The fully automated line, from the loading from storage silos to the transport of the finished product to the casting of the dies, has as main characteristic the management of all the production parameters managed by PLC. The type and number of recipes to be set, allows a great flexibility to achieve totally customized blends to be used for different needs and solutions. The automatic management of dosing and mixing water temperature is one of the great advantages also and above all for those who produce plaster molds for spag-less casting. The extreme precision of the dosing instruments, the accuracy of the management software as well as an extreme care of the mechanical-structural part, make the system extremely flexible and effective. In the production of gypsum mixtures for the construction of spagless type molds, it is possible to set recipes that allow the determination of the parameters necessary to achieve the porosity characteristics to which it is desired to work during the casting phase. This peculiarity represents a great advantage in the management of the life of the mold and a quality of sanitary molded by casting that is clearly superior to the standards. The plant works in automatic sequence producing the required mixtures that are subsequently discharged by the appropriate containers in the matrices placed on a special casting carousel. The plant can work according to requirements by varying the quantities to be produced, increasing or decreasing the volumes according to the setting. It also has a carwash system for containers containing the mixture of gypsum, which does not affect the continuity of the production cycle. The system can be customized according to different needs. Source: Setec News
Recently Teide refractory solutions has employed special machinery to dry and cure refractory parts. This new burner complements the four driers the company already owns. The advantage of having an auxiliary burner lies in the ability to perform more precise drying and use temperature control that is more suited to the circumstances and conditions required by the refractory material. Source: Teide refractory news
Smoked bricks in Maasmechelen(B) purchased the first hood kiln for blue smoked products from Instalat. The kiln with two kiln cars and its layout is specially designed by our engineers for blue damping of bricks from several different customers. As commonly usual, the Kiln is equipped with a state of the art firing equipment and PC-PLC controls, which allows a fully automatically and reliable process. The kiln has already been successfully assembled and commissioned. Source: Instalat News
In 2018 the Belgian company Dumoulin Bricks has renewed their two main equipment for molding and shaping clay bricks: The Filter Mixer and the Extruder. They chose Verdés as their technical partner for the supply of the two new equipment. The purpose of the intervention was to incorporate a new equipment capable of surpassing the production rates and working pressures accomplished by the existing machinery already working on the limit of its capacities. Verdés accepted this challenge relying on its long experience in molding and its new design of MAGNA extruder, released in 2013 and counting with the newest technologies in extrusion.The supply consisted in the filter mixer model A-750-F and the MAGNA 675 extruder. Filter Mixer A-750-F The model A-750-F is the largest machine of its range. It consists of a 1800 mm long trough open mixer which incorporates a compression zone of 875 mm that compact the clay against a grid, thus obtaining a high efficiency in homogenization and catching the impurities of the material in the process. The capacities of this model exceed the actual production requirements to allow the possibility of a future increase in productivity rates. MAGNA 675 extruder The extruder Magna 675 has a production capacity up to 85 t/h, highly superior to the current production. It counts with an auger diameter in the vacuum chamber of 675mm and 650 mm in the front. This configuration permits applying a range of pressures up to 25 bar that provides flexibility to produce different clay block formats. The higher applied pressure also allows to work drier and reduces the consumption in the drying furnace that follows. After several months in production, the results are clearly visible: the working pressure has increased, giving more stability to the wet blocks and enhancing the productivity of some critical product formats. The machines are currently working far from their maximum capacities, resulting in a reduction in the wearing of the critical parts. The molding process has improved its efficiency and is prepared for a future increase of capacity in production. Source: admin-verdesnews ...
CeramTec is presenting high-quality cutting materials and tool holding systems for metal machining as well as technical ceramics for forming processes and wear protection at the AMB . The product portfolio on display at the international exhibition for metal working will include a new tangential milling cutter. It is ideal for applications which require a soft cutting tool to reduce cutting pressure as well as for machining exact 90° shoulders. The TFL-WP tangential milling cutter works with indexable inserts with six cutting edges. The positive cutting geometry enables milling to be carried out with significantly reduced cutting forces. Exact 90° shoulders can be machined at any height thanks to the tangential arrangement of the inserts. The advanced ceramic inserts guarantee enormous process reliability due to possessing the largest possible cross section. They are easy to replace using the screw clamps. Users benefit from a longer service life and improved feed rate on account of the tangential positioning and the resulting cutting edge spacing of the milling system. The cutting material variants available for the milling system open up a wide spectrum of workable materials. For instance, GJL and GJV cast iron materials can be machined using these cutting materials with high process reliability. Its high axial and radial runout accuracy enables an Ra value of 6.3 μm. Ceramic tools from CeramTec are used in the high-performance machining of cast irons, hard-to-cut materials and hardened steels. Source: CeramTec Press News
As demand for Tabular Alumina expands with India’s refractory requirements, Almatis is committed to support and enhance our customers’ success with Quality alumina products and excellent service. A positive outlook for Indian produced steel, leveraged by growing GDP and per capita steel consumption requires premium alumina for longer refractory life. “Almatis is committed to providing continuous support to the Indian refractory industry,” Emre Timurkan, Almatis’ CEO said. He assured the market that, “Almatis is on a path of rapid construction to satisfy our customers’ increasing demand for high quality Tabular Alumina.” Source: Almatis News
