance, and zero waste are not only technical advantages, but strategic tools for business growth.
Air Power Group continues to invest in research and development to offer solutions that meet market needs and support ceramic companies toward a more efficient and competitive production future.
