Making

of
EPS - blocks
Kurtz Altaussee GmbH
11.11.1999 KAA Ro_R

Block moulding.ppt

page 1

BLOCK MOULDING
Blockmould Criteria

Blockmould Criteria
Production capacity - shortest cycle time
Homogeneous fusing
Low moisture content
Homogeneous density distribution
Weight control
No surplus of raw material

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 2

BLOCK MOULDING
Blockmould Criteria

Blockmould Criteria
Low steam consumption (insulated mould walls)
Different EPS materials
High share of reground material
Easy operation - fully automatic cycle process
Gentle to material
High availability
User-friendly

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 3

BLOCK MOULDING
Block Production

Block Production
1.

Transport of virgin material

2.

Admixture of crushed material

3.

Positioning of side wall (Monoflex)

4.

Filling of the blockmould

5.

Density correction (option)

6.

Production of the block

7.

Side wall demoulding movement (Monoflex)

8.

Block discharge

9.

Block weighing device and marking (option)

10.

Block transport to the intermediate storage

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 4

BLOCK MOULDING
Block Requirements

Requirements for good blocks

Sufficient dimensioned steam unit (with steam accumulator)
Sufficient dimensioned aeration (flaps, line diameter)
Sufficient dimensioned vacuum unit (with vessel)
Sufficient dimensioned condensate lines (for drain water)
Sufficient dimensioned cooling water unit
Sufficient stored and preexpanded material
Bringing in of well mixed material (virgin material + recycled material)

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 5

BLOCK MOULDING
Steam Supply

Steam Supply
Sufficient big steam accumulator (1,5 to 1,8 bar)
Sufficient dimensioned steam lines
Controllable main steam valve
Sufficient dimensioned condensate lines (for drain water)

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 6

BLOCK MOULDING
Vacuum Unit

Vacuum unit
Is used to evacuate the block mould
(faster steam distribution possible)
Consists of:
-

Vacuum tank (for one steaming variant it is divided)

Sufficient number of vacuum pumps

Condensator

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 7

BLOCK MOULDING
Vacuum Unit

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 8

BLOCK MOULDING
Steam Pressure / Foam Pressure
foam pressure set point
steam pressure set point

opening
pressure
purging pressure

vacuum set point

vacuum tank + pump
vacuum pump
vacuum purging
purging in normal atmosphere
autoclave steaming
post-steaming
exhausting
stabilization

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 9

BLOCK MOULDING
Super Fusion

Steaming Versions
Version N

Version A

Version B

steaming with one

steaming with two

steaming with change

flowing direction

flowing directions

of flowing direction

Vacuum and exhaust

Main Steam

Main
Steam

Main
Steam

Main
Steam

Main
Steam

Vacuum
and
exhaust

Main
Steam
Vacuum
and
exhaust

Main
Steam

Vacuum and exhaust

Vacuum and exhaust

Application

Application

Application

Standard

Standard

light material

for all materials

for materials difficult to weld

(e.g. sound dampening)

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 10

BLOCK MOULDING
Condensate Drain

Condensate drain
Special contructed lid wedge wire
Sufficient dimensioned condensate lines
Possibilities of demounting for

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 11

BLOCK MOULDING
Requirements Block Quality

Filling of the block mould

Use of a mixing and dosing unit (for addition of recycled material)

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 12

BLOCK MOULDING
Requirements Block Quality

Filling of the block mould

Bringing-in of the material into the blockmould
-

Material is transported by a suction fan in to the blockmould

advantage: a minimum of segregation

Complete filled block mould
-

Checked by a flowing detector

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 13

BLOCK MOULDING
Quality Standard Density

Suction filling

Adjustable steam deflector

Blow back during filling

Density corrector

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 14

BLOCK MOULDING
Filling

Suction Fill

Blower Fill

light

heavy

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 15

BLOCK MOULDING
Characteristics horizontal/vertical Blockmould

Characteristics of horizontal and vertical Blockmould

horizontal:

lower height of shed

block turner necessary (to store the blocks vertical)
length adjustment possible
adjustable bottom

vertical:

low space of shed required

no block turner necessary, if blocks stored vertical
only one filling gun
movable side wall possible (block weight correction)
faster condensate drain

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 16

BLOCK MOULDING
Blockmoulds / Standard Types

Ecomat

Monoflex

Vario

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 17

BLOCK MOULDING
Advantages of the 3 KURTZ Blockmoulds

Advantages of the 3 types of KURTZ

blockmoulds
Filling: even and gentle to material
Homogeneous density distribution
Electronic controllable main steam valve
Adjustable steaming variants
Homogeneous fusing
Shortest cycle times

