algeria

NEWS
CLEIA NEWSLETTER - Number 1 - March/April 2012
CONTENTS
Special review
CLEIA: History of a successful restart /
CLEIA expertises
Algeria
CS-Coelho da Silva:
The most modern roof tile plant in Portugal
Presentation of our kiln
manufacturing workshop
EDIT
2 years after restarting our activity, 2 years which are rich in events
and evolutions for our company, we are publishing the 1st edition
of our information review for our customers and partners.
Special review:
ALGERIA
CLEIA AlgeriA:
"CLEIA News" will keep you informed of the company activities,
the upcoming projects, the one in progress but also of the
prospective developments and the implemented innovations.
Opening mid 2012
SBMT2: A complete brick plant /
innovation in brick firing
NBS: Upgrading of the production line in
the AMIZOUR factory
SOAB: New installations with fully
automated setting machines and dehackers
R&D
4C Laboratory:
CLEIA Ceramic Competence Center
Our developments:
new rapid dryer, energy saving burners,
new PLC control system
Press review
Grinding machines with large grinding
wheels for bricks - ICV
CLEIA revisits the roof tiles and bricks
factories - Les Echos
CLEIA practical
This first edition is the opportunity to come back on the CLEIA
renewal, our motivations and our ambitions.
We are also proud to present the new roof tile plant CS-Coelho
Da Silva, the most modern in Portugal, under construction and
commissioning. It is also a special "ALGERIA" review with the erection of the brick plant
SBMT 2 in TOUGGOURT, which will integrate two major innovations for the bricks firing,
the revamping of the brick plant NBS, the evolution of the products and, in prime, the
opening of CLEIA ALGERIA for a better service to every customers in this country.
You will also find a complete inventory of the services that CLEIA is now offering; specifically
concerning the firing technology where we are able to perform either maintenance works
or new projects on kiln car refractory, kiln masonry, supply of burners… as well as the
implementation of a kiln panel manufacturing workshop on our industrial site in Burgundy.
This edition will continue with a visit of our laboratory 4C, newly equipped with a preparation
and extrusion line to produce test samples and also it’s drying and firing equipment
dedicated to any industrial clay product manufacturer.
The R&D is also in honour! We will present our projects and innovations based on energy
saving research.
With a heading "Press Review", you will also discover CLEIA through recently published
press articles.
We wish you a pleasant reading of CLEIA News n°1, while hoping to develop soon
together one of these headings!
Philippe Penillard - CEO
Key figures:
Contact and visit us
Contact and visit us Shows /
Events in spring 2012
•Turnover: 19,4 M€
•Net result: 435 K€
•Employees: 90 permanent and
up to 140 at a peak
CLEIA
Expertises:
• Global
engineering projects for brick
and roof tile plants and technical
ceramic industry
• Clay
preparation and shaping units
(turn-key projects)
CLEIA:
history of a
successful restart
• Cutters
(Design and construction) and
roof tile presses (integration)
• Dryers:
tunnel dryers, Chamber
dryers, fast dryers "Sirocco" type
• Refractory
concrete kilns "ECOFAST"
type or with refractory pieces
"TECHNOFAST" type
• Kiln
cars (all technologies)
• Firing
equipment: Complete range of
gas burners, Dual energy burners,
Fuel oil circuits, Saw dust firing
systems, Biogas…
In April 2010, thirty former managers
and employees of Ceric and Ceric
Automation restart the industrial site of
Ceric located at Nolay in Burgundy and
create Cleia which owns 50 years of
experience in the heavy clay sector
and in the technical ceramic industry.
the development potential still very
important. Since its inception, Cleia
won three major contracts in Europe
and North Africa and is currently
operating the construction of two roof
tile plants (Portugal and Poland) and a
brick factory in Algeria.
Enjoying a revitalization plan for
employment and with the support
of the Burgundy region
and department, the
business starts with
O
an empty order book
DENE
but a lot of motivation
DIC
AT
and quality teams who
ED
SIN
want to continue to
CE
develop the industrial site
19
61
known for its high technology
and innovation capacity.
Cleia has done many factory
modernisation in France and on an
international scale. During the summer
of 2011, no less than 17 renovation
works on site were completed thanks
to the quality of its technical teams
and multi-customer service skills.
