DecoImprint®

A new Rusticating machine . . . again?

DecoMachines considered it necessary. The machines currently on the market simply do not offer the best possible value machine for money. So we faced a serious challenge to design a machine that would be the best of both worlds. 
We spent lots of time to survey the market needs and the suppliers offers.
This resulted in the best machine ever built: the DecoImprint, a new machine for rusticating clay columns after the extruder press.
In the technology paragraph of our website we explain to you how we work: with the best performing engineers and the lowest priced manufacturers all based on 30 years of experience.

Down below we will show what we met on the market:

General information for Rusticators with texturing belts.

The machines are suitable for clay columns of minimum size 185 x 30 mm and maximum 300 x 150 mm. The DecoImprint needs more width due to the lengthened arms of the texturing belt subassemblies that make cleaning of those belts easier. In general width is not the problem, length is…
Regarding this length, in practice the space between the die and the cutter following, if the DecoImprint should consist of all the features that makes the treatment of your clay column flexible, and your space is limited, the DecoImprint still is your best choice. In the case of a lack of width texturing rollers can be offered instead.
As the machines are modularly built up, we are able to manufacture every possible concept that suits your needs. Our option list consists of peeling units, random sanding facility, dry stains supplying equipment, wet spray stations of engobes etc.
Naturally we are able to offer you all possible machine frame lengths that you require with or without deleting some modules. Even in the worst possible case of hardly any place we can offer texturing facilities at request.

Form firmness of the extruded clay column:

Our imprinting belts will bring pressure to bear on the clay column. In case of very stiff columns ( Penetrometer value < 1,5 ) our rubber composed belts are hardly suitable to provide rough profiles, and the change over to either polyurethane or steel profile rollers could be necessary. Another important issue: the speed of the column coming from the extruder press must be constant and independent from the plasticity of the material. Speed deviation of more than 5% might affect the working of the Rusticator in a negative way.
In some cases one should extrude columns with reinforced ribs to encounter the forces of the texturing machine.

The DecoImprint for the sanding, profiling of the clay column direct behind the extruder press. Engobing and dry colour application are optional and described in the option list.

Item1:
One tacho speed control roller. The machine conveying system and the surface working units will follow the speed of the clay column automatically.

Item 2:
One sanding unit. The sanding will take place on the three sides of the extruded clay column. This unit includes the recycling of the excess sand and the pneumatic elevating of the complemented sand at a bin on wheels underneath. On top of the sander another bin is collecting the sand that returns from the pneumatic sand transport unit. New sand can easily be added to the ground level bin.
Diagonal positioned rollers roll the spread sand at the sides into the column, a flat positioned one finishes the top face.

Item3:
Two separate texturing units, each consisting of three driven belt profile systems. The profiling takes place on the 3 visible sides. All units are separately controlled by a frequency inverter. The position of the belt guidance frames are adjusted by means of pneumatic cylinders. Another cylinder stretches the belts onto the rollers and relaxes belts for a fast exchange. The machine provides a system to change the speed value according to the automatically controlled column speed. Effects of this method are columns texture alterations from tiny till very rough by turning around the belts rotating direction.
At request we can supply profiling rollers instead of belts.

Item 4:
One scraping unit, consisting of three driven belt scraping systems. The scraping takes place on the 3 visible sides. The construction of this unit is equal to the ones of the profiling units. The turning is provided by means of direct driven SEW gear boxes and drives.
At request we can supply scraping rollers instead of belts. In this case the machine frame construction becomes 1.000 mm smaller.

Note: all elements of the profile and scraping units items 03 and 04 can be assembled very close to each other. This is made possible by constructing the single sided mounted and driven belt devices in such a way, that the removal and placing of belts can be executed by travelling out their structures from the column area at the only free accessible side. Connections are therefore made flexible.

Item 5:
The conveying system for the internal transport of the clay column through the profiling- and scraping units. This transport system is effected by means of two driven endless stainless steel chains. These adjustable chains will support the column as close to the edges as necessary.

Item 6:
The machine framework that carries all described units and the sanding machine with its recycling parts. It stands on its own feet or is alternatively either sidelong movable by means of a set of rail-wheels and / or adjustable in height when the vacuum press is fixed to the floor ( option ). The operating panel with touch screen is mounted onto a flexible carrier that provides the operator visible access to both sides of the sanding machine.