NEWS
CLEIA NEWSLETTER - Number 3 - January 2014
SUMMARY
Special Section
News
n
RUSSIA
Ashur Brick Company entrusts CLEIA for
the realization of its new production site in the
Iraqi Kurdistan
Turkish brick and roof tile
manufacturers meet CLEIA
n Terreal is acquiring its first OpenCer
n
R&D
LEIA supported by ADEME and
C
TOTAL for its ambitious project of energy
consumption reducing
n Energy intelligence in the service of
brick and roof tile production - CLEIA
n Patent approved for the Zephyr®
dryer
n 4C Laboratory: CLEIA CERAMIC
COMPETENCE CENTER
n
Edit
Two Editorials for this special issue Russia / CIS, CLEIA's organization enables us to
propose ambitious projects on this vast market for which we have just set up several
significant plants.
Based on our experience for facing bricks and building blocks
factories, CLEIA is gaining a reputation in Russia and the CIS area.
Our technical solutions are appreciated because they are at the
forefront of technology and very flexible. And our achievements
prove it right! Novomoskovsk, Tchaikovsky, Aksai, Mozdok,
Radozhkovichi... We rely on our knowledge in robotics to improve the
productivity of facilities and on our ceramic engineers to modernize
existing plants: chamber dryers, flashing equipments on facing bricks
kilns, increase of production, etc.
We offer the best of technologies, many industrial projects are under
discussion with our customers, and our growing strength with very
positive feedback encourages us to enhance our efforts on this
market.
Special Section
Russia / CIS
Overview of CLEIA Russia
New: Three new lines in Russia and
Belarus made by CLEIA
n Flashing firing mastered by CLEIA at the
brick plant AKSAY
n CLEIA insures technical support
for MOZDOK brick plant
n
n
Customer
Service
ulti-skills customer service:
M
Renovation of kilns and kiln cars
n New generation CLEIA PLC control
systems for GASSER CERAMIC brick
and roof tile plants of Morandi sites
n
Michel Cristallo
Area Sales Manager Russia/CIS
To provide the best service to customers, CLEIA Russia is based in
Moscow. Our experience in the field and our perfect knowledge of
the market enable to both deepen technical projects and to provide
a high quality service.
We operate from Ukraine to Siberia. Evidenced by exhibitions
KievBuild, MosBuild and SibBuild in which we participate.
Our expertise for carrying out projects in the CIS, confirmed by
a constant service activity in the field of supply of spare parts,
technological diagnostics, logistical assistance and certification of
different types.
This ensures continuity in sustaining collaboration, responsiveness
and punctuality well appreciated by our customers during pre-project
and during the achievement of contracts.
Roof tile plants
n
New roof tiles plant Erlus
in Germany
AG
Press review
n
Firing bricks: Why not dare
the 1 200 x 1 200 mm stacks!
CLEIA praCtical
n
n
ontact and Visit
C
CLEIA 2014 expo
Rouslan Svintsitski
Manager CLEIA Russia in Moscow
us
Key figures
1 200 tons /day
for the new brick plant Ashur Brick
in the Iraqi Kurdistan
> 50 people
Rise in power of our subsidiary
Albaraka C.I.E for
Maghreb markets
25% energy savings
90%
of our turnover 2013
at the export
/ Cis
:
project for reduction of the thermal consumptions:
DEFORCET kiln selected by the ADEME and TOTAL
among ambitious energy projects
News
Ashur Brick Company entrusts CLEIA
for the realization of its new production
site in the Iraqi Kurdistan
The choice of CLEIA has been justified by the
recognized experience of CLEIA's experts in
drying processes and firing of bricks as well as
optimized flow organization within the factory.
The technological line includes a line of preparation
of material, an extrusion line, a cutter for oversized
products and a cutter for standard bricks, a new
generation tunnel dryer, a Tradifast kiln and an
automatic packaging line.
The project plans 3 robotics stations
designed by CLEIA to bring precision to
automatic handlings.
Thanks to its 4C laboratory and after
a mission of study on the site, CLEIA
advised its customer on the choice
of raw materials. This collaboration was
crucial for the development strategy of
Ashur Brick.