• Automatic
handling (multi-supports
technology for roof tiles), bricks,
insulating blocks
• Kiln
car and dryer car handling
equipment
• Robotics
(integration, hot line, vision)
• Grinding
machine for rectified bricks
• Production
management (Software,
automatisms, development and
programmation)
• Customer
Service: Technical audit,
modification of machineries,
troubleshooting and spare parts
20
1
SI 1
TE
0
yea
rs
Just two years later the proposed
takeover is successful, the results
are beyond expectations and
The engineering company Cleia
who has expertise in the complete
process including ceramics industry
has consolidated its leading position
in high-tech units, retrofits and
restarts a laboratory for ceramic tests
and installed a kiln workshop on his
25-hectare site.
CLEIA builds for CS-Coelho da Silva the most
modern roof tiles plant in Portugal
CLEIA is building an ultramodern roof tiles factory in
Portugal for the CS-Coelho
da Silva company. This is the
first major investment in Europe
since 2009 and it is a significant
success for CLEIA, confirming
its position as world leader in
engineering and supply of
complete high-tech roof tile
and brick plants.
2 March/April 2012 - Number 1 - CLEIA Newsletter
For the CS-Coelho da Silva
company, the future "Plant 5 will
produce high quality products
fired on unitary refractory support,
designed with outstanding characteristics and unmatched aesthetics
features, which is very popular in
its local markets as well as export.
For this private company which
has become the first national
producer of roof tiles and acces-
sories, investing in a high quality
plant at this difficult time is an
ambitious strategic vision which
aims to achieve the best profitability in a still very tense market.
The keys to success of this project
lie in the team involvement, its
skills, and the high reactivity of
CLEIA to serve its Clients.
The cooperation spirit and trust
that the managers
of
CS-Coelho
da Silva gave in
the CLEIA team
- mainly composed of former
employees of the Ceric group
now grouped in the Burgundian
company for greater efficiency and that boasts nearly 50 years
of experience in the heavy clay
industry are also among the
factors for success.
New workshop
for kilns fabrication
in France
CLEIA installs, in its industrial premises of
Nolay, a workshop for the manufacturing of
kiln panels dedicated to the firing of heavy
clay building materials. CLEIA invested in
a set of equipment and tooling to produce
Ecofast kiln panels in its full range. This type
of kiln with modular structure is made of
refractory insulating concrete casted in a
waveform steel sheet.
The first kiln panels were fully realised. "The
manufacturing process is well controlled
which guarantees a very high level of
quality," said Jerome Degueurce, Director
of Operations.
CLEIA provides innovative solutions especially for the reduction
of energy consumption of the
dryer, and an optimal control of
the firing process within a tight
kiln with liquid seal.
This new plant will be completed
in just over nine months for the
first phase and will also benefit of
the latest developments in automatic handling of tile refractory
This workshop is unique in France and will
allow CLEIA to achieve the renovations of
many types of kilns built with this technology
as well as brand-new ones.
“
CLEIA wanted
to control all the
manufacturing
to guarantee its
customers high
quality and efficient
service
„
CLEIA wanted to control all the
manufacturing to guarantee its customers
high quality and efficient service. With its
expertise in firing processes and ceramic
technologies, CLEIA also uses this
workshop for all following services:
• Replacement of kiln panels and roofs
made of refractory pieces,
• Renovation of kiln cars,
• Repair of kiln and dryer equipments.
supports, and can significantly
reduce their rate of replacement,
thus greatly reducing operating
costs.
The first fired roof tiles will come
out from the Ecofast kiln within
2012 spring. The second phase
will double the capacity of the
plant.
CLEIA Newsletter - Number 1 - March/April 2012 3
Special review
ALGERIA
SBMT2 brick plant:
New brick plant in TEMACINE
for TEDJINI group
1200 X 1200 packs on kiln cars:
The new brickplant SBMT2 in TEMACINE (Wilaya of
TOUGGOURT) realised by CLEIA for TEDJINI group is
currently in construction.
CLEIA performs the complete brickworks, including the
preparation and shaping line with roller mills and extruder of
VERDES brand.
The fast dryer is a Sirocco with automatic chain tensioning
device for an easy maintenance and longer life of mechanisms.
The Technofast kiln 100% tight and 100% in refractory pieces
will be the first one in Algeria.
The characteristics of the clay in this region of Algeria
required kiln adapted to corrosive exhaust fumes.
The automatic handling systems and the cutters are designed
and made by Cleia. The factory is equipped with the same
high technology equipment than the others Cleia plants.
