YOUR RELIABLE partner

KVM INTERNATIONAL A/S

KVM world-wide
KVM International A/S is the largest manufacturer of machines, equipment and turnkey plants for the concrete industry in Northern Europe. With over 50 years of experience KVM is among the leading manufacturers globally. KVM has had a great influence on the way concrete products are manufactured today. The KVM head office is situated in the city of Kjellerup in Denmark. Besides the head office KVM consists of subsidiary companies operating in the USA, Poland, the UK and Germany. Furthermore KVM has local sales staff and agents all over the world.

These points are achieved in co-operation with existing customers and through feedback. Therefore KVM is familiar with the market demands and solutions, creating increasingly efficient plants and continual developments.

SERVICE - ESSENTIAL FOR EARNING

KVMs team of experts is at your disposal 24 hours 7 days a week. With our service line we guarantee quick respond and help if a problem occurs in production. KVMs world-famous operator academy ensures machine and concrete understanding. We educate, talk, listen and gather interesting information and develop these into useful production support.

KVM - a reliable partner

RESEARCH, DEVELOPMENT AND TECHNOLOGY ARE HIGHLY VALUED
KVM is world known as a reliable producer and a loyal partner through the entire project process: Pre-phase, production, commissioning, service, training of operators and continued support. Moreover KVM values points as product development, technology, security and quality as important factors.

VERSATILITY - TODAYS KEYWORD

The trends among designers and architects are to use a large variety of different concrete products in the Landscaping process. This gives the producers an extra challenge as they have to develop the mould and the production process to suit. To make this process profitable it is necessary to have a very versatile production machine. This scenario has been a fact for the Danish concrete producers for several years due to the fact that their consumer volume is in the low end. For this reason a KVM block machine is constructed to operate profitably, making high class output, with a large variety of products even products not normally seen made on a block machine.

Block making machine

The heart of all block and paving producing factories is the blockmachine. KVM blockmachines can produce all shapes and sizes from large slabs 1m by 1,2m to kerbstones, blocks and pavers. The smallest 28mm thick pool slabs to the largest 600 kg retaining wall blocks - all on the same machine and all with exactly the same high quality.

MACHINE PROGRAMME

KVM International manufactures three different series of Block Making Machines. Depending on the customers needs and demands large or small production capacities KVM will guide the customer in the direction of the most suitable blockmachine. Series I: Type 62/80, pallet size 750 x 900mm Series II: Types 62/105, 90/105 and 62/125, pallet size up to 750 x 1400mm Series III: Types 80/125, 105/125 and 125/125, pallet size up to 1300 x 1450mm All types of blockmachines use the well known KVM controlled concrete handling system ensuring that every kilo of concrete delivered into the mould is handled in exactly the same way. The controlled concrete handling is based on the following features:

Transport of concrete to the silo on the blockmachine is done with a slow moving belt conveyor that delivers concrete in the same rate as it is being used. This gives the same weight and density of the concrete all the time A cone shaped rubber sock in the silo guarantees against segregation of the concrete The silo is lowered into the filling box each cycle to ensure that only the needed amount of concrete is delivered The filling box has no internally moving parts making it possible to empty it after each cycle The tuning vibrator allows for adjustment of both amplitude and frequency during both the filling and the compaction part of the production cycle All movements are controlled by the advanced proportionally controlled hydraulic system. The easyto-operate control system enables the operator to quickly implement changes and to adjust to changes in materials and products. KVM blockmachines are delivered with the following standard features: The blockmachine is placed on rubber dampers under the machine frame which minimises the need for foundation work and reduces the vibrations transmitted to the surroundings High efficiency motors and a special energy saving hydraulic system reduces the environmental impact.

Handling system
All KVM handling systems are designed to be faster than the blockmachine at all times and have built in buffers to enable the system to avoid small stops giving delays for the blockmachine.

Quality control Weight, height and density can be controlled and the information can be presented to the operator and it can be used to either manually or automatically adjust the settings on the blockmachine; A laser based height measurement unit controls the height of the product A weight measuring unit weighs the products An offline control position allows for detailed measurements while the production continues scrap ejector To scrap the waste from cleaning or reject bad products the control position can include a function to tilt the materials into a skip. Afterwards the empty pallet will automatically return to the wet side conveyor system.

transport wet side

Transport from the blockmachine to the elevator is done by roller or v-belt conveyors that ensure a gentle transport of the wet products. The wet side conveyor is divided into several individual sections that allow the conveyor to work as a buffer zone.

Options for WET side

The wet side can be equipped with additional optional equipment:

HANDLING SYSTEM
The size and shape of the handling system is decided by and adapted to the needs and demands from the customer based on product portfolio, site layout, climate, capacity, existing buildings etc.

Rack system

The racks are designed according to the demands of the customers product programme regarding shelf distance, load bearing capability, steel type etc. Racks can be made in Zinc-coated or stainless steel materials or a combination of both. The racks can be left open or insulated in individual sections with automatic roller doors or as one closed big chamber solution that also includes the elevator, the finger car and the lowerator. The curing climate can be controlled and improved by air circulating and ventilation systems adapted to the demands of the customer. Advanced climate control units can enhance the curing climate by adding active gasses or preheated moisturised air to the curing area.

ELEVATOR AND lowerator

KVM elevators and lowerators are as a standard of a double pallet configuration ensuring that the handling system always works faster than the blockmachine and cubing units, whether it is working with 28mm slabs on every shelf or 500mm high chimney elements on every third. The elevators and lowerators can be fitted with active or passive buffers that reduce the risk of delays caused by different cycle time on wet and dry sides. The elevators can be equipped with service platform and automatic lubrication of the chains.