3 product lines and a long-term vision
of the Iraqi market of building materials
with standard bricks, hollow bricks and
structural bricks. Following market's
evolution, production of grinded bricks
like 'Monomur' and production of high
insulating bricks with filling of alveoli will
also be considered in the future.
The factory can produce up to 1 200 tons
/ day corresponding to the very numerous
reconstruction building sites in the country.
The market has a demand for big volumes
of very high quality building materials
and this is in this highly competitive world,
Ashur Bricks chose CLEIA to answer this
demand and prepare the future with a
reliable partner.
Contacts: [email protected]
and [email protected]
Turkish brick and roof tile
manufacturers meet CLEIA
A large assembly of Turkish professionals
was gathered to Turgutlu for the conference
on kilns and dryers innovative technologies
developed by CLEIA.
Murat CEVIK, sales manager CLEIA for
Turkey and our adviser and ceramic expert
Michel Bernard hosted this conference
which has enabled CLEIA to introduce its
last innovations:
• Rapid dryer Zephyr,®
• Processes and modern PLC control
systems,
• New generation Technofast kiln.
After being present at the TurkeyBuild
exhibition in Izmir last October, CLEIA
positions itself as an essential actor on the
market of turnkey units of building materials
in heavy clay for Turkey.
Contact: [email protected]
Terreal is acquiring its first
OpenCer
TERREAL in Roumazières UT8
production unit of roof tiles has just
acquired its first OpenCer IT supervision
system.
The SQL database and the archiving
Historian integrated into OpenCer make
of this new control system a powerful
p2 January 2014 - N°3 - Newsletter CLEIA
and scalable management tool:
simultaneously open to Enterprise
networks and connected with Wifi
systems, as perfectly safe thanks to its
unlimited storage data base.
Contact: [email protected]
R&D
CLEIA supported by ADEME and TOTAL
for its ambitious project of energy
consumption reducing
The ADEME-TOTAL program to support innovative projects for the
energetic efficiency has chosen the Kiln DEFORCET,* project developed
by the Process and R&D teams of CLEIA.
The first success for this ambitious project, which aims to reduce
by more than 25% energy consumption in industrial tunnel kilns
for firing of heavy clay building materials, is part of the considerable
investment made by CLEIA in R&D projects.
Contact: [email protected]
* Kiln DEFORCET: DEvelopment FOr Reduction of Consumption and Energy Transformation
Energy intelligence in the service of
brick and roof tile production - CLEIA
Energy efficiency covers not only equipment performance
and getting the best yield from installation, but also the
regulation and energy intelligence that applied to them. At
the ultra-modern CS-Coelho da Silva 5 turnkey roof
tile plant that CLEIA has just completed in Portugal,
energy consumption in the drying chambers has
been significantly reduced using an innovative hot air
recycling circuit, optimised use of the drying chambers
and automatic regulation of the ventilation circuits.
Connected to the OpenCer automatic supervision system
installed by CLEIA, drying chambers are automatically
controlled according to the recovery of hot air from the
kiln, products to be dried, chamber availability and the
recycling circuits. Optimising the flows and the air circuits
makes it possible to save up to 15% of the gas used in
roof tiles drying.
Patent approved
for the Zephyr®
dryer
ADEME publication
4C Laboratory
“
CLEIA Ceramic Competence Center
4C
„
Send us 30 kg of your raw materials
and we will achieve
complete tests
Cleia Ceramic Competence Center
Raw material tests:
• Roller mill and mixer for clay preparation
Shaping:
• Extruder group for the forming of hollow bricks, solid bricks
and tiles for samples
Drying / Firing:
• Lab dryer for the drying in the laboratory
• Kiln to reproduce industrial firing cycles
From left to right Franck Bigeard, Michel
Peaudecerf and Jean-Claude Boissinval
with the model of the Zephyr® dryer
INPI "French Institute of the industrial
property" has published the patent for
drying process used in the Zephyr®
dryer developed and registered by
CLEIA. Designers for this creation are:
Frank Bigeard, Michel Peaudecerf and
Jean-Claude Boissinval.
A real success for this rapid tunnel
dryer - without doors and designed with
variable pitch - which 2 installations are
under construction and others are in
project.
Contact the process department: +33 3 80 26 71 00
Newsletter CLEIA - N°3 - January 2014 p3
Special Section
Russia / CIS
The Russian and the CIS market consist of a large variety of
customers (groups and independents) and products, from
solid bricks or facing bricks, to klinker pavement, including
multi-size blocks, facing panels or thin bricks. This range of
products makes this market very interesting for a company
like CLEIA which involves all its energy and imagination into
innovation and adapted solutions for each product and each
customer.
CLEIA High technologies
Robotics + High Tech drying and firing
➜ To improve the performances of
existing facilities in Russia / CIS
➜ For quality products
Overview of
CLEIA Russia
The office of CLEIA in Russia, in Moscow, is a real technical support for
our customers on the whole Russia and CIS area.
Made up of engineers and technicians with extensive experience of
our industry of brick and roof tile plants, CLEIA office insures a set of
services for:
• Delivery of spare parts,
• Administrative and custom formalities,
• Technical translations and interpretation,
• Logistic Assistance,
• Technical support,
• Audits and modernization of installations.
CLEIA Russia's office guarantees a reliable and proactive connection
between our customers and the operational departments of CLEIA.
CLEIA RUSSIA'S OFFICE
Moscow,
101000, Pokrovski bd,
4/17, build.1 of.12
Rouslan SVINTSITSKI
Tel: +7 495 937 70 25
Mobile: +7 919 105 80 51
[email protected]
p4 January 2014 - N°3 - Newsletter CLEIA
Area Sales Manager CIS:
Michel CRISTALLO
Mobile: + 33 6 84 64 08 22
[email protected]
www.cleia.ru
New
Three new lines in
Russia and Belarus made by CLEIA
The first line was settled in Russia on the site of Novomoskovsk
located in the area of Tula in the South of Moscow. This new line
has been set up in parallel of the existing installation.
The second line has just been put into service on the site of
Tchaikovski located in the area of Perm in Russia. This ultra
modern installation is going to enable to increase the efficiencies
of the brick plant and the quality of finished products, thanks to the
technologies set up by CLEIA.
The third line was delivered very recently in Belarus on the site of
Radochkovitchi implanted in the region of Minsk. It is a supply for
multi-size bricks including a new type of packaging.
These new facilities benefit from the latest advancement proposed
by CLEIA, which aim to improve the quality of products and to
increase the efficiency and profitability of the brick plant.
Flashing firing mastered by CLEIA at
the brick plant AKSAY
From right to left: standard bricks and flashing bricks
Taking advantage of its expertise in ceramic
process, CLEIA has just put into service
a new installation of flashing firing for
facing bricks at the brick plant AKSAY,
located in the area of Rostov. The customer
AKSAY is extremely satisfied with the
first results, and can, from now on, offer
new bricks with trending colours thanks to
this technology of flashing firing "made
by CLEIA."
CLEIA insures technical support for
MOZDOK brick plant
The MOZDOK brick plant in Russia - which was achieved by
various engineering companies - calls on CLEIA to insure
commissioning and the rise in production of the facilities
of drying and firing. Once more, the know-how of the
automation specialists and the ceramic engineers of
CLEIA brings satisfaction to the customer with a fast rise in
production of the dryer and the kiln.
Newsletter CLEIA - N°3 - January 2014 p5
Customer Service
Multi-skills customer service
Renovation of kilns and kiln cars
With numerous references on French and international markets, CLEIA is recognized from now on as an expert for
all types of works on cars and kilns, whatever their technologies are:
• Renovation of kiln cars' park (in refractory parts or refractory
concrete for brick or roof tile plants and with U or H firing
technologies)
• Kiln car transformation (bricks -> tiles or vice-versa)
• Repair of former kilns with our Ecofast or Technofast
technologies
• "Anti-acid" and "anti-corrosion" devices installation on kilns
• Extension of kilns and works of insulation
• Cathodic protection on kilns with water seals
• Replacement of rails and kiln car wheels
Contact: [email protected]
New generation CLEIA PLC
control systems
for GASSER CERAMIC brick and roof tile plants
of Morandi sites
Swiss limited company Morandi Frères of GASSER
CERAMIC group entrusts CLEIA to renovate PLC control and
IT management systems of its various bricks and roof tiles
production units on its site of Corcelles-près-Payerne.
