Pallet soakers

IFAMAC ceramic pack wetting systems apply water in a controlled manner to bricks, blocks and other palletised structural ceramic products when the process requires the pieces to be conditioned before storage or dispatch.

The equipment, also known as a brick pallet wetter, moves the pack through a station equipped with the components required to distribute water over the specified surfaces.

Each installation is designed according to the type of ceramic product, pack dimensions, required quantity of water, production throughput and conveying-system configuration.

Controlled application of water to the pack

The pack enters the wetting station on a conveyor and is positioned in the working area.

The system applies water to the specified sides of the load according to the sequence established for the product. Distribution, flow rate and application time are adjusted to the requirements of the process.

Once the operation has been completed, the pack continues towards the accumulation, storage or dispatch area.

The amount of water must be determined according to the characteristics of the pieces and the required result, avoiding both insufficient application and excess liquid.

Wetting bricks and ceramic products

In certain structural ceramics production processes, water may need to be applied to the fired product before storage or sale.

Wetting can help condition products manufactured from certain clay compositions and control defects associated with the subsequent behaviour of the pieces.

Whether it is required, when it should be applied and the amount of water needed depend on the composition of the raw material, the firing process and the specifications of each product.

The system configuration must therefore be based on the technological criteria established by the ceramic manufacturer.

Uniform distribution over the specified surfaces

The application components are arranged around the clearance area to direct water towards the sides of the pack that require treatment.

The position, number and orientation of these components are adapted to the width, height and arrangement of the load.

The design aims to achieve consistent coverage over the accessible surfaces and reduce variations in application between different areas of the pack.

The effective penetration of the water will depend on the porosity of the product, the arrangement of the pieces and the time available for the operation.

Adjustable flow rate and application time

The water supply can be configured according to the amount required for each pack and the capacity of the line.

The control system coordinates the start and end of the application with the presence and position of the load.

Where the installation allows, parameters such as the flow rate, application time and operating sequence can be adjusted to accommodate different compatible products.

The values used must be defined according to the product characteristics and validated during testing and commissioning.

Adaptation to the pack format

IFAMAC sizes the structure and clearance area according to the width, length and height of the packs.

The design takes into account the arrangement of the pieces, the areas to be wetted, packaging components and the type of support used to form the load.

When a plant handles different formats, the possibility of incorporating adjustments to adapt the position of the application components or cycle parameters must be assessed.

The compatibility of each format is determined according to its dimensions and the accessibility of the surfaces to which the water must be applied.

Water collection and management

The station can incorporate a lower section designed to collect water that is not retained by the product.

Trays, pipework and drainage points are configured to prevent accumulation around the conveyor and facilitate cleaning of the installation.

Depending on the project conditions, water treatment, filtration or recirculation can be considered. The final solution must be established according to the required water quality, residues present and plant requirements.

Components exposed to water are selected with consideration for moisture, corrosion and operating frequency.

Integration with pack conveying systems

The wetting system can be integrated with chain conveyors and other equipment used to move packs of ceramic products.

Sensors detect the arrival of the load and verify its position before authorising the application of water.

The control system coordinates the entry, wetting and exit of the pack with the equipment located upstream and downstream of the station.

This integration allows the operation to be incorporated into the end-of-line flow without requiring separate handling of the pack.

Applications in the structural ceramics industry

The systems can be adapted to packs of bricks, blocks, hollow clay floor blocks, roof tiles and other structural ceramic products compatible with the wetting process.

The need to treat each product must be determined according to the raw material used, manufacturing conditions and quality requirements established by the plant.

The equipment is generally installed during the final stages of the process, after firing and pack formation and before storage or dispatch.

Its exact location depends on the packaging sequence, required conditioning time and plant layout.

Process automation and control

The control system coordinates pack conveying, positioning and water application.

Sensors can verify the presence of the load and prevent the system from being activated when no pack is correctly positioned in the station.

When the line processes several products, the automation system can incorporate different parameters for compatible formats.

The machine can exchange availability, cycle-start and cycle-completion signals with the conveyors and end-of-line equipment.

Safety and maintenance

The installation can incorporate enclosures, guards and safety devices adapted to the moving parts and application components.

Access points are configured to facilitate the inspection and cleaning of nozzles, pipework, trays and conveyor components.

The design must limit the presence of water in access areas and facilitate its drainage to maintain appropriate working conditions.

Maintenance operations are defined according to water quality, operating frequency and the possible formation of deposits in the application components.

Custom design and manufacturing

IFAMAC adapts the structure, clearance area, application components, water circuit, collection system and automation to the requirements of each plant.

The solution can be incorporated into both new production lines and existing installations, provided that the available space and technical conditions allow its integration.

Each project is developed according to the ceramic product, pack format, required quantity of water, throughput and end-of-line configuration.