Wienerberger Brick Factory Kiprewo
UNIVERSAL MACHINES FOR BLOCKS AND STANDARD SRICKS FOR THE RUSSIAN MARKET
In 2008 Wienerberger assigned to Sabo the construction of all the machines for the second line of plant Kiprewo in the promising and booming market of the Russian republic The project was delivered successfully in the first half of. 2009 Woenerberger was already operating a line in Kiprewo
With this second line it aimed to establish a high capacity plant directed towards the production of large porous blocks which yet would have the ability to produce small standard bricks of Russian (mainly 2 NF and 3 NF) SABO paid special attention to design machines that are able to handle the production of the complete range of the Wienerberger porous blocks as well as small sized products.
The nominal production capacity of the plant is 190-200 mil NF per year corresponding to approx 950 tons of fired product per day. Thanks to the appropriate design of the machines this capacity is attainable for both big blocks and small bricks.
The need for capacity and flexibility is particularly obvious in the wet area where a very wide (1300mm) electronic cutter has been used to handle the need for multiple exits in small bricks us well as big blocks
In this extrusion line with the multiple exits two high capacity Fanuc robots have been installed to load the metal trays of the dryer Each robot is equipped with four special grippers so that to be able to handle all different types of products and different settings on the tray
The change of the grippers is done automatically without manual intervention to facilitate the fast change of production to the different products.
Special heavy type elevator and forks has been installed that can handle two columns of dryer pallets per cycle so that to ensure a fast loading of the car . The car can be loaded with 10, 15, or 20 pallets in order it's loading to be optimal depending on the product size.
The hydraulic forks are equipped with a system that permits the easy automatic change of the step of the gripper.
Sabo also delivered al the automatic moving systems for both dryer and kiln cars.
In the dryer special emphasis has been given in the fast handling of the dryer cars , in the efficient use of the available space and the use of a buffer area for empty dryer cars that is essential for the uninterrupted operation of the dry and wet side.
The big capacity of the line in both small and big blocks required the duplication of the dry material and thus it's effective unloading from the metal trays
The setting machine is composed by two universal programming benches for maximum capacity and two robots that are loading the 6 m wide kiln car .
The unsetting of the ready product and the creation of final pack is done through a similar design with two programming benches and four robots , two for unloading from the car and two for the final pack
The final pack is completed through the possibility for horizontal and vertical packing as well as the application of a thermishrinking hood
