El Moumtaza - State-of-the-art roofing tile factory
Production capacity of 12 million units/year in Wilaya de Boumerdes, Algeria.
This new factory will make Roman and Marseilles-type roofing tiles along with all their accessories. This project represents the largest and most modern roofing tile factory in Algeria.
Equipceramic, S.A, as a supplier of complete factories, was in charge of the execution of the entire project from dry grinding of clay through to a chamber dryer with automatic cycle and a sealed kiln.
State-of-the-art technology has been applied including robot technology for loading and unloading on/off firing refractory supports as well as extensive automation and control of the plant by means of advanced software and hardware packages.
Clay preparation and grinding
Equipceramic counselled El Moumtaza on the process and equipment to be applied for the clay preparation and grinding line, on the base of the results of the laboratory tests conducted on the samples of the raw material to be used. A high quality final product was always the main target.
A dry grinding process was ultimately selected on the basis of state-of-the art technology. Particular attention was paid to the installation of a clay dryer, so clay is delivered to the manufacturing process with the most suitable moisture content. Clay is then ground in a hammer mill to obtain the best grain size to shape the manufactured products.
Cutting and loading lines
At the exit of the extruder, the clay column is shifted to a cutter and the resulting clots are led to two presses provided with special rubber moulds for the manufacturing of roofing tiles.
The drying process is performed in a chamber dryer with a longitudinal ventilation system. Trays with a load capacity of 8 roofing tiles are used as drying supports. These are loaded and unloaded fully automatically. Roofing tiles are picked up from trays by means of a multiple gripper coupled to a motorised transfer car with no on-board driver and equipped with a turning platform. Then they are sent on a conveyor to the setting area where they are placed on U-setters, which were the firing supports chosen for this project.
Top-priority for our customer in this project was to assure excellent quality of the finished product. For this reason, Equipceramic opted to use refractory U-setters as firing supports because they allow for homogeneous coloration and quality over the entire setting
U-setters setting and dehacking
To meet the high level of quality demanded by the customer, the decision was taken to install robots for setting and dehacking roofing tiles on and off U-setters. These ensure accurate and gentle handling of products and therefore a high quality of finished products
The use of robots makes this roofing tile factory the most modern production unit in Algeria and the whole of Africa.
Roofing tile sorting system
A roof tile sorting system has been installed at the exit of the kiln in order to ensure that pieces meet quality criteria at the end of the manufacturing process.
This system comprises the following stages:
- Delivery of roofing tiles on two conveyors for the sorting of pieces on a one-by-one basis.
- Having passed quality control, roofing tiles are set on packs adapted to pallet format.
- Automatic strapping of seven roofing tiles packs and distribution for the collection by robot for their final packaging and wrapping.
Roofing tile pack-making and film wrapping line
Roofing tile pack-making and film wrapping is performed automatically by means of robots. Two rows of roof tile packs are stacked four layers high on pallets. The robot inserts a thin sheet between layers to protect products.
Pallets loaded with roofing tiles are shrink wrapped.