Types of Red clay Bricks and Manufacturing processes for their production

Transcription

1 Types of Red clay Bricks and Manufacturing processes for their production Examples and analysis of production linew ranging from the manual to the fully automatic George Koukas Commercial director Harris Makrigiannis Sales Manager 1

2 The company Established in 1984 More than 300 employees 2 factories 6 halls of total m2 Large investment in machine shop Specialized machinery ISO certified 2

3 Expertise of SABO SA Cutting Drying Kiln setting Firing Packaging Regulation Turnkey automatic plants 3

4 Our projects and customers 4

5 Large Scale Projects Expertise Experience in large scale and large capacity projects Expertise in using Robotic systems 5

6 Interventions on bottlenecks Example : Easy modification of bottleneck at the wet side to increase capacity by adding a robot 6

7 THE PRODUCTS 7

8 Clay as a material An old traditional material with excellent characteristics Used since ancient years 8

9 Properties of clay material Abundant raw material (in most cases) Excellent thermal and sound insulation Moisture regulating, Comfortable indoor climate Long life-cycle / sustainability Environmentally friendly / ecological Resistant to fire Resistant to eaerthquakes 9

10 Building with clay External walls Internal walls Face Ceiling Roof Chimney External Paving Figure adapted from brochure of Wienerberger AG 10

11 Families of products External walls 11

12 Families of Products-Roofing systems 12

13 Families of Products-Ceiling blocks 13

14 Different families of products facades,partition walls 14

15 Trends the importance of energy consumption Higher thermal and acoustic insulation through new products Trends in energy preservation leads to new products that require a different level of technology 15

16 Cross country comparison of cost drivers Important cost drivers Greece Tunisia Algeria Sudan India Turkey 1Price of block per kilo 0,030 0,037 0,031 0,064 0,016 0,022 2Price of least expensive fuel , ,32 3Price of MJ of fuel 13,27 7,17 2,8 1,35 2,9-5,8 2,07 4Type of least expensive fuel Heavy oil Heavy oil Natural gas Heavy oil Coke Coke 5Price of Kwh 0,1-0,13 0,030 0,093 0,066 6Salary of operator Salary of skilled mechanic, electrician Salary of engineer High cost related to price Obviously related to the existing product quality The road to mechanization will not be easy New products and marketing is needed 16

17 THE AUTOMATIC FACTORY 17

18 The automatic factory Simple preparation line (but needs good research for the clay) Simple automation and tunnel drying Tunnel kiln (combine local supplies) and economic life 18

19 INDEPENDENT PALLETS Top view Side view Loading, unloading system with elevating fork Use of bigger frames (less cars, higher capacities) Lower investment cost High flexibility in terms of products 19

20 INDEPENDENT PALLETS Loading, of the product to the frame Loading, of the car with frames 20

21 DRYER CARS WITH FIXED SHELVES Mainly for high perforation blocks High rates of loading, unloading 21

22 THE SEMIAUTOMATIC FACTORY 22

23 The semiautomatic factory Single platform but option for a second Setting, unsetting of kiln car manually 23

24 MECHANIZED FACTORIES 24

25 Mechanizing the manual factory Going from the manual to mechanized 25

26 Comparison of automated to mechanized Automated factory with tunnel dryer and kiln (capacity 400 tons/day) Manual factory with Hoffman kiln (400 tons) Required Personnel Person 150 persons meaning 1/5 of the cost Fuel consumption Kcal Kcal all necessary energy for dryer and kiln Only for the kiln Big differences in fuel costs Drying in Natural conditions Plus a biq consumption from forklifts Electric energy Double electric energy needed Less electric energy Scrap Material 1-2% 5-10% Stability of quality Quality independent of weather conditions Weather conditions affect the quality Quality less affected by personnel Quality directly depended on operators Stability of production capacity Production independent on weather conditions Winter months zero or small production Product Range All sizes can be produced Only small amd medium sizes can be produced Big porotherm blocks easy to manufacture Working conditions and safety High Low, less controllable enviroment Required space and buildings Big space and cost of metal structures Smaller space 26

27 THE SCALABLE SOLUTION WITH LOW DRYER MECHANIZED FACTORIES 27

28 Solution with small packs-initial 28

29 Solution with small packs-upgrade 29

30 Adding the automatic handling and the dryer 30

31 THE SCALABLE SOLUTION WITH MULTILEVEL DRYER RACK MECHANIZED FACTORIES 31

32 Working with hofman kiln 32

33 Mechanizing the hoffman kiln 33

34 Section of later addition of setting machine 34

35 Thank you for your attention Please visit as at or us at in Greece. It will be our pleasure to welcome you at our premises in Greece. Tel , Fax