Plant (re)construction

Examples of projects

Wet side

Last winter (2011/2012), the Bad Neustadt facility's wet side for two presses was converted from turntable to robot. That scope also covered replacement of the adjusting and scrap bands, the pallet transfer belt and their segregation setup, and the existing pallet stores were expanded. Thermoplan supplied all the requisite physical equipment, including a brand-new low-voltage switchgear plant with cabling. The new S7 control system has an integrated plasticity control function for shaping (Thermoplast) with controlled material flow and plasticity. The installation was commissioned in mid-February 2012 and is now running at 100% output (»2). Both projects were approached with special attention to finding customized solutions with close deference to the plant's maintenance needs. But then, that always applies just as well to Thermoplan's entire product array. Naturally, both projects' reconstruction measures also included a machine-safety upgrade to state-of-the-art status.

Setting installation

Winter before last (2010/2011), the setting installation at Wienerberger's Malsch facility was completely rebuilt, and a total of three unloaders/handover grabs were replaced with a robot. The grouping belt and setting gripper were replaced at the same time. In addition to markedly reducing the number of moving parts (= less maintenance required), the change even increased the throughput a little and improved product quality by reducing the lineup loads and times. Thermoplan not only did the mechanical engineering and installation work, but also replaced the S5 control system while retaining the control cubicles and cabling. The plant has now been running a full year for the fully satisfied customer.

Integration of mechanical solutions for U-block production

Back in spring 2009, a new grouping pusher was integrated in the existing setting station, which had previously only been equipped with an aligning bar. Thermoplan undertook the mechanical planning and installation as well as integration into the installed S5 control system. In the next step, the packing plant was extended over winter 2009/2010. The mechanical components including robots were dismantled at the previously shut-down Hainichen plant and successfully integrated at the Eisenberg packing station in a new design and spatial arrangement. With intelligent utilization of existing components in the mechanical and electrical systems, despite limited space, an interesting integrated concept could be supplied.