Ceratec Engineers Advanced Robotic Production Line for Emsländer Sand-Lime Brick Prefabricated Walls

Ceratec Automates Heavy Prefabricated Wall Production for Emsländer

Ceratec was commissioned by Emsländer, a major manufacturer of sand-lime bricks, to develop and integrate a fully automated production line for prefabricated walls. The installation was designed for a new production hall, which was built with increased ceiling height specifically to meet the technical demands of this mechatronic solution.

The primary challenge involved the handling and sequencing of heavy and varied materials. The line processes base bricks (kimstenen), standard bricks (up to 82.5 kg), and lintels.

Integrated Mechatronic Solution:

• Robotic Handling: A primary robot (Robot 1) is responsible for depalletizing the bricks, gripping half-layers at a time. This same robot uses a versatile gripper capable of also handling heavy lintels (up to 100 kg and 2 m long) to place them onto the line.
• Sequencing and Sawing: A second robot (Robot 2) manages the complex material flow. It positions the bricks in the correct production sequence on the main supply conveyor. It is also tasked with feeding the sawing installation (for which Ceratec provided the integration and electrical controls) and retrieving the cut-to-size blocks to reinsert them into the flow.
• Software Integration: The machine control system, developed by Ceratec, interfaces directly with Emsländer’s “Plansysteme” software. Production orders are thus transmitted seamlessly, allowing the line to efficiently manage production changes, although the client is responsible for grouping orders by wall thickness to minimize these transitions.
• Production Flow: The line includes four input conveyors for full pallets, two stacked buffer belts to optimize the flow to the saw, and multiple centering positions to ensure accuracy. The assembled wall (max. 8 m) remains stationary and is removed via an overhead crane.

This project demonstrates Ceratec’s expertise in engineering heavy-duty automation solutions, combining advanced robotics and electrical control integration for the building materials industry.