[10:20] Victor Callmyr
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ABECE Large – the fully automated production line

Produce 50 000-150000 tiles a day with our high output production lines. Designed for your specific needs to give you the lowest possible cost per tile. Done through unique solutions assuring lowest energy usage, lowest cement usage, lowest pallet-oil consumption and minimizes manpower.

closeup of black roof tiles
  • Up to 25% higher output/productivity, more tiles with less people

  • Save more than 700.000 EUR per year on energy, raw materials and maintenance

  • Make the highest quality tiles


(Typical modern state of the art ABECE Large Plant compared with an average existing high speed plant)

With ABECE machinery you get the most productive solutions that maximize your return on investment!

The Walk Through – reasons for choosing ABECE

Highlights

  • A fully automated process, requiring a minimum number of operators

  • Best long-term equipment availability/OEE

  • Lower maintenance requirements

  • Machinery and know-how to minimize cement and other raw material consumption and waste

  • Greener and more economical solutions with extremely low energy consumption

  • Outstanding service, support and spare parts management

  • Most comprehensive supply

  • We always finish what we have started and we will be there for you!

Concrete feeder – is a holding bin just before the extruder that will keep the concrete quality much longer compared having the concrete spread out on a concrete belt. This enables the mixing system to supply concrete earlier and gives a better consistency in the tile quality, increasing line efficiency and uptime.

 

SE140 Extruder – Unique carry through machine technology, causing no wear on pallet underside which gives a longer durability of the pallets. This advantage is obvious when increasing population after a time of production, where new pallets can be added without the need for machining off material on the new pallets.

 

M32 Extruder – Unique Pushing through machine technology, made for easiest and safest operation and changeover with Roll in – Roll our head design. Extremely strong and durable, outstanding compaction capacity to make stronger tile with less cement. Configurations for all tile dimensions and profiles are available.

 

Tile design and optimization – all our standard and customized tile designs are developed for optimizing the tile properties with unique features. The secret of reducing weight and thickness but improving strength is a key for all successful manufacturers and is something we do when designing the tile. All to reduce cost of manufacturing and increase value and profit for the producer.

 

Single Servo Knife system – for best tile cut appearance with least effort and maintenance. Easy to operate and provides highest possible line availability with fine tuning made while in operation. The 100% circular motion design gives an outstanding cutting control, providing low noise, low wear and low energy consumption. Safely installed at any extruder of any make for any speeds!

 

Twin Servo Knife system – the absolute solution for best tile cut appearance and control of hanging length. All waste concrete is returned back into the system through the metal detector and can be saving 2% of total concrete usage! Safely installed at any extruder of any make for any speeds!

 

Racking system with Twin Cross Conveyor – delivers extremely high efficiency numbers. Loads of unique features in the rackers like seted chains, dust collector, pneumatic tile stop, flip slats etc etc. The TCC secures full flexibility between racking and deracking, adding to the line efficiency and leaving no tiles in the system overnight. Together with the balanced conveyor system, the number of pallets removed when changing profile can be kept to an absolute minimum. All together a very solid and proved solution for highest plant efficiencies.

 

Green Box Curing system with Kraft Curing – reducing your curing heating CO2 impact up to 100%, while the need for added energy can be eliminated. This gives massive cost savings in energy, cement and less scrap, beneficial for both wallet and climate. Full control and flexibility when having several profiles and colors, keeping the curing consistent throughout the chamber, ramping up the temperature in the cold lane, getting warm tiles out for dry side top coating which reduce drying time for the paint. To that the maintenance is kept to a minimum and there are only three motion-controlled units inside the system.

 

Multi profile depalleter – easy changeover between different profiles with levers on each side. The TC-inlets with pre-depalleting discs are loosening the tiles from the pallets and separated in the unit. Has a very long history of high efficiency and low maintenance. Safely installed but still accessible for easy maintenance and monitoring.

 

Conveyor system – all our conveyors are frequency inverter controlled and the whole balance in the tile line is controlled through the queue control sensors, giving a consistent flow of pallets back to the extruder and tile downstream to the packer. All of this is built up during decades of using the Siemens PLC platform which is now S7 TIA version.

 

SUMAL Mould Oil Applicator – The Original brush applicator that is installed in more than 100 lines since first introduced. This system can reduce oil consumption up 80% compared to conventional spraying systems and will reduce the carbon footprint in the same time as improving profits. The working environment is also highly improved as the system does not create any hazardous fumes like seen with a spraying system. Depending on production volume, this unit usually has a very fast ROI and is after that just a win-win investment!

