Fanelli Relies to Marcheluzzo for the New Production Line “Fanelli 3”
Marcheluzzo S.p.A./IT after receiving the customer’s order, carried out the assembly and start-up of the new production plant for Ceramica Fanelli, company belonging to the UNICER Group in Buenos Aires, Argentina. The customer has a great deal of experience in the brick sector and thanks to his experience, he was able to find in Marcheluzzo the ideal partner for this important project.
The large production capacity due to automation and dryer in particular, pushed Fanelli and Marcheluzzo to a deep collaboration, generating the most suitable solutions for the product type and quality required by the market. The plant will be able to manufacture daily 1300 t of dry products.
The cutting line is equipped with a pre-cut headband, a multiple in-line cutter with a useful cutting width of 1400 mm. The cutting line has accessories for checking and cleaning the wires, designed and built to significantly reduce the breakages of the threads themselves in such a way as to maintain the production constant and minimize material waste. This area is equipped with a wet disintegrator device to convert the waste material when products are not loaded on the platforms in order to be reinserted into the production line.
Loading and unloading system
The loading and unloading system of the dryer cars has been designed to make the loading device of green products independent from the unloading device and to be able to perform on the warehouse frames all pitch changes on the dryer cars provided to optimize the load without losing more or less spaces and passages getting the ventilation air as uniform as possible. The supporting material frames are large and have been specifically designed to support a considerable amount of products. This involves handling large quantities of material while maintaining medium/long working cycles of the plant. By that, wear of mechanical components can occur very slowly.
The semicontinuous tunnel dryer was entirely designed by Marcheluzzo. The tunnel’s structure is built using traditional high-thickness bricks with excellent thermal efficiency. This ensures a very high level of insulation in order to minimise energy consumption and eliminate heat losses. The decision to use ventilation on both sides of the cars has optimised drying and made the drying process uniform across the entire width of the dryer. But above all, this system improves the quality of the air blown over the material, thereby guaranteeing higher finished product quality.
The eight car lines are ventilated by moving cones with special technical characteristics in terms of flow rates, air flow inside the material and fixtures to the fan parts. A series of recirculation, ejection and electricity saving solutions have allowed the creation of a highly responsive, high-precision control system divided into different zones, which is capable of automatically adapting to the dryer’s output quantity without operator intervention. Special attention has been devoted to the possibility of accessing the dryer’s ventilation equipment, greatly facilitating cone checking and maintenance, if necessary.
The setting machine, an imposing machine and beating heart of this plant, achieves very high production, manipulating the material in large but gently quantities, safeguarding the quality of each individual piece. It is suitable for all product types. Kiln cars loading is carried out layer by layer by a pair of Fanuc robots to which Marcheluzzo applied two innovative grippers for handling any type of product, each very light and capable of pick up the products from the module program belts with two rotating heads. In this way, the production capacity of a single robot is practically doubled, with extreme customer satisfaction.
The continuous development of technologies together with the great experience given by over 50 years of activity in the bricks sector, allows Marcheluzzo S.p.A. to enjoy an excellent reputation as a reliable partner for any type of machinery supply, from small to large projects according to the customer request.