Brictec Double-Stack Firing Line with Automatic Pallet Handling System in Lvzhan Project for Brick Factory Brick Making Machinery

Brictec Double-Stack Firing Line with Automatic Pallet Handling System

I. Overview
1. The Double-Stack Firing System represents the core of modern, high-end clay brick and block production.
2. It is the key automation equipment for producing premium wall materials with precise forming, stable drying, and uniform firing.
3. Among all subsystems, the Automatic Pallet Handling System plays a vital role — enabling continuous, efficient, and intelligent circulation of green and dried bricks between drying and firing stages.
4. This system integrates advanced PLC automation, servo motion control, and modular mechanical design, ensuring smooth operation, consistent quality, and high productivity.

II. System Composition
The complete system includes multiple coordinated modules:
• Clay Strip Cutting System – servo-driven for precise, vibration-free cutting.
• Brick Cutting System – dual-frame configuration with automatic wire-change and optional chamfering.
• Green Brick Grouping and Loading System – automatic defect detection and waste brick removal.
• Automatic Pallet Loading System – accurately places wet bricks on moving pallets.
• Pallet Transfer System – moves loaded pallets toward the drying area via conveyor lines.
• Pallet Storage & Buffering System – temporarily stores loaded pallets in sequence.
• Pallet Lifting & Shelving System (Upper & Lower Racks) – the core of this design, enabling automatic vertical lifting and placement of pallets into the single-layer tunnel dryer.
• Pallet Unloading System – removes dried pallets and transfers them for unloading.
• Dry Brick Grouping and Pallet Unloading System – prepares bricks for secondary stacking onto kiln cars.
• Automatic Stacking System (Kiln Car Loading) – arranges dry bricks according to the required firing pattern.
All units are linked via the PROFIBUS field bus network, controlled through a central PLC, and supervised by an industrial PC for real-time monitoring, parameter adjustment, and production data management.

III. Core: Pallet Lifting and Shelving System
1. The automatic pallet lifting system is designed to:
• Transfer wet pallets into the tunnel dryer shelves efficiently and safely.
• Retrieve dried pallets and send them to the unloading station automatically.
• Operate in continuous cycles to ensure uninterrupted drying-firing flow.
2. Technical Highlights
• Servo-Controlled Lifting: Ensures smooth motion and precise positioning.
• Dual-Column Elevators: Provide structural stability and safety redundancy.
• Automatic Rack Alignment: Optical sensors ensure accurate docking with shelf positions.
• Pallet Tracking System: Monitors pallet ID, position, and drying status in real-time.
• High-Speed Exchange Cycle: Supports simultaneous loading/unloading for minimal idle time.
This system eliminates manual pallet handling, significantly improving safety, accuracy, and production efficiency.

IV. Product Features
1. Servo cutting system ensures accurate clay strip length, vertical cut surfaces, fast speed, and minimal vibration.
2. Dual-frame brick cutter with automatic wire switching; optional chamfering available.
3. Grouping system includes automatic detection and removal of defective bricks or waste clay strips.
4. Single-layer drying effectively protects the surface of green bricks from cracking or deformation.
5. Smooth-code switching function, supporting multiple production modes.
6. Optional gripper tools (standard or gap-type) for various stacking patterns.
7. Multiple programmable logic sequences, allowing quick adaptation to different product types.
8. User-friendly HMI interface, easy to operate, learn, and maintain.

V. Automation & Control
1. Centralized PLC control (Siemens or equivalent)
2. PROFIBUS fieldbus linking all intelligent modules
3. Industrial PC for automatic data setup and process adjustment
4. Real-time fault diagnosis, data recording, and remote monitoring
5. Optional MES integration for smart factory management

VI. Advantages and Value

Feature

Benefit

High Automation Level

Fully automatic stacking, lifting, shelving, and transfer system

Stable and Reliable Operation

Servo motion + field bus communication ensures precision

Improved Product Quality

Consistent drying and handling reduce cracking and deformation

Labor Efficiency

Reduces manual operations by 80%, lowers labor intensity

Energy Efficiency

Optimized transfer cycle minimizes heat loss between processes

Flexible Production

Easy switching between different brick types and sizes

Long Service Life

Robust mechanical design, low maintenance requirement

VII. Application Scope
This Automatic Pallet Handling Double-Stack System is ideal for:
• High-end clay facing bricks
• Hollow insulation blocks
• Porous wall materials
• Eco-brick and decorative sintered brick production
It serves as the core automation platform for modern double-stack tunnel kiln plants, representing the future direction of intelligent, energy-efficient brick manufacturing.

VIII. Summary
The Brictec Automatic Pallet Lifting and Handling System provides an intelligent solution for high-end clay brick production lines. With its advanced mechanical structure, servo precision control, and smart PLC integration, it achieves:
1. Continuous automatic operation
2. Reliable production stability
3. Uniform drying and firing performance
4. Significant labor and energy savings
It is the essential automation equipment for any enterprise aiming to upgrade to European-standard double-stack firing technology.