Maximum manufacturing flexibility as regards size changeovers and mould replacement. Product handling with practically zero wear on mechanical parts. And, lastly, advanced solutions to recover the kinetic energy in the press and so provide considerable savings from an energy standpoint. These are the distinctive characteristics of the new line installed by Spanish firm Mazzaron Tejas following the company’s decision to expand using the plant engineering solutions offered by Sacmi Heavy Clay.
The core of this order for the well-known Spanish roof tile manufacturer based in Numancia de la Sagra (province of Toledo) consists of solutions for the pressing department in which the two existing presses have been joined by a third press with two moulds, specially configured for smooth integration with the existing dryer loading/unloading system. Thanks to the new RAT drying platform control system – which has a high output capacity of 6,000 roof tiles per hour - the line can be managed according to strict criteria to ensure maximum production flexibility from the point of view of both size changeover and mould replacement: moreover, the ability to operate with one, two or three presses simultaneously lets operators carry out work on machines in absolute safety without any need to shut down the line.
The platform conveying system, now equipped with high-resistance straps with a strong grip on the metal frame, has also been made much more efficient, minimising frame-strap chafing and, therefore, practically eliminating wear on the belt itself. Moreover, even lower maintenance costs have been achieved thanks to the new Siemens S7 1500 PLC automation control system, a technology that does away with the use of mechanical manoeuvring components and allows Profinet control of all drives.
Careful attention to production flexibility, combined with the outstanding levels of plant engineering safety and reliability guaranteed by Sacmi Heavy Clay solutions, places this Spanish manufacturer at the very pinnacle of roof tile manufacturing, with excellent performance also in terms of efficiency. Substantial energy savings have been obtained thanks to the innovative regenerative inverter installed on the press control. The latter recovers kinetic energy during motor braking so that energy, instead of being wasted as heat, is converted back to electricity; this gives press operation savings in the order of 16 kW/h.