The Process Of Our In-House Ceramic Fibre Lining Production

This project initially began as an R&D initiative several years ago, and has now become an indispensable aspect of our business operations. Not only does it supply our kilns with the necessary fibre, but it also allows us to meticulously inspect and qualify each module, ensuring a uniformed end result. Additionally, our in-house department ensures swift turnaround times for maintenance and repairs. We are capable of manufacturing different types of heat-resistant fibre right here, tailored to meet your specific requirements.

Follow our process below. 

Ceramic fibre in its self is a bought in product produced by specialist manufacturers, it may be purchased bagged in loose form (cotton wool) or as a blanket pressed in roll form.

The fibre itself may be obtained in different grades to suit various temperature applications.

To be of use as an insulating element in kiln or furnace it must be assembled into block of sufficient thickness to provide the correct insulation properties.

The first challenge encountered was to be able to cut the rolls of fibre into sections from which we were able to produce the blocks.

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A bench was created onto which the rolls of fibre could be hung on a spindle, this roll was flattened on to the table bed and fed under power through a cutting device which reduced the fibre to a manageable size for the blocks to be manufactured.

During stage a number of problems presented themselves,

• The drive system had to be sufficient to move and unroll the fibre into the machine without tearing or damaging the surface.
• The cutting disc had to be of a material which would not leave any type of residue on the fibre
• The disc would have to be fully adjustable to accommodate fibre sizes required
• The table speed would have to be variable
• The table would be equipped with and automatic stop system which could be adjusted for the lengths required
• The table would be equipped with a cutting guide across the width of the table.

BAGGING MACHINE

The resulting cut pieces were then assembled into a block of the size required on the bagging machine platform.

The bagging machine was developed to assemble the required number of individual sheets for a block into a unit which could be inserted into a plastic cover to avoid contamination and provide a manageable form.

BLOCK SIZING AND TRIMMING

The machine is basically a modified band saw used for the final sizing of blocks.

FURNACE MOUNTIG ASSEMBLY

For final use in a furnace the blocks are required to have a means of

1. Mounting them to the steel substructure
2. An internal structure to hold the pieces in place during use

The left hand side of the unit shown was developed to insert the internal bonding structure to the blocks.

The right hand side of the unit was developed to insert furnace mounting plates.

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