The Signature of Flawless Production: High-Speed Sizing and Smart Stacking
The superior quality achieved through precise dosing at the head of the plasterboard production line and the flawless thