KELLER HCW plant technology sets new handling standards for bricks with highly sensitive surfaces

Once again, the KELLER HCW engineers in Laggenbeck succeeded in developing a future-oriented installation for the ceramic industry. Thanks to cutting-edge conveyor and drive technology they created a reliable solution with high availability that sets new standards both for quality management and for plant productivity. For the Brüggen plant (lower Rhine area) of Röben Tonbaustoffe GmbH, KELLER HCW developed a fully automated plant using robots to unload roof tiles from the kiln car, to check their quality, and to sort and pack them for transport to the customer.

4300 roof tiles per hour are unloaded from a kiln car with a one-layer free-standing setting. The roof tiles are then separated and put into a horizontal position. At defined intervals, they are conveyed to an automatic surface inspection system. Without any contact, the surfaces of the high-quality roof tiles are then scanned for dimensional accuracy, absence of cracks, shape and surface finish. In fractions of a second, the system decides whether the scanned roof tiles meet the high quality requirements and can be passed on to the packaging station. Every single non-conformity, no matter how small, which is not within configurable, very tight tolerances is registered, stored and the respective roof tile is automatically discarded. Robots pick up the tested and approved roof tiles and regroup them into small packs which are strapped for further transport. The number of roof tiles composed to small packs can be configured, giving the customer high flexibility to react to current market requirements.
As a turnkey project, KELLER HCW adapted the machinery to the existing space available and it turns out to be another successful example for the good cooperation between the companies Röben Tonbaustoffe and KELLER HCW.


Picture 1: Kiln car unloading station with craneway
Picture 2: The standing roof tiles are forwarded to the separating station
Picture 3: Small pack-forming with robot technology


Picture 4: Palletizing with intermediate layers