Plant to manufacture roofing tile special accessories
Production: 10,080 pieces/day into 3 8h-shifts/day.
Products: Roofing tile special accessories: ridge roofing tiles, side end pieces, half-roofing tile, double roofing tile, ventilation roofing tile.
Dryer: CHAMBER DRYER with a total number of 4 chambers.
Location: Cobeja, Toledo- Spain.
Hermanos Díaz Redondo – A new plant to manufacture roofing tile special accessories
The project conception joined Hermanos Díaz Redondo’s ceramics experience in roofing tile manufacture and EQUIPCERAMIC’s technological development, with priority being attached to the concepts
of quality and efficiency.
The result was the commissioning of the most important automated plant to manufacture roofing tile special accessories in the country.
CUTTING AND PRESS FEEDING
The whole project was housed in a new hall of about 2,600 m2 next to the existing mixed roof- ing tile plant. A guillotine-type cutter and a line for feeding a FAVOLE mechanical press, SSO2 type, with 2 piece moulds, were installed to press clay clots. The nominal production rate of the installation is 15 strokes per minute.
The shaped pieces are laid onto trays conveyed by a “RAT” type conveyor. They are routed to the loading point where an automated loading arm puts them into dryer cars.
The same loading automatism unloads trays loaded with dry products to lay them onto the RAT bottom conveyor.
DRYER CAR LOADING
Dry roofing tiles–loaded trays are conveyed to the point where roofing tiles are unloaded to the engobe line by means of an automated device comprising seven individual grippers.
Two buffer stores, dedicated to the storage of either dry roofing tiles-loaded trays or empty trays, were integrated to the installation to bring the required flexibility.
At the exit of the engobe line, dry roofing tiles are conveyed to the U setters loading and unloading area, consisting of a closed circuit where dry roofing tiles are introduced into empty setters.
A stationary chamber dryer with cone-shape air-recirculation fans, installed between dryer cars, was built to dry special accessories. This way, air is vertically distributed resulting in the suitable drying uniformity over the different decks dryer cars consist of, thus decreasing temperature differences at height.
Three loaded setters are collected by a gripper and loaded onto kiln cars. The same gripper unloads three setters full of fired roofing tiles from the same kiln car. It routes them to the circuit where they are unloaded and conveyed to the point where they will be loaded with new dry roofing tiles.
Moisture and temperature in each chamber are PLC controlled. The PLC monitors a fre- quency inverter which works on the impulsion fan and on a set of motor dampers.
Our applied programming software allows for working either on “stationary positions” mode or on “variable regulated” mode.
It gradually changes setpoints, thus improving energy efficiency. It is structured around a series of PID’s: the first one creates a “floating” set- point assigned to a second PID that regulates the temperature in the impulsion duct, thus making the installation safer.
After unloading from setters, fired roofing tiles are strapped in 5 or 6 unit packs.
Finally, resulting strapped packs, wrapped in plastic film hoods are conveyed to the exterior of the plant where they are collected by a lift-truck.