Elematic Fixed Sawing Concept
This may just be the most remarkable innovation in decades in prestressed concrete production. The concept is actually very simple: Having cast a full bed with your extruder or slipformer, only a minimum of cuts is made on the bed. The long pieces are then lifted up onto a conveyor and transported to a fixed sawing station, where the rest of the cutting is done. All the splashing of slurry, which turns into health-hazardous dust when dry, all human contact with dangerous moving machines, and next to all noise from sawing, is eliminated. The Elematic Fixed Sawing Concept enables the production of more precast products with the same number of beds, presenting you with the flexibility to adapt to fluctuating market demands. At times 8 casting beds are sufficient and at other times 10 or 12 beds would be needed to meet quotas. Now the circulation rate of the beds is increased drastically, as the cutting is done elsewhere and the empty beds are immediately ready for cleaning and reuse. A major part of the slurry, dust and noise that are generated when cutting, is now transferred from the production area to the insulated sawing station, from where they do not reach the factory floor. The casting area is cleaner, safer and quieter. If you are using Elematic extruders or slipformers in your factory, it may well already be comfortably silent, but with the new Elematic Fixed Sawing Concept, even the rest of the noise is as good as gone! This new concept is a real alternative to the traditional moving saw on the bed, and the degree of automation can easily be increased as Elematic ELiPLAN ERP controls the functions of the fixed sawing station. It feeds the sawing information - cross cutting, skew cutting, and ripping - from your plant's CAD/CAM-system to the saw. It all flows automatically. Elematic and Consolis have performed extensive simulations and tests in their research work and the results speak for themselves: production efficiency with the old method of sawing on the beds was 199 hours per 1000 m² of slabs. Using the new Elematic Fixed Sawing Concept: 80 hours per 1000 m². When building a new factory, the investment cost stays approximately the same if you include the fixed sawing station with its required equipment and functions. However, you can just as easily adapt an existing factory to this new method and if you do so, you update your factory for another 20 years to come without having to extend the plant or build new premises to achieve more capacity.