Capaccioli s.r.l. starts up new brickworks for Sarl Banou Messaoud
Capaccioli, the Italian plant engineering company, recently commissioned a new plant for the Algerian brick producer Banou Messaoud. At this plant, one of the largest brickworks in Algeria, high-quality materials and components as well as state-of-the-art technologies were installed for brick production. Annual production totals 250 mill. bricks, which corresponds to 1 500 t/ day. Key technical parameters of the brickworks include:
› Clay preparation: complete Capaccioli Aral line with a capacity of 160 t/h, consisting of: box feeder (CDM and CDG series), LD1210 disintegrator, four Jumbo roller mills, one mb 800 mixer, two 600 mf mixers, two m750 extruders and silo storage (capacity: 25 000 m3)
› Bridge crane type bucket excavator with 120 buckets, roof width 20 m, arm length 16 m
› Electronic components from ABB and Siemens
› Two extrusion lines complete with cutting line and dryer loading systems
› Two dryers
› Two automatic setting machines with four ABB 760-450 robots
› Two kilns, each with a width of 7 m and a length of 151.20 m, 130 kiln cars
› Kiln car handling system with seven rail lines
› Robotized unloading system with two double lines
› Packing lines with eight strapping units for the production of shipping packs without pallets
› Automatic packing store and forklift for direct loading of shipping packs on trucks
Construction of the kilns began in June 2012, commissioning of the plant followed in May 2013, 100% production capacity was achieved by July 2013. The plant produces high-quality bricks, which are successfully sold on the market.
Special features of the plant and achieved goals
In the realization of this project, Capaccioli applied findings derived from its strategic decisions taken in the recent and early past.
1. State-of-the-art technology
State-of-the-art technical solutions are used in all production steps, from pre-treatment through automation to drying, firing and packing. The latest innovations from Capaccioli, with a focus on automation technology, are installed. The plant can be run by a total of 15 people per shift for full operation of the two production lines. The benefits for the customer: low operating costs, decreased consumption, and high-quality products.
2. Reliability and after-sales service
As plant downtime incurs high losses, production continuity is a top priority – that is why reliability must always be ensured. Capaccioli carefully analyses all aspects and adopts appropriate solutions to optimize plant reliability:
› Design: an accurate and careful design together with calculation of the lifetime of machine components is the first step towards reliability
› Production and adoption of an SQG: the product quality can be improved by adopting an SQG and applying a series of test and controls in production
› Vertical integration: Capaccioli designs and produces more than 90% of the components for its plants, including all the electrical parts. This ensures direct control of the quality of the product
› Tele-support: the plant is equipped with remote monitoring modules to allow customer service to connect to the software of all machines to enable quick intervention and find prompt solutions to shorten the time necessary for technical intervention
› Training of local technicians by Capaccioli Arab employees on site in order to limit intervention from the headquarters and minimize repair times and plant downtime
› Capaccioli only uses high-quality components. Components are sourced exclusively from renowned manufacturers who can guarantee high quality standards, including drives (motors and inverters) and robot technology from ABB and electronics and accessories from Siemens
› Assured after-sales service: simplified technical support and easy availability of spare parts
› Fast customer service and direct access to spare parts, including bought-in parts: ABB, a strategic partner of Capaccioli, is known not only for its product quality and its worldwide support network. As one of the world’s leading manufacturers of industrial robots, ABB also has a wide sales network in Russia. Siemens provides global support and has both spare parts stores and a sales network in Algeria. Siemens has had its own branches in Russia for over 160 years
High-quality products
As Capaccioli plants are designed to produce high-quality bricks, all technical aspects are carefully analysed: clay body, quarry clay, feeding systems, automatic wetting system, control of the drying process and monitored firing, automation for quick handling of the products to eliminate any risk of damage. The results at the Messaoud plant impressively confirm that this strategic goal was also achieved.
