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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.
