KELLER HCW expands the Wienerberger Plant in Torun with High Tech Equipment
[October 2010] In 1998, KELLER in Ibbenbüren-Laggenbeck supplied all machinery and installations for the facing brick plant at the site of Torun in Poland which was operated by Boral. The plant was then taken over by Wienerberger Ziegelindustrie AG from the intermediate operating company Hanson Bricks.
KELLER HCW was awarded the contract to implement the second building stage for a performance increase of the factory with the objective to double the productivity of the plant from 30 million to approximately 60 million facing bricks per year.
For KELLER HCW, the scope of deliveries and services for this project covered engineering, manufacturing, erection and commissioning of shaping, setting, handling and packing installations, and, as a supplement, a second tunnel dryer and a second tunnel kiln.
A really big challenge was the integration of the new plant into the existing plant. The existing plant already had a wet storage, a tunnel dryer, a holding room, and a tunnel dryer and was now extended by a separate tunnel dryer and a tunnel kiln; the existing tunnel kiln and tunnel dryer were lengthened by approx. 30 m. The same process-engineering requirements were applied to the new installations – with a total increase in production of 100%.
The plant has a wet side line with a universal cutter with vertical cut. The established KELLER cutter was further developed for the production of facing bricks. In order to meet the high requirements regarding the quality of facing bricks together with high output rates of more than 12000 facing bricks per hour it was decided to use of a fivefold cut with chamfering.
Loading station for tunnel dryer cars
The new production sequence was adapted to the conventional setting patterns. For this purpose, it was necessary to implement a supplementary craneway, which transfers the stacking pallets of the old plant. Thus, the handling of the products and the stacking pallets is now carried out by both craneways in parallel.
Tunnel dryer cars and tunnel kiln cars
Originally, the products were set on stacking pallets in 4 layers. As a consequence of the increased output it was necessary to put an additional layer on top of the setting. This measure also required to lift up the ceiling of the existing tunnel dryer and the wet storage. Furthermore, as a result of the increased payload, it was necessary to exchange the axles and bearings of the wheel set of the existing 46 tunnel dryer cars and 45 tunnel kiln cars. The additionally required 50 dryer cars and 54 kiln cars were newly set up.
Wet storage
Due to the increased output and the sensitive wet products, the existing wet storage was extended by approx. 5 m.
Girder unloading and setting machine
After the drying process the loaded dryer cars are moved into the holding room. During the same working cycle, the craneway gripper takes the stacking pallet and dry goods, sets the pallet on the advancing dryer car and then sets the products on the setting machine feeding conveyor.
Contrary to the old setting installation, the products to be dried are now passing a setting machine with complex grouping facilities and are not directly set on the kiln car by two robots.
Moreover, the newly designed setting plant offers the option to run the required products first through an engobing installation.
Details for the dryer
In its general design, the new dryer is identical in construction to the existing one, but was extended at the exit by approx. 25 m. The tunnel dryer is made of brickwork and now has a new total length of 190 m.
Details for the kiln
The kilns are identical in construction and have a length of 170,5 m. In the second building phase, they were extended by a preheater with a length of 25 m. The kilns are top-fired and laterally–fired with natural gas and are equipped with high-velocity burners and injector burners.
Transfer car
As a consequence of the extension of the tunnel dryer, tunnel kiln and storage track, the existing track beds for transfer cars 1 and 2 also had to be extended. The higher payload of the tunnel dryer cars and tunnel kiln cars made it also necessary to exchange the drives of the "old" transfer cars. The former storage track in the area of the unloading station was shifted and reused as an unloading track. Transfer car 3 and the repair track are a supplement to the second building stage.
Unloading and packing station
A second unloading track was integrated into the process in the area of the unloading and packing stations. With this provision, the craneway can unload two tunnel kiln cars at the same time. The following pack de-hacking is carried out by two high-velocity industrial robots.
The following machine part is a combination of existing installations, such as a paper storage, a packing line, a pack transfer carriage, etc. and new technology, such as a transfer device for lifting bars, a combined de-facing and positioning device and a row transfer device, etc.
Production time
The installations for the new plant were laid out for a production with a three-shift operation on 7 days per week and 50 weeks per year. The production time of the dryer and the kiln amounted to 24 hours per day and 50 weeks per year.
Scheduled timeline for the project
As a result of the excellent cooperation between Wienerberger-Ziegelindustrie and KELLER HCW, the extremely ambitious integration of new installations into the existing production plant could be implemented after a construction time of only 10 months, and the completion of the building project could be finished as scheduled.
Today, the plant is operating with its full nominal capacity and produces bricks that match the highest quality standards.
Further information can be found under the following link:
Project data of the plant »
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