A PCCER control system will be installed to manage this new unit.
All the plant has been designed, fabricated and delivered in
the short time of 8 months.
4 March/April 2012 - Number 1 - CLEIA Newsletter
The innovation for a better
profitability
For this new plant, as for all new brick plant
projects offered by Cleia, packs on kiln cars
are 1200 mm in width x 1200 mm in depth. This
innovation offers several advantages:
•Optimized kiln loading,
•Handling circuits are simplified by a double
row counting,
•Machines speed decrease,
•Handling circuit reliability increase,
•Fabrication of future products of 400 mm
length possible by program modification
•Easy loading of products on the delivery trucks
CLEIA ALGERIA: Opening mid 2012
In order to offer a better service to its clients, Cleia
will open a new company in Algeria. This new
company will include:
•A spare parts store,
•A sales office,
•A Customer service team.
•Claude Okon: Sales Director for Algeria and
Maghreb
•Jean-Pascal Monin: Spare parts manager
•Valérie Delavault: Shipping manager
•Mikael Legouhy: Construction manager
•Jérôme Bonin: Construction and
commissioning manager
Saad ALLAF, our local manager, will better
serve and inform our clients for new projects
and assistance with the very efficient support of
our Algeria team:
NBS: Revamping of
AMIZOUR brick plant
NBS company at AMIZOUR
(Wilaya of BEJAÏA) trusts CLEIA for
the modernisation of the existing
production line with replacement of
new extruder group, the complete
revamping of the dryer and the new
automatic handling circuit for the wet
and fired side.
CLEIA ALGERIA:
SERVICE RAPIDITY QUALITY PRICE
Our spare parts store will allow our clients to rapidly
get a great variety of spare parts and components
which are currently installed in brick plants: wear
parts, first aid spare parts, a set of strategic pieces
and standard components.
The local team will offer a local service with high
competences in automatisms, robotic and ceramic
process. All services will be locally invoiced.
SOAB brick plant:
2 new multi-products
automatic handling
equipments
In order to increase the output of the
plant, CLEIA will install a new extruder
group type Verdes Monobloc and a
new cutting line including the loading
of wet products.
The existing dryer will be extended
and totally modernised. To complete
the automatisation of the brickwork a
new unloading gripper which can set
packs directly on the delivery truck or
in storage area will be installed.
Mr SADOUDI MECHERI, focusing on
the product quality, selected Cleia
because of the high reliability of the
proposed solution which definitely
meets his expectations.
The unit which is currently under
construction will be commissioned in
summer 2012.
CLEIA delivered and installed in 2011 at
SOAB OUM ALI (Wilaya of TEBESSA), two
multi-products machineries for loading and
unloading on kiln cars.
The two equipments designed and made
by CLEIA, run with B8 or B12 brick, ceiling
products or new sizes bricks. These two
facilities provide full satisfaction to the client
that compliments the robustness and the
reliability of the delivered machineries.
After the setting machine which was the
first successfully commissioned equipment,
SOAB convinced by the Cleia Quality, quickly
placed the order for the dehacker.
The SOAB brick plant was thus able to
increase production facilities with having now
excellent returns.
CLEIA dares to quality of this equipment,
reliability of its facilities and its experienced
technical teams to continue to expand on
Algerian market.
CLEIA Newsletter - Number 1 - March/April 2012 5
R&D
“
„
Using wet products manufactured
by our customers, we can exactly
reproduce drying and firing
conditions of the future plant
4C Laboratory
The 4C laboratory or "Cleia Ceramic Competence Center”
is a unique and essential support to the Research and
Development department of the company.
This laboratory is equipped with powerful equipment for clay
preparation and forming, to perform drying and firing tests
on heavy clay products which is the core business of CLEIA.
4C is located on the industrial site of CLEIA
The 4C laboratory is located on the industrial site of Nolay in a
hall which is specifically dedicated to the ceramic know-how.
The laboratory is equipped with:
•1 Raw material preparation and forming line
including the mixing, the grinding and the extrusion
of customer clay samples
•1 Mobile dryer
•1 Industrial tunnel kiln
•1 Shuttle kiln for high temperature firing tests
•1 Laboratory
Real-size tests with customer products
"Using wet products manufactured by our customers, we
can exactly reproduce drying and firing conditions of the
future plant" says Didier Brun, CLEIA Process Manager in
charge of the 4C.