Nine PLC in operation for 25 years distributed on
3 production lines will be replaced by new generation
PLC control systems. An evolution of the IT supervision
systems with redundant servers will be organized, to give
a new dimension to the production management and
optimization of these installations. New features such as:
access to production reports about energy savings,
products tracking, facilities efficiency… All of this is
available via terminals like PC Tablet and smartphones.
A part of PLC and supervision systems will be replaced while
the plant running with limited break times.
Contact: [email protected]
“
„
A new success for CLEIA's industrial
computing teams which have already
replaced 50 control systems
these past years!
p6 January 2014 - N°3 - Newsletter CLEIA
Roof tile plants
New roof tiles plant
Erlus AG in Germany
The steady demand on the market for Erlus AG high quality roof tiles led the company to be equipped with a new production
line. Thanks to its high expertise of kilns' technologies and the reputation of its Hi-Tech automatic installations, CLEIA
was selected to realize this installation within 9 months.
The project consisted in replacing a U firing technology - on the line 4 of the factory 2 at Neufahrn which was stationary - by
a new H production line.
The challenge to put into service the factory before summer 2013 for an order placed in September 2012 was
successfully met.
CLEIA: world leader for new generation
of kilns with water seal
The Erlus AG Company uses water seal kilns since 1990,
and always remained faithful to this technology which brings
the best results of firing. With the successful achievements
of CLEIA in Algeria, Poland and Portugal where a HydroEcofast kiln had just been put into service in the roof tile
plant, CLEIA was able to demonstrate how constructions
and services quality had not only been maintained but also
improved.
The Hydro-Ecofast kiln was built with prefabricated and
assembled on-site elements. The prefabrication was realized
during demolition works and civil engineering, with an
assembly of the kiln which began in January, 2013. The first
fired roof tile went out of the kiln in June, 2013, less than
6 months after the construction began.
Evolution of automatic machines
The installations supplied by CLEIA get last technological
evolutions with, in particular, widespread use of servomotors and transmissions by timing belts. Machines
gained in precision and smoothly of accosting and
machines resumption in case of shutdown upon defect or
emergency stop are now very fast. These new techniques
also significantly reduced the sound level generated by
machines.
Decreasing energy consumption
The last technical evolutions brought by CLEIA ensure a
10% reduction of consumption compared to the last
generations of equipments delivered to Erlus AG.
This result from the installation of innovative technologies:
• Ecofast kiln with new compositions and trimmings
distributions for an optimal insulation
• Kiln extraction and overpressure distributed in several
points
• Hot air supply for air combustion to burners
• Individual ventilators steered by variable speed drives
for each firing unit
• High speed roof burner of our "Top Jet" range
The construction site and the set up of this new production
unit took place in a perfect coordination and a partnership
spirit with technicians, the operators and the management of
Erlus AG's project. CLEIA supplied a successful installation
completely meeting the expectations and Erlus AG tiles
quality reputation, while reducing significantly operating
costs.
Contact: [email protected]
Tiles and accessories produced
simultaneously
The new feature of this installation is about flat accessories
packaging, produced in the same time than roof tiles. These
products are recognized after firing, deviated from the roof
tile line and packaged under beams form on a dedicated
line, then palletized on the common line. This functioning
makes the production management for this type of
accessories easier.
Editorial Board:
Michel Cristallo • Rouslan Svintsitski •
Frank Bigeard • Eric Girardot • Murat Cevik •
Bruno Daret • Mathieu Hervy • Thierry Allanic
Newsletter CLEIA - N°3 - January 2014 p7
“
Press review
„
It was necessary to propose
alternatives to brick manufacturers
and new solutions for the future
Industrie Céramique - ICV N°1045 / March-April 2013
Firing bricks:
Why not dare the 1 200 x 1 200 mm hacks!