BERALMAR has just commissioned a new plant in Malaysia. It is a new production line for KILANG BATU BATA HAP KEE (Serandah, Malaysia) for which BERALMAR has supplied a dryer and a tunnel kiln for a production of 750 tonnes/day of solid bricks. The new facility, which in the first phase has a production of 480 tonnes/day, is made up of a LLEVANT direct kiln car setting dryer and a PRESTHERMIC airtight tunnel kiln. Both the tunnel kiln and the two drying tunnels are 168 metres long with an internal width of 6.3 metres. It is important to note that the only thermal energy consumed in the factory is petcoke, using a MICROMATIC system. The LLEVANT dryer, thanks to a comfortable drying cycle of more than 50 hours for all formats, is fed only hot air recovered from the kiln. As usual in this type of factory, the commissioning has been very simple and all the material in the first kiln car out of the kiln has been of the highest quality: from the kiln car to the lorry. Although the new HAP KEE plant will currently produce only solid formats, its senior management plans to introduce thermoblock formats to Malaysia soon. We wish them the best of luck in this project which is so important for the future of the Malaysian company. Source: Beralmar Press News
The scope of the project was the replacement of the old existing equipment with a new robotic packaging line. Before the modernization, the plant was using an outdated robotic system that was influencing negatively the quality of the final product. Moreover, the often stops of the old equipment was impeding the capacity of the line and the whole plant. The new system was designed to be simple and reliable ensuring minimum stress on the final product and the creation of a robust final pack of bricks. In this new packaging line, one new robot is taking the layers of bricks from the two existing programming benches and builds the final pack on a new roller conveyor. An additional spacing mechanism was added as an extension of the existing programming and sorting bench to replace the old slow stand-alone mechanism. The spacing mechanism is creating the third layer with the suitable lifting openings of the pack.   After the pack is formed it is transported on the roller conveyor to be strapped at first and consequently to be hooded by a stretch-hooding machine. While strapped the formed pack is supported at the sides so that to ensure the effectiveness of the strapping. The vertical strapping machine is working in combination with a heavy duty pusher that ensures the accurate step-by-step movement of the pack at the 4 strap positions. During strapping it is placed plastic angle protection at four of the edges of the final pack. The pack is then passed on the hooding station, lifted and hooded. Lifting is ensuring the hooding all around the 8 vertices up and down. At the end, the final packs are passed to a chain conveyor for picking up by the forklift. Special attention was given in the designing of the safety of the line. All fences and access platforms were detailed designed and studied to ensure the safe working environment for the operators as well as the efficient access to the machines. An analytical risk assessment study has been carried out to guide the selection of the equipment and the design. In terms of implementation time the project was quite challenging since all the works including disassembly of existing...
Vishay New mixer EIRICH mixers have been used in many preparation processes in the technical ceramics industry for decades, and thanks to their underlying design and system layout, these mixers can perform mixing, granulating, coating, kneading and dispersing. In addition, a quality of disintegration is attained that cannot normally be reached by other systems. Vishay was impressed by the advantages that this technology has to offer and decided to install an EIRICH mixing granulator. Vishay Electronic GmbH is part of Vishay Intertechnology Inc. The global high-tech company with production sites in 17 countries is one of the leading manufacturers of active and passive electronic components. In 1987, Vishay took over the company Draloric in Selb in Germany. Today, Vishay Draloric is one of the trade names for MELF (metal electrode leadless faces) resistors and ceramic capacitors. Just like in all other product classes of technical ceramics, the preparation process also plays a pivotal role when it comes to ceramics for electronics applications. The requirements in terms of the mixing results are high – the aim is to achieve the most uniform possible distribution of all components. This is the only way to ensure that, later on, every component offers exactly the properties assigned to it by the specification. This was already the reason why the predecessor companies of Vishay Electronic chose to use the best available preparation technology and manufacture with EIRICH mixers. Technological advancements have led to numerous innovations, both in ceramics for electronics applications and in machine engineering and plant construction. This is why, after repeated test series at the EIRICH test center in Hardheim, Vishay Electronic decided to install a new EIRICH mixer. As is typical for mixers for technical ceramics, all parts that come into contact with product are made of stainless steel. A frequency inverter allows the mixer to run in different speed ranges. The mixer, which was taken into operation in November 2017, enables Vishay Electronic to continue producing high quality components. Mixers with a size below 150 liters are normally large enough for applications in technical ceramics. However, it is often important for the manufacturers that these mixers are not only able to mix, but that they can also perform granulating, coating, kneading or dispersing. With the EIRICH technology, it has been possible to...
Shaping The milled clay is fed from a box feeder to a double shaft mixer on a conveyor belt. Water is added to the clay in the mixer until the body has a moisture content of around 30%. As the production body leaves the mixer, it is pressed through a filter and drops onto another conveyor that takes it to a vertical blending mixer that sends the body on to the next system in operation: either a floor –tile press, a brick moulder or a special product press. Three each floor tile moulds, measuring 150 mm x 300 mm are arranged on a given mould carrier. The washed and dried moulds are sprayed with oil and then powdered with sawdust to give the fired tile a rustic appearance. The oil holds the sawdust in place, and any excess sawdust is vacuumed off. The thusly prepared moulds are the moved in under the dispenser. This newly engineered filling system from Capaccioli, named “APE”, fills body into the three moulds at once and combines three steps: mixing, compressing and clay distributing into the mould. Special devices inside the “APE” randomly combine the three phases. Such randomness is generated by a computer that makes the procedure always different and never repetitive in order to obtain items different one from the other. Each product is unique – unlike those made in older press systems, where certain surface finish effects are constantly repeated. One of the plant’s most important feature is that Capaccioli has managed – before any one else – to make products with the same, low body density as that of hand made products.By contrast, products made by older systems have higher body densities. Furthermore the APE can be programmed to give the desired, preset body density.The lower density reportedly generally keeps low body stress levels, so the products are not only more frostproof, but also easier to dry and fire.While the tiles are still in the moulds, their backs are sanded a little in preparation for drying. A metal drying frame is placed on each of the three – mould carriers and then turned over together with the moulds, and the live bottoms of the moulds move...