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Röben Tonbaustoffe GmbH
Bannberscheid (Germany)
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Year of construction 2008
Complete plant
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Scope of project:
• Planning and realization of a new clinker plant
• 3 production lines for the production of ceramic clinker, quarter bricks and clinker pavers (Line 1-2: Shaping line for facing bricks, pavers, special sizes / Line 3: Shaping line for facing strips)
Scope of delivery:
• Machinery
• Surface processing plant
• KELLER cutter "Stargate"
• Chamber dryer
• Setting machine
• Tunnel kiln plant
• Unloadung – Pack forming
• Control system PLC Simatic S7
Specialties:
• The capacity was adjusted to today’s market conditions
• With the new plant construction energy costs can be reduced by around 20%
• The production programme includes more than 40 sizes with different surfaces, colours and dimensions
• Due to high flexibility of the plant it is also possible to manufacture even smaller loads fast with the variety of colours, surfaces and sizes at low cost
• The size variety makes high demands on the machinery: sanding, turning, face-setting, doubling and setting are considered in the respective machine units
• By means of bypass lines engobing and glazing of the products are possible at any time
Products:
• Facing bricks
• Ceramic clinker bricks
• Pavers
• Clinker facing strips
Output:
• Production quantity of 18 million NF sized ceramic clinker bricks per year
• Production capacity for clinker quarter bricks is increased to 20 million units per year
Working time:
• 7 days / week
• 1 shift / day
Further information can be found under the following links:
Press Release 12/2009 »
Press Release 02/2009 »
Press Release 12/2007 »
Brochure 10/2009 »
Video 05/2009 »
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Picture 3:
Production line
(Photo: Zi 03/2009)
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Picture 6:
Fully-automatic dryer car control system
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Picture 7:
Slotted jet walls in the dryer passage
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Picture 8:
Pallet unloading – 4-axial robot with row gripper
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Picture 9:
Kiln car loading position – 2 robots with layer grippers
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Picture 13:
Sorting conveyor to the feeding table – pack forming
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Picture 14:
Palletizing robot with combination gripper suction device for the paper take-up
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Picture 15:
Automatic film hood machine with integrated shrinking frame
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Picture 19:
Legend:
Wet and dry side
Line 1-2
Shaping line for facing bricks, pavers, special sizes.
With rusticator (optionally).
Line 3
Shaping line for facing strips.
With rusticator (optionally).
1. Extruder – line 1-3
2. Universal cutter with chamfering device
3. Transfer robot to the grouping conveyor (Cellaflex)
4. Pallet loading (small pallets) with four-axial robot
5. Craneway – finger loading of the dryer cars
6. Dryer car unloading and transfer to the unloading robot
7. Unloading robot
8. Switch cabinet
9. Setting table with adjusting, turn-over, grouping and turning devices
10. Two setting robots
11. Switch room
12. Chamber dryer with 16 units
13. Hot air channel of the kiln
14. Preheater
15. Inlet sluice
16. Firing zone
17. Cooling zone
18. Exit sluice
19. Craneway with two transfer grippers
20. Facing strip sorting and packaging
21. Setting robot to separate the packs
22. Feeding conveyor to the pack forming robot with adjusting and turn-over devices
23. Pack forming robot with suction head gripper for the paper take-up
24. Craneway to transport the pallets ready for dispatch outwards
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