Traditional hacks of 900 x 900 mm have been used for almost 20 years for bricks firing,
but now modern brick plants use setting of 1 200 x 1 200 mm.
Why this change?
Because 900 x 900 mm hack corresponded to a level of
technology and a management of heavy clay brick plants
dating from the late 1990s.
How?
Through better control of firing achieved by modern PLC
control and handling facilities done automatically with
accuracy. Also through the development of robotics in our
industry, this now enables constitution of larger packs on
kiln cars and at high velocity. Many projects are now based
on brick production output of approximately 800 or 1 000
tons / day. These production levels are in line with the high
demand for building materials noticed in North Africa in recent
years. By optimizing cargo volumes through the kiln hacks of
1 200 mm, the novelty meets the expectations of industrials
for hi-tech and high capacity production units.
This new hacks on kiln cars module also helps to reduce
investment costs as well as to reduce energy consumption.
1 200 mm module is universal: 3 bricks of 400 mm
or 4 bricks of 300 mm
Being a multiple of 2, 3 and 4 products, 1 200 mm hacks are
suitable for many brick formats that simplify the manufacturing.
The creation of "locked" layers at the setting is carried out
in automatic mode, which provides excellent stability of the
loads. Fork lift holes in the final pack may be provided at the
loading operation, therefore it is not required to reconstruct a
new pack format after the firing. Unloading and packaging are
fully optimised.
A perfect firing quality
With 1 200 mm hacks, the pushing rate in the kiln decreases
in the ratio 4/3 and provides a gain of about 5% on the total
firing cycle compared to a firing process with 900 mm hacks.
There are less joints between kiln cars, so less hot air leakage
which allows a more homogeneous firing.
To better penetrate the length of the hack of 1 200 mm, the
soaking time is increased of about one hour. The results are
convincing. The firing quality is more reliable with setting
pattern of 1 200 mm - compared to 900 mm loads - with the
same clay and in the same factory.
A unique and economical format
Another benefit is done by the simple and economical aspect
of packs without wooden pallets: hacks of 1 200 mm are
perfectly adapted for standard delivery trucks with a width
of 2,50 m.
Two packs are loaded in width on the truck loading platform,
which it is easier for the logistic, optimises the loading and
decreases the transportation costs. Moreover this saves costs
for packaging straps about 15%.
Today brick producers are modern manufacturers who must
meet their evolving market for the production of larger sizes
bricks, as well as the development of future products with
higher insulation and efficiency.
By Michel PEAUDECERF - Head of CLEIA Technologies department
Contact: [email protected]
CLEIA 2014 expo:
cleia practical
We invite you to visit CLEIA during the next international events:
OSM Expo: January 28th to 31st in Moscow
Indian Ceramics: February 26th au 28th in Ahmedabad
Kievbuild: March 4th to 6th in Kiev
Mosbuild: April 1st to 4th in Moscow
Batimatec: May 4th au 8th in Algiers
Libyabuild: May 19th au 22nd in Tripoli
Visit us
By train:
By car:
From Paris: approximately two hours
TGV: Paris/Le Creusot Montchanin TGV:
approximate duration 1 hour and 10 minutes
Then Montchanin-Nolay: 40 minutes by car
Motorway A6 from PARIS: about 3 hours
A6 exit N°24 Pouilly en Auxois
Direction Arnay-le-Duc D981 then N6
and D973 towards Nolay
From LYON: about 1 hour and 20 minutes
TGV: Lyon/ Le Creusot Montchanin TGV:
approximate duration 40 minutes
Then Montchanin-Nolay: 40 minutes by car
Motorway A6 from LYON: about 1 hour and 30 minutes
A6 exit N°25 Chalon Nord
Direction Chagny N6 then D33 and D973
towards Nolay
Engineering turn-key solutions
2, avenue Spuller - 21340 NOLAY - FRANCE
www.cleia.fr
+33 3 80 26 71 00
[email protected]