We realise the following tests:
•Clay analysis (with a partner laboratory)
•Clay preparation and raw material mix
optimisation
•Clay sample forming for tests
(tiles, small bricks or small blocks)
•Drying and firing curves definition
•Setting pattern
(with a lot of refractory supports available)
•Test reports (shrinkage, colors, porosity,
products defaults, recommendation)
4C laboratory owns a great quantity of supports which can
be used for testing: drying trays, U and H cassettes adapted
to various roof tile models, VFT firing trays to study the firing
conditions depending of the supports used.
New rapid dryer, energy saving
burners, new PLC control system
Innovation and equipments in progress:
• A new dryer of high capacity adapted to the evolution of bricks and insulating
blocks. A patent is registered for this innovation. Launching on the market:
may 2012 during Batimatec expo in Algiers.
• New generation of high efficiency burners allowing to reduce energy
consumption are currently studied.
• A new PLC control system: modern, open and intuitive is developed by
engineers. Exclusive presentation during Ceramitec in Munich.
6 March/April 2012 - Number 1 - CLEIA Newsletter
Press review
ICV
December 2011
Grinding machines with
large grinding wheels for bricks
by more than two the lifetime of the grinding tools.
The grinding machine evacuates dust in an optimal way:
the bricks are placed with the holes vertically, which allows
dust and brick chips to be evacuated easily through, while
being directed downwards by a double system of blowing
and aspiration. At the exit of grinding, the bricks are clean
from any grinding dust, which considerably improves the
adherence of the adhesive on the grinded faces.
Grinding machines available in 2 sizes : Q5 and Q10
CLEIA and QUADRA have just signed an agreement for the
distribution of grinding machines in the heavy clay industry.
QUADRA, manufacturer of grinding machines for concrete
product, and CLEIA, integrator in clay product, have jointly
carried out tests with these grinding machines with clay
products. They correspond to the technical evolution of
bricks and walls blocks, which require a high degree of
accuracy and an optimal flatness for an installation with very
thin joint of adhesive. "These machines are economically
interesting, specifies Thierry ALLANIC, responsible of
communication in CLEIA. Moreover, the wear of the
rectifying tools is limited, thanks to the very large diameter
and the low rotation speeds of the grinding wheels." "We
have signed an exclusive partnership with CLEIA, confirms
Yannick ANCRENAZ, managing director of QUADRA, and
performed all the necessary technical developments: the
quality of rectification was validated after very successful
grinding tests performed on various types of bricks. The
agreement with CLEIA includes the integration of the grinding
machine into clay product handling equipment.
Patented machining device
with vertical axis
These machines are designed on the basis of a machine
tool with grinding wheels fixed on a separate shaft,
independent from the driving shaft, which gives more
strength and rigidity. The driving motor of the grinder is
standard. The pin is put in light overpressure to guarantee
a very good sealing. The grinding of the two faces is
carried out separately and the bricks are maintained
during grinding to obtain the best accuracy. The lower
face of bricks is grinded first and is used as a reference
for the grinding of the upper face, which limits the lacks
of flatness. The two faces are grinded in only once. In
comparison, the other machines simultaneously grinds
the two faces of the products, therefore the product can
move between the grinding wheels when the grains hits
the material, the new grinding machines can guarantee an
optimal flatness. The products are laid out flat as a bed
and the moderated speed decreases considerably the
temperature during the grinding process, and increases
Integration in a production line
The integration of a grinding line is simple and easy, since
the grinding machines were designed to be installed in
by-pass of the lines of conditioning, or directly integrated on
the main manufacturing line. Two models of machines, Q5
and Q10, make it possible to match the various production
rates we can find in any brick plant. The Q10 constitutes
the ideal machine for bricks and blocks productions up
to 200.000 tons/years according to the products. Thanks
to its very rigid grinding-wheel holders, only two, large
diameter grinding wheels (1250mm and 1600mm) equip
this high capacity grinding machine. The machine can
process a full layer of bricks with the holes positioned
vertically, which often corresponds to the finished layer
on the palettes. This principle simplifies considerably the
brick handling equipments, upstream and downstream
from grinding. The Q5, made for smaller production rates,
can grind the bricks one by one to guarantee the surface
quality and geometrical quality of the finished products.
The grinding installation can be fitted in a very small area
with two robots located at entry and exit of the machine.
