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Press Release
September 2010
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KELLER HCW supplies the first plant for grinding and filling of ceramic blocks in Russia
[September 2010] In the brick plant "Kaluzhski zawod strojmaterialow" situated in the settlement of Towarkowo in the near of the Russian town Kaluga the first plant for grinding and filling of ceramic blocks with mineral fibres was started up on the territory of the Russian federation in July 2010.
The group of companies TEREX intended to introduce a new and innovative product – the ground block with integrated insulation – on the Russian market for building materials. The product is a ceramic insulating brick having surface-ground surfaces and an increased heat-insulation reached by chambers filled with mineral fibre.
Due to the high size accuracy of the porous blocks in combination with the ground surfaces and the highly heat-insulating material it is possible to reduce the thermal conductivity decisively. Now by this innovation it is possible to create a brickwork out of such a building material having an extraordinary thermal conductivity of theoretically up to 0.07 W/(m*K).
The group of companies TEREX has placed the order for a modern and trend-setting production line with the German partner, firm KELLER HCW GmbH, on March 2010 after intensive engineering and development work.
Operational principle
The grinding and filling plant was integrated into the existing block plant. Thus fired blocks can be fed directly to the grinding and filling procedure after being unloaded from the tunnel kiln cars or transferred alternatively directly to the packaging plant.
Grinding of the fired products as well as cutting of the mineral fibre slabs and filling of blocks with mineral fibre pieces is effected fully automatically. An absolute advantage is the packing of mineral fibre pieces without any cut-offs which was developed in a German-Russian development procedure in cooperation with firm ROCKWOOL.
The pre-packed mineral fibre slabs are automatically cut into cuttings of predetermined sizes so that they can exactly be filled into the chambers of the blocks. The mineral fibre slabs are prepared "just in time" from firm ROCKWOOL, Russia.
The ceramic blocks are fed to the grinding plant via a bypass where grinding of the cutting surfaces exactly to the millimetre is effected. The grinding plant was manufactured at firm novoceric in Mellrichstadt specialised in grinding technologies. novoceric is a 100% affiliated company of KELLER HCW.
Then the ground blocks are fed to the robot filling plant via a system of chain conveyors. There the vertical filling of blocks with the ready-cut mineral fibre pieces is effected by a particular gripper installed on the robot.
The use of FANUC industrial robots guarantees the high flexibility of the plant for this operation. The later extension and increase of the actual installed output of the grinding and filling line of approx. 800 pcs. of filled blocks of size 10.7 NF per hour can certainly be enabled by this plant conception. Naturally the plant also permits filling of a large number of other large-sized bricks according to GOST 530-2007.
The ready-filled products are finally fed to the packing equipment by means of a transfer device.
In order to guarantee a continuous and functional operation of the grinding and filling line, the operating staff of the brick plant "Kaluzhski zawod strojmaterialow" was intensively trained to this technology. The KELLER HCW GmbH’s specialists accompanied and supported the customer during the complete project run until the end of commissioning.
The supplied technology commissioned in brick plant "Kaluzhski zawod strojmaterialow" corresponds to the latest state of development on the market for machines for the heavy clay industry. This plant sets new standards in the heavy clay industry and due to its compact installation and high flexibility it will be the pattern for numerous brick plants in the world.
This brick is the result of an intelligent connection from ceramic blocks and mineral fibres. Thus ecologically and economically effective brick houses can be built without complex and often expensive additional insulation. Therefore the filled ceramic block is an ideal external wall construction material for one family house and multi-storey house building with high standard to the thermal insulation and noise protection.
Further information can be found under the following links:
Video 08/2010 »
Project data of the plant »
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