FINGERCAR

A heavy duty fingercar transports the products from the elevator to the racks and back to the lowerator. The fingercar is controlled by lasers and is driven by servo units for fast and precise movements. The fingercar can be equipped with turn table and with displaceable forks for high and low products.

Roller conveyors handle the transport of cured concrete products from the lowerator to the cubing position. The dry side conveyor is divided into individual sections that allow the conveyor to work as a buffer zone.

transport dry side

Options for dry side

Quality control zone where the operator can remove rejects safely while the rest of the dry side conveyor system continues without delays In-line splitting unit Prepress unit for loosening products Doubling unit for delivering 2 layers at the time to the cuber Scrap ejector for removing rejects Production board de-doubling unit

The dry side can be equipped with additional optio nal equipment:

Handling of empty production boards

At the end of the dry side conveyor the pallet return system cleans, oils, turns, stacks and accumulates the production pallets before sending them back to the blockmachine. The pallet return system comes in several variations depending on the need to accumulate empty pallets:

Single pallet return on roller conveyors with up to 10 pallets between cuber and blockmachine A transfer car system that accumulates approx. 100 pallets and allows for easy fork lift access to the area between the blockmachine and cuber An additional transfer car buffer with up to 1000 pallets A traditional crane unit stacking up to 4000 pallets in a buffer

cubing
KVM cubers are constructed for maximum versatility and can handle all the products produced on a blockmachine with high speed and precision. The clamp is encoder controlled and driven by a high power hydraulic unit. The drive unit is by a toothed belt drive and the cuber has an elevated service platform and ladder for safe and easy service. Product formatting units are used to reshape the product format to fit special types of transport pallets or to build void packs with holes for forklift fingers. As an option a vacuum lifting device can be installed to handle special products. robotics For special jobs standard industrial robots with special grippers can be utilized.

cubed product transport

Products can be delivered with or without transport pallets. Depending on the demands of the customer the following types are used; Chain conveyor Roller conveyor Slat conveyor Steel pallet circulation systems

Depending on the local requirements, stacks can be strapped or wrapped. KVM offers several different types of packing; Plastic wrapping Horizontal strapping Vertical strapping Stretch hood Shrink wrapping

SECONDARY PROCESSING - refined surfaces

The demand for special products big/small, round/ triangle concrete products etc. products with refined surfaces and with a natural stone appearance, is steadily increasing. KVM offers specially developed product after treatment either as fully automatic integrated inline systems in the concrete stone production or as off-line systems: Tumbling Splitting Washing Insulation elements ISO Line 2000

KVM tumbling systems

KVM offers complete production lines for tumbled products, both in-line and off-line systems. The concrete products are tumbled in heavy duty rubber lined drums. KVM tumbling systems are based on a simple organiser and the patented QS-1 quality sorting unit that automatically rejects failed products. The sorting unit can also be used for sorting of up to 3 different sizes at the time. Advantages by in-line systems; Can handle 24 hour old products Capacity up to 375 m 2 per hour Can handle products directly from an in-line Splitting system Advantages by off-line systems; High output and flexibility Up to 4 different colours can be mixed The Tumbling Systems are fully automatically with minimum manual intervention necessary by operators.

KVM SPLITTING system

KVM manufactures complete splitting systems. The splitting unit is capable of both I and Y splitting of products of up to 1200 mm. Splitting lines can be installed as in-line units capable of keeping up with the rest of the blockplant and as stand alone off-line systems. The splitting line can be joined to a tumbling line making it possible to tumble the split products giving a unique finish.

insulation elements - iso line 2000

In order to preserve the global climate the insulation standards world wide are sharpening the demands for walls and foundations in houses. KVM has developed a process where two standard building blocks are made into a sandwich block with insulation inside. This process has several advantages; Different inner and outer block materials Different type and dimension of insulation materials Different types of adhesives can be used Easy change in block dimensions The ready made insulated blocks greatly reduce the workload on the construction site.

washing system

The KVM washing unit is integrated into the wet side line on the blockplant. The unit washes the surfaces with an adjustable high pressure water spray. The products are then cleaned by water flowing over the surface and finally dried with a high speed air fan.

KVM CONTROL TECHNOLOGY

All machines in a KVM supplied factory can be connected to the central PC giving the operator op timum survey and easy control. The central control system is used for easy communication between the operator and the complete plant by means of screen pictures and flow diagrams. The operation of the control system is user friendly and designed by experienced plant operators. The control keeps track of plant performance and allows for easy fault finding and production analysis.

Downtime is very expensive for any company and even the very best plants need regular maintenance to obtain optimum efficiency. Customer service is a crucial issue for KVM.

OPERATOR TRAINING
The KVM plant operator training academy has been in operation for more than a decade with more than 1000 block plant operators passing through so far. Participation in the operator training courses results in; Better product quality Better maintenance Enhanced plant performance Less down time Lower operating costs

kvm support and service

All new KVM supplied factories are backed up by on-line service 24 hours a day 365 days per year. Multilingual experts are available to solve problems and to increase plant performance.

kvm i n t er nat io nal a /s i n d us t rive j 24 d k 8 620 k j elleru p d en mark pho n e: + 45 87 702 70 0 fa x . + 45 87 702 701 e- mail : kvm@kvm . d k w w w. kvm .com

K VM - the perfec t par tner on your way to success