Makeram, a unique factory in Russia.
Producing perforated facing bricks, solid bricks and thermal insulation blocks.
Equipceramic, S.A. has completed the construction of the new brickworks for Stroyservice in Mamadish, Tatarstan (Russia). This new factory, named Makeram, can produce a wide range of different clay products and formats.
Erection works were set up after the signature of the agreement between STROYSERVIS and Equipceramic on the construction of this factory in the spring 2013. The factory’s opening ceremony was punctually held on the 6th August 2014 and it was attended by, among other personalities, the president of the Tatarstan Republic.
At present, this plant has no equal in Russia and it can be considered the most modern one in the region on account of its outstanding automation and robotic system implemented by Equipceramic. It has been accurately designed to guarantee the best possible handling of products in order to obtain a high quality product and to provide it with the required flexibility for shifting from one product format to another in a rapid and simple way.
Attention must also be attached to both the installation of comprehensive process monitoring circuits allowing the remote control of the operation of the different manufacturing sections, and the application of innovative telematic technology for enabling remote either control or operation interventions, if it was required.
Cutting, loading and unloading
The cutting area consists of a new cutter with chamfering device applying the chamfer to 3 faces of the brick by means of chamfering rollers and equipped with a double wire-holder frame. This mechanism allows for saving operation time since it is provided with a spare set of wires that can be used whenever a wire of the first set is broken, so there is no need of stopping the manufacturing flow to replace the damaged wire.
Resulting pieces cut to the suitable size are loaded on dryer car decks by means of robots and then they are conveyed by means of transfer cars to the dryer entry.
At the dryer exit, dryer cars loaded with dry ware are driven by a different transfer car to the loading-unloading track so the unloading process can be performed.
Dry ware is set on spare tables by means of robots. Then ware is shifted to some marshalling tables where some robots provided with grippers arrange the layers of ware to be loaded on kiln cars.
The drying process is performed in a continuous dryer comprising state-of-the-art cone-shape air recirculation fans that suction the air from the main duct and from the top of the dryer to discharge it vertically so as to obtain a uniform drying all over dryer car decks. These air recirculation fans can rotate and they are arranged at variable distances in order to obtain a perfect ventilation system, meeting the required thermodynamic conditions for a quality drying: high and uniform air speed over the entire load and air direction parallel to the widest surface of the products to be dried.
Hot air for drying comes from the kiln waste recovery circuit and from some additional auxiliary generators. Air is distributed by means of some ducts running the whole length of the drying tunnel. The dryer is divided into four sections, each one allowing the autonomous control of: drying air volume pressure and temperature. Drying air flow can also be automatically adjusted in each section.
The dryer is equipped with electronic equipment for the control of: hot air inlet flow and temperature, hot air inlet/outlet flow in each distribution section as well as air temperature and moisture.
The firing process is performed in a “FT” tunnel kiln. Kiln cars are used as firing supports.
A prekiln is installed running parallel to the kiln. Kiln cars loaded with ware are introduced into the prekiln in order to decrease drying residual moisture and to suppress moisture regained by ware prior to its introduction in the prekiln. This way, ware is in the most suitable condition for being fired.
Inside the kiln, ware is heated by convection and it is shifted in the opposite direction to the gas coming from combustion in order to guarantee the homogeneous firing over the entire load. To this same purpose, an air-recirculation fan has been installed, thus avoiding gas stratification and ensuring a homogeneous firing and temperature uniformity inside the whole section of the kiln.
The kiln is provided with cutting edge control and regulation equipment to maximize the firing curve for every sort of product. It allows for identifying the type of product and for applying the most suitable firing curve. It also permits a progressive modification when shifting from one curve to another resulting in significant energy savings and quality increase of the fired product. Sophisticated systems have also been installed for the comprehensive monitoring of the entire process.
De-hacking and packaging.
Robots play a major role in the dehacking and package making line.
Kiln cars with fired ware are dehacked by means of robots that set pieces on marshalling tables in charge of arranging them in layers to make packages on pallets. The use of robots provides the possibility of making different pack formats regardless of the load arrangement on kiln cars.
The package making line is equipped with a full automated wooden pallet feeding line that delivers them to a conveyor belt and up to the robot area where dispatch packages are made.
The production line is completed with a fully automated package shrink film wrapping station consisting of a film wrapping machine equipped with a film uncoiler and a cutter-welder. After being wrapped, packages are shifted to a film shrinking frame provided with gas-operated burners in charge of shrinking film around packages to obtain a perfect packaging, useful for advertising purposes too.
The line has been equipped to allow, if necessary, the installation of the required equipment for vertical and horizontal strapping of packages.