Production 100 million of 1NF/year.
Production: 100 million of 1NF/year.
Products: 1 NF and 1,4 NF chamfered perforated bricks, 1 NF solid bricks.
Geographic location: Novosibirsk.
Important brickworks in Novosibirsk
25% increase on nominal capacity of a plant producing 1NF bricks in Novosibirsk, Rusia.
The factory was founded in 1988 and the technology it was equipped with had a nominal capacity of 75 millions of 1NF/year, building bricks. After 25 years of continuous operation, the production capacity of the factory had dropped significantly due to normal wear and tear making upgrading necessary.
The upgrading project designed by the customer set the bar quite high since:
- In terms of production: We had to ensure a 25% increase on the nominal capacity.
- In terms of quality; our customer focused on the facing brick market and so we had to supply some equipment provided with outstanding technical solutions in order to ensure the perfect quality of products.
- In terms of project execution, we had the challenge to fit the new machinery in the already existing halls and to reuse the maximum number of machines of the already existing production line.
Our capacity to adapt our high quality, state-of-the-art equipment by taking advantage of the maximum number of machines of the already existing line was determinant to gain our customer’s confidence.
Our upgrade technical solution:
The cutting line is equipped with two cutters. The first one cuts the clay column at the exit of the extruder and it has the capacity to cut large size blocks.
The second one is our multi-wire cutter which can perform a chamfer on three sides. In order to avoid any deformation of the side in contact with the conveyors, a device for taking off the excess of clay is installed at the exit of the cutter on the side below. The chamfering depth can be adjusted and its angle can be adapted to the customer’s preferences. Thirty minutes are enough to restart the production of a new product. Our cutter is equipped with chamfering rollers, Teflon coated, specially adapted to the Russian clays. It is equipped with a an automatic system to replace the wire-holding frame in the event a wire was broken and with an automatic system for cleaning wires. Special alloys have been applied to minimize friction at the time of cutting. It has a nominal rate of 10 strokes/minutes and therefore it is well adapted to the high production of the factory. The cutter can cut 2 x 15 products at the same time.
Both technologies, the former cutting line on the left and the EQC line on the right operate together. At present, solid products, which are cut by the former cutter, are conveyed to the EQC dryer car loading area. The customer intends to install a EQC cutter to replace the old one.
GREEN PRODUCT LOADING LINE
Green product loading line on dryer cars is a EQC solution particularly well adapted to this factory. Equipment is distributed into two groups: a belt conveyor loaded with a layer of products shifts the opposite of the kiln car, the motor-operated roller device that gets inserted between the bars of each deck, accurately lays down green products on pallets.
The old heavily worn setting gripper had become very inaccurate resulting in a lot of working stops.
The former setting machine Kiln cars before upgrading
We have rearranged the setting line from dryer car unloading area to the setting machine. We have proposed a solution to optimize all the space of this area consisting of belt conveyors and a 90º turning gripper . The line is equipped with turning devices to enable flat loading of facing products. Products are loaded on kiln cars by means of robots. Loading can be performed on flat or on edge according to the type of product.
Products are hand- dechacked.
At present, the line is equipped with two dehacking robots that unload products on a layer-basis and release them on 2 lines. A visual control is performed and two turning devices are installed.
Some accurately synchronised buffers for layers of bricks allow two palletization robots to work in the preparation of the same pallet.
Wooden pallets are handled by one of the two robots.
2 strapping machines apply four horizontal strappings and two vertical strappings.