 

SEW Motors/drives/inverters – throughout the whole line AC or Servo driven motors with highest possible quality securing the longevity and productivity of the installation.

 

RotoDryer system – well proven in many installations and delivers extremely high efficiency numbers. Loads of unique features like seted chains, dust collector, pneumatic tile stop, flip slats, pack accumulation system etc etc. All together a very solid and proved solution for highest plant efficiencies and with smoothest tile handling with servo-controlled motion.

 

Redundant multi profile robotic packer solutions – developed during last 10years for increasing packer efficiency and flexibility, but reducing maintenance, wear parts and scrap. We have since our start installed over 50 Fanuc robots all over the world help roof tile producer become more profitable and efficient. These are easy to adapt for new products, pack sizes or patterns.

 

Small pack strapping systems – robotic integrated for best availability, smoothest handling of tiles, highest flexibilities for pack sizes and profiles, lowest maintenance and wear parts usage. For speeds up to 140tpm

 

Large pack strapping systems – robotic integrated robotic integrated for best availability, smoothest handling of tiles, highest flexibilities for pack sizes and profiles, lowest maintenance and wear parts usage. For speeds up to 140tpm

 

Yard conveyor system and load secure – quality OEM partnerships with integration in the ABECE control and safety system gives maximized functionality and easy production supervision. Automatic labeling and marking of pallets for production control and yard management. Customized load secure systems, depending on market requirements.

 

Safety systems – as a world leading machine and process solution provider it is our duty and responsibility to ALWAYS supply safe machines and installations. ABECE will NEVER differentiate between countries, regions, cultures, continents when supplying and installing machines and systems. We will ALWAYS follow the CE machine directive and proudly leave when every machine is safely installed. Our workers and operators shall always have a safe and healthy working environment.

Automation control and HMI system – the automation platform provided today is refined over last 30years, going from Siemens S5 to S7 and now the TIA portal. We have developed the present control system to give the operators, production managers, plant managers and yard managers, the optimal tool for production control and process management. Every motor, pneumatic valve or moving part is monitored through the PLC and visualized in the HMI operator screens and on production screens. Preventive maintenance planning and instant production support is made easy through images leading the line operators focus to the root cause, instead of spending time searching the actual problem. Having this tool will increase OEE and reduce cost for maintenance and unnecessary downtime. Control is everything when running production processes with thousands of variables, automatically helping line productivity and plant profitability.

 

Keeping this platform as our standard system help us helping you when a new control system generation is introduced. Compatibility and basic programming language are kept which helps when moving to newer generations has reduced impact of investments and complexity. Your are securing your future by choosing this path together with us.

rendered image of a large plant concept
rendered image of a large plant concept

Concrete feeder

– better tile quality and efficiency. As the concrete is kept in a holding bin before reaching the extruder the concrete consistency is preserved compared to having the concrete spread out on a concrete belt. The feeder also ensures that the extruder never runs out of concrete which increases line efficiency and uptime.

Highlights
  • Continuous extrusion machines with speeds up to 150tpm

  • Single/Twin Servo Knife gives the best tile appearance/cut

  • GreenBox -saves energy for curing

  • Fully automated Robot packer- highly efficient for great display of tiles on pallets

  • Smooth tile handling minimizes damages on tiles and reduces cement needs

  • Operator/user friendly easy operations large HMI touch screens

  • Full flexibility and control with our optimized PLC system

  • Separate safety PLC controlling restricted areas meeting highest safety level and Zero Harm

SE140 Extruder

– increasing mould lifespan and saves money. The unique carry-through technology causes no wear on mould underside. It enables longer lifetime and adding new moulds to existing without the need for machining off material on underside of new moulds.

Or

Single or Twin Servo Knife system

– best tile cut appearance as cutting every tile. The circular servo motion design is outstanding for cutting control, low noise, least wear and energy consumption, made easy to operate and maintain. The Twin Servo Knife provides consistent tile hanging length by cutting every tile a second time. All returned cut-off concrete saves up to 2% of the total concrete usage (example producing 20M tiles@5kg = 2000tonnes of concrete annually in savings)! Both options are safely installed at any extruder of any make for any speeds up to 150tpm!

Racking system with Twin Cross Conveyor

– best through-put and designed for fresh tiles with unique ABECE-features like seted chains (unique slat configuration), dust collector, pneumatic tile stop and flip slats. Full flexibility and buffer zone between racking and deracking, adding to the line efficiency with keeping the number of moulds removed when changing profile to an absolute minimum and no tiles in the system overnight.

Green Box Curing system with Kraft Curing

– massive cost savings in energy and cement. Eliminate the cost of heating and reduce your CO2 curing impact up to 100%, beneficial for our climate and your profits. Full rack control and flexibility for multi profiles and colors, zero tile variations with consistent curing throughout the chamber and warm tiles for fast drying of top coating. Minimal maintenance with only three motion-controlled units inside the system.

Multi profile depalleter

– highest efficiency and lowest maintenance, safe and superfast trouble-free changeover for up to five different profiles as standard! Fully fenced for highest safety level, yet easily accessible for maintenance and monitoring.

Conveyor system

– intelligent line control for highest OEE with low energy consumption and maintenance. Frequency inverters and queue control sensors ensures a consistent flow of moulds back to the extruder and tiles downstream to the packer. All developed and proven in the last decades in our up-to-date Siemens PLC platform.

SUMAL Mould Oil Applicator

– adding profits and reducing your carbon footprint. Can reduce oil consumption by 80% giving the fastest ROI possible and creates no hazardous fumes compared to a spraying system, improving the working environment. Our Original SUMAL brush applicator is installed in more than 100 lines.

RotoDryer system

– enables up to 30mins drying time of top coating and delivers extremely high efficiency numbers, securing the surface quality by unique features like seted chains, dust collector, pneumatic tile stops and flip slats etc. The collating system presents small stacks with smoothest accumulation to preserve the surface quality. A very solid and well proven solution for highest plant efficiencies with smoothest tile handling through servo-controlled motions without the need for adding more cement as when collating large stacks directly from the deracker.

Or

Redundant multi profile robotic packers 

– highest efficiency and flexibility with lowest maintenance need and few wear parts. Easily adapted for new products, pack sizes or pack patterns. We have soon installed over 100 Fanuc robots all over the world helping roof tile producers become more profitable and efficient.

Small pack strapping systems

– for best availability, smoothest handling of tiles, highest flexibility for different pack sizes and profiles, lowest maintenance and wear parts usage. Robotic integrated and fast reliable StraPack strappers for speeds up to 140tpm.

Large pack strapping systems

– for best availability, smoothest handling of tiles, highest flexibility for different pack sizes and profiles, lowest maintenance and wear parts usage. Robotic integrated and fast reliable StraPack strappers for speeds up to 140tpm.

Yard conveyor system and load secure

– maximized functionality and easy production supervision through high quality European OEM partners, fully integrated in the ABECE control and safety system. Automatic printing and labeling on pallets for production control and yard management. All choices of load secure available - stretch, shrink or spin wrapping.

Safety systems

– of highest standards for Your safety. ABECE will never differentiate between countries, regions, cultures, continents when supplying and installing machines and systems. We will always follow the CE machine directive and proudly hand over every machine safely installed. Zero Harm is not a vision but a mission.

Automation control and HMI system

– the optimal tool for production control and process management, increasing OEE and reducing cost for maintenance and unnecessary downtime. The easiest way for operators, production managers, plant managers and yard managers, to do the correct and fastest actions for highest plant availability. The Siemens S7 TIA portal is refined over last 30years to control every motor, pneumatic valve or moving part in the PLC and visualize all actions in the HMI and large production screens. This enables preventive maintenance planning and instant production support leading the line operators focus to the root cause, instead of spending time searching for the actual problem. Control is everything when running production processes with thousands of variables, automatically helping line productivity and plant profitability.

M32 Extruder

– safe, strong and flexible. Made for easiest and safest operation and changeover with Roll in – Roll out head design. Extremely strong and durable, outstanding compaction capacity to make stronger tiles with less cement. This push-through extruder has configurations for all tile dimensions and profiles available.

Tile design and optimization

– increased profits by reduced tile weight and less cement usage. Optimizing tiles is about improving strength while reducing weight and thickness, all to increase value of the tile, making producers even more successful with ABECE as partner.

Our options of Field tile extruders up to 140tpm:

TwinLoader with Stack Collator

– creating small stacks smooth and efficient, at speeds up to 150tpm without scuffing any tiles. Easy to maintain, flexible, robust and proven for highest plant efficiencies with smoothest tile handling through servo-controlled motions.

SEW Motors/drives/inverters

– highest possible quality, secures longevity and productivity. AC or Servo driven motors used throughout the whole plant.

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