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Mazzaron Teja: Flexibility and Efficiency with SACMI Heavy Clay

Maximum manufacturing flexibility regarding size changeovers and mould replacement; product handling with prac­tic­ally zero wear on mechanical parts, and advanced solutions to recover the kinetic energy in the press in order to provide en­ergy savings are the characteristics of the new line installed by Mazzaron Tejas/ES applying the plant engineering solutions offered by SACMI Heavy Clay/IT.

The core of this order for the Spanish roofing tile manufacturer consists of solutions for pressing in which the 2 existing presses have been joined by a 3rd press with 2 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 hourly output capacity of 6000 roofing tiles – the line can be operate with 1, 2 or 3 presses simultaneously so that 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. 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.

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