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 18

BLOCK MOULDING
Advantages of the 3 KURTZ blockmoulds

Advantages of the 3 types of KURTZ

blockmoulds
Energy-saving and efficient vacuum system
Stainless wedge wires with steam nozzles, easy assembly
Solid construction
fully automatic cycle
Intelligent control with display screen
Recording of operating data for quality

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 19

BLOCK MOULDING
Super Fusion

Electronic controllable main steam valve

Main-steam valve aperture in %
P1
0%

Vacuum

P2
32 - 40 % Vacuum rinsing
P3
35 - 43 % Rinsing
P4
55 - 80 % Steam shock
V
a
c
u
u
u
m

V
a
c
u
u
u
m

R
i
n
s
i
n
g

r
i
n
s
i
n
g

S
t
e
a
m

D
w
e
l
l

s
h
o
c
k

s
t
e
a
m
i
n
g

M
o
u
l
d
i
n
g

P5
10 - 15 % Dwell steaming
P6
0%

Moulding

P7

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 20

BLOCK MOULDING
Advantages of KURTZ Blockmoulds
Slotted Plates Versus Wedge Wire Plates
Competitor

KURTZ

- lighter type of construction

- compact unit with continuous (constructive) support

- small steaming area

- homogeneous, fine steam distribution

- big steaming area

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 21

BLOCK MOULDING
Ecomat System / Design

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 22

BLOCK MOULDING
Ecomat advantages

Advantages of the Ecomat Blockmould

Short Pay-Back period
The most economical way to produce blocks
Compact design
Low space requirement
Minimum steam consumption
Low moisture on the top of the block

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 23

BLOCK MOULDING
Ecomat advantages

Advantages of the Ecomat Blockmould

Low moisture on the top of the block
Few moving parts
Mixing up to 30 % recycling material
Minimum maintenance requirement
User-friendly controls
Standardized valving

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 24

Block Moulding
Monoflex System / Design

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 25

Block Moulding
Monoflex System / Design
Steam connection DN 300

Filling pipe 300

Compressed air connection R "

Condensate drain DN 100

Exhaust DN 350
Steam connection

Filling blower 300

Hydraulic
plant

Vacuum connection DN 200

Control
panel

Block take away

Weighing unit

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 26

BLOCK MOULDING
Monoflex System / Design

Advantages of the Monoflex Blockmould

Stable, enclosed mould body
Movable side wall, newly developed side wall drive
Precise and absolute route measurement
Blocks of 100 % recycled material
Block is not tapered
Low moisture on the top of the block

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 27

BLOCK MOULDING
Monoflex System / Design

Advantages of the Monoflex Blockmould

Sealing surface only at the front door
Flexible, universal, variable steaming
automatic weight compensation possible
Low space requirement
Simple wedge wire attachment
Excellent cleaning facilities

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 28

BLOCK MOULDING
Monoflex System / Design

Side wall drive

Cylinders outside the steam
chamber

Efficient hydraulic system

Precise and absolute route
measurement

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 29

BLOCK MOULDING
Monoflex System / Design

Stable mould body

Steel bracing

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 30

BLOCK MOULDING
Vario System / Design

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 31

BLOCK MOULDING
Vario System / Design

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 32

BLOCK MOULDING
Vario System / Design
Filling pipe DN 150

Condensate drain DN 65
Steam connection DN 250
Vacuum connection DN 200

Vacuum tank

Exhaust DN 300
Condensate drain DN 65
Hydraulic plant

Filling blower DN 250

Protection grid locally

Compressed air connection R "

Block take away

Supply
Control panel
Filling silo

Layout
Kurtz Altaussee GmbH
11.11.1999 KAA Ro_R

Block moulding.ppt

page 33

BLOCK MOULDING
Vario System / Design

Advantages of the Vario Blockmould

Best accessibility
Adjustable in length or height
Fast filling system (filling guns)
Flexible, universal, variavle, steady steaming
Block is not tapered
Mixing up to 30 % recycling material

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 34

BLOCK MOULDING
Vario System / Design

Advantages of the Vario Blockmould

Low building level
Long block sizes
Minimum maintenance requirement
User-friendly controls
Trouble-free block ejection

Kurtz Altaussee GmbH

11.11.1999 KAA Ro_R

Block moulding.ppt

page 35

back to the Content

For Additional or Special
Information Please Contact:

KURTZ GmbH
Frankenstrae 2
D-97892 Kreuzwertheim/Germany
Tel.: +49/9342/807-0
Fax:
+49/9342/807-294
E-mail: smv@kurtz.de
http://www.kurtz.de
Kurtz GmbH
17.11.99.smv.wk-wsc

basic_e.ppt

Seite 3