Tactile tools and easy maintenance
All the commands of the grinder are regrouped on a touch
screen operating panel. Commands and adjustments are
very easy to do, and the screen gives to the operator all
necessary information such as speed, cutting depth,
moving speed and more. They are clearly indicated for an
easy exploitation. The accesses for maintenance are made
very easy, due to the low level from the floor of the machine.
The lower and higher grinding plates (grinding wheels) are
equipped with easily interchangeable tools. The whole
machine is covered by an air tight hooding, with a powerful
dust collection system as well as a waste collection flexible
container located under the grinding machine. Initially
designed for very abrasive concrete products, the grinding
machines Q10 and Q5 are perfectly adapted to the humid
and dusty environment.
Editorial Board
Philippe Penillard • Frank Bigeard • Michel Conry
Claude Okon • Didier Brun • Thierry Allanic
CLEIA Newsletter - Number 1 - March/April 2012 7
Press review
DECEMBER 7th 2011
“
The first asset
of the company
rests on a highly
motivated
workforce
Burgundy region
CLEIA revisits roof tile
and brick plants
„
The Burgundy company restarts the design and the construction
of production lines for the heavy clay industry
Is CLEIA trying to save a national know-how that few
companies have the expertises in the world, knowing
the design and construction of brick and roof tile plants?
Philippe Penillard, its chairman, is convinced of this with the
first results very promising. "In the time of eighteen months
we realise a turnover of 20 millions Euros and we totalize
30 millions of orders for 2012". Even better, the industrial
which employee - on its site of Nolay (Côte d’Or) 90 permanent and 120 on peak, will construct the only
2 roof tile plants in Europe, in Poland and in Portugal.
"Contracts of 15 to 20 millions Euros per unit", specifies
Mr Penillard. The first asset of the company rests on a highly
motivated workforce. The company renewal starts with
the court decision of the attribution of Ceric Automation
and Ceric System, former subsidiaries of Keyria (Legris
Industry group). CLEIA owners are the employees.
In particular to the 35 managers and technicians which
help Philippe Penillard to develop the project restarting the
activity considered viable by the commercial court of Dijon.
At this time, The Burgundy regional council and the Côte
d’Or general council grant 1,1 Million Euros of financial aids
and since, the French organism "Coface" supports the
development of the company with deposit back guarantees
and prospecting insurances.
The others assets of CLEIA are an engineering which is in
its own genes, with more than 60 technicians for studies,
design and process.
The Research and development department will soon
propose an innovation with a new burner able to reduce
energetic costs for the heavy clay material production units.
In a world market still very tense, the industrial company
takes advantage with a complete proposal including the
civil works for the Buildings construction "We also work to
realise brick plant in emerging countries and we multiply,
with more than one hundred projects, operating in small
units for modernisation or replacement of equipment all
over the world", explains Philippe Penillard. Tomorrow,
CLEIA wants to propose its expertise in robotics and PLC
control systems dedicated with flow simulation to other
industries, as agribusiness or bottling.
Correspondent in Dijon - Didier HUGUE
Shows / Events
in spring 2012:
CLEIA Practical
Join us on upcoming international events:
INDIAN CERAMICS in Ahmadabad from march 20 to march 22
MOSBUILD in Moscow from April 2 to April 5
BATIMATEC in Algiers from May 3 to May 7
CAUCASUS BUILD in Tbilisi from May 16 to May 19
LIBYA BUILD in Tripoli from May 20 to May 24
CERAMITEC in Munich from May 22 to May 25
Visit us
By train:
By car:
From Paris: approximately two hours
TGV: Paris/Le Creusot Montchanin TGV:
approximate duration 1 hour and 10 minutes
Then Montchanin-Nolay: 40 minutes by car
Motorway A6 from PARIS: about 3 hours
A6 exit N°24 Pouilly en Auxois
Direction Arnay-le-Duc D981 then N6
and D973 towards Nolay
From LYON: about 1 hour and 20 minutes
TGV: Lyon/ Le Creusot Montchanin TGV:
approximate duration 40 minutes
Then Montchanin-Nolay: 40 minutes by car
Motorway A6 from LYON: about 1 hour and 30 minutes
A6 exit N°25 Chalon Nord
Direction Chagny N6 then D33 and D973
towards Nolay
www.cleia.fr
Engineering turn-key solutions
2, avenue Spuller - 21340 NOLAY - FRANCE
+33 3 80 26 71 00
[email protected]