Roof Tile Factory Upgrade

Roof Tile Factory Upgrade

Alice Roof Tiles (Bacchus Marsh)

    • Project Details

      Customer: Alice Roof Tiles
      Duration: 11 Months
      Completion: May 2018

    Intro

    Alice Roof Tiles is a division of Barro Group Pty Ltd, a wholly Australian owned family company which has been servicing the construction industry for over 60 years. Alice Roof Tiles manufacture a range of concrete roof tiles that are marketed directly to all builders, big or small, through our supply and fix contracting division or our selected distribution network.

    Scope

    The Project Scope was to fully upgrade the electrical systems to create efficiencies, reliability and speed in the process of manufacturing tiles. This was achieved over four stages, each stage specifically targeting an area of the plant. The safety systems also had an overhaul to meet Cat IV safety, with new safety PLCs, and new safety devices. This Project consisted of new control panels, new VSDs, new cabling, and new motors where required. To achieve all this a new control room was purpose built, housing 6 new control and distribution boards. This project was engineered, designed, built and installed all by the Integrelec Engineering and Electrical Team

    Commissioning

    Overall this project was a huge success, with the plants operational speed increasing, the cement product much more consistent in its makeup, wastage has been minimalised, and overall efficiency has improved. The Plant’s safety around the machinery is much better with more safety gates, light curtains and safety devices, allowing prompt powering down of machinery if barriers crossed.

    The plant being 20years in production had hardware that if failed could see them out of production for multiple weeks awaiting parts. Parts that were used were up to date hardware and software, with much easier breakdown analysis and diagnosis, along with more readily available parts.

    One of the challenges with this project was that it was interstate, meaning all planning had to be thorough to ensure all necessary gear was on site and ready for installation.

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  • Highlights

    • Entire Factory Upgrade
    • Complete new PLC code and HMI screens
    • High customer satisfaction
    • Increased Production / Reduced Downtime
    • Simplified Operation
  • Project Breakdown

    Stage 1:

    The first stage consisted of a new Distribution Board, a new PLC cabinet, and a new cabinet for the tile racker, and a complete change over of the racker area with new motor cabling to 13 motors, some new motors, 7 new VSDs, new sensor devices, two light curtains with forklift sensing loops, complete takeover of the safety system and a new operator console with HMI screen. Electrically onsite for two weeks, with programming commissioning assistance for the following week.

    Stage 2:

    The Second Stage was the Tile circuit, which consisted of two new cabinets, and complete changeover of motor cabling for 28 motors, 15 VSD and control of sensors. Also take over of all safety in this area. This stage also consisted of a Operator console with HMI screen. Electrically onsite for two weeks, with programming commissioning assistance for the following week.

    Stage 3:

    The Third stage was the raw materials area, this stage consisted of one new cabinet, control of 12 motors, 6 VSDs, all sensors, and safety systems. Electrically onsite for 8 days, with programming commissioning to follow.

    Stage 4:

    Finally the smallest stage was the knife cut stage and was the most complex , it only consisted of one Servo Motor and one sensor, but the engineering behind it was phenomenal with very complex motion control to ensure the knives would cut the tiles precisely as required. Electrically onsite for two days with programming commissioning to follow.

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