Prepared for the future by two-stage modernisation
[February 2007] Two existing brick factories at the traditional Novi Becej factory site in the north-west of Serbia were comprehensively modernized in two construction stages. The results are two modern and high-capacity roof tile plants operated by Industrija Gradevinske Keramike POLET, a company of the Nexe Group. The machinery and equipment were delivered by KELLER HCW in Ibbenbüren-Laggenbeck.
In the first construction stage a roof tile plant for the production of interlocking tiles, designed for an annual output of 24 Mio. high-quality roof tiles, has now been achieved.
On the basis of this successful first construction stage there was no question that Polet would continue the good cooperation with KELLER HCW and proceed with the second construction stage. A closed brick plant was modernized into a highly-flexible plant for the production of shaped tiles. Since the successful commissioning, Polet has been selling high-quality special roof tiles as well as plain beaver tiles to the expanding market.
The following concept of the shaped tile plant serves as an example for the successful reconstruction of a factory.
The product range of the plant comprises the complete range of shaped tiles (e.g. verge tiles, ridge tiles) for different types of roof tiles up to various extruded products. For the comprehensive range of products, a made to measure machine plant, particularly in relation to the wet and dry sides as well as special drying frames, were designed by KELLER HCW. By means of the wet side machinery the pre-shaped slugs are firstly cut by the cutter, pushed onto a slug feed conveyor and conveyed to the specials’ press removal position.
In the case of the production of extruded tiles, for example beaver tiles, the cutter cutting table has to be exchanged. The beaver tiles are doubled by a distributing shunt and are fed in pairs to the suction device where the products are set down carefully on drying frames.
Machinery
All the machinery for the cutting and transporting of slugs, for punching and transporting of extruded tiles as well as the equipment for the transport of drying frames, of dry products and U-cassettes, including the equipment for loading and unloading of dryer cars and kiln cars, were delivered by KELLER HCW.
A modern industrial robot equipped with gripping and suction devices is used for the unloading of drying frames.
During the transport to the kiln car setting plant the dry products pass through an engobing station with a following drying line.
The system has been prepared for the automatic loading and unloading of U-cassettes, but is initially being done manually. Loading and unloading of kiln cars, as well as the handling of U-cassettes, is done fully automatically. The kiln car loading and unloading equipment are separated by a stationary U-cassette storage machine.
Dryer
The existing tunnel dryer was improved and equipped with new process equipment. For optimum air circulation, the intermediate space of the load between the two dryer car forward tracks was equipped by KELLER HCW with a further circulation wall. The design of the circulation wall was based on long experience and comprehensive testing. Under operating conditions the design of the circulation wall proved to be highly-efficient with 100% output of the specials’ plant.
Dryer equipment and dryer car setting have been adapted to suit each other. The dryer car consists of a rail-borne chassis on which stackable drying frames are set. These frames can be turned-over and both sides are designed for a part of the range of products.
Furthermore, new dryer car transport equipment as well as the KELLER dryer control system, Type K-matic TD, were successfully installed.
For the dryer control system KELLER HCW has further developed a version which has already been installed in some plants. All functions of the proven K-matic system were included in this new system. Access and use of this new system is simplified by further developed, but in principle same menu structures. Due to further configuration possibilities older computer systems can be replaced by the process computer. By the outsourcing of important control and regulation functions into the PLC system, the process computer is very reliable. Today, the reproducible production becomes ever more important. This is optimally supported by the comprehensive automation functions and extended filing of all relevant process data in the KELLER HCW process computer system.
The computer system can be provided in several languages, thereby being adapted to suit the requirements of our worldwide customers. By connecting the process computer to telecommunication systems the operation of the plant can be monitored from all sites.
Because of the convincing technical characteristics and the drying results the decision for the KELLER dryer concept was a real success.
Kiln
A tunnel kiln is used for firing the extensive range of products. The existing tunnel kiln building of the former brick plant was improved with regard to the design and equipped with modern control system, as well as new burner technology and process equipment by KELLER HCW. A new pre-heater was installed on the outside track with the kiln car loading and unloading station. The kiln car transport equipment as well as the kiln car decks were replaced. The kiln car decks were equipped for U-cassette setting.
The new kiln control system with the process computer system offers the characteristics and possibilities as specified above for the dryer control system.
Summary
The photos of the plant, which in the meantime is being operated above the set output, give an impression of a successful reconstruction of a factory to a modern roof tile plant. In further extension stages the factory can be fully automated. Dryer, kiln and machinery allow for the flexible production of high-quality clay roof tile products. The existing plant and building were integrated into the reconstruction process so that they could be used optimally and economically.
Further information can be found under the following links:
Press Release 02/2005 »
Press Release 10/2004 »
Press Release 05/2004 »
Brochure 11/2004 »
Brochure 11/2004 »
Brochure 11/2004 »
Brochure 10/2004 »
Video 05/2004 »
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