Firing process optimization of platform trucks
Tracking increases quality, reduces costs and improves energy efficiency
Starting situation
Firing and drying processes are of central importance in the brick and ceramics industry. Kiln cars – also known as kiln cars – transport raw materials such as bricks, tiles or clinker through dryers and kilns. These processes can take hours or even days. Until now, it has been difficult or impossible to monitor the position and temperature of the kiln cars without a kiln control system. In order to guarantee the quality of the products and use energy more efficiently in terms of sustainability and competitive advantages, more precise monitoring is essential.
Challenge
One of the biggest challenges of the firing process is the continuous monitoring of the position and temperature of the kiln cars, especially in the extremely hot environments of the kilns. These high temperatures make tracking particularly challenging, as conventional monitoring systems often fail in such conditions. This not only causes material losses, but also a considerable waste of energy, as defective products have to be produced again. The lack of transparency regarding the location and temperature of the wagons also makes it difficult to plan and coordinate the subsequent processing steps.
Solution approach
Each platform trolley that is transported through the dryer and kiln is equipped with durable, high-temperature resistant sensors. These sensors provide detailed data on the position and temperature of the trolleys in real time. Continuous monitoring of these parameters enables precise control of the temperature curves at the various positions in the oven. This ensures that the products are always fired and dried under optimum conditions. Temperature fluctuations are detected immediately and can be corrected immediately, which significantly reduces the risk of cracks and other damage to the fired products.
The system not only helps to improve quality, but also optimizes energy efficiency by avoiding unnecessary firing processes through post-production. As a result, energy is used more efficiently, waste is reduced and the service life of the systems is extended. This leads to a significant reduction in production costs and makes the entire firing process more sustainable, as less waste is produced and emissions are reduced. The increased transparency in the production process also makes it easier to plan and coordinate the subsequent processing steps, resulting in a smoother and more efficient production process.
Implementation
The implementation of Dex7 begins with a retrofit by equipping all platform trolleys with robust, high-temperature resistant sensors. These sensors continuously record position and temperature data and transmit it to a central control platform, transforming existing systems into a modern IoT-based system without the need to purchase a new oven controller. This provides a live overview of the weighers, enabling precise temperature control and efficient adjustment to the respective conditions. The live data ensures that optimum conditions for firing and drying the products are maintained at all times, which increases quality and minimizes energy losses.
Results
- Increased quality: Precise monitoring of the position and temperature of the weighers ensures that the products are baked and dried under optimum conditions. This significantly reduces the number of faulty or damaged goods.
- Energy efficiency: Precise control of temperatures prevents energy waste and contributes to sustainability.
- Cost savings: The reduction in material losses and energy wastage significantly lowers production costs.
- Planning and coordination: The increased transparency of the location of the weighers facilitates the planning and coordination of subsequent processing steps, resulting in a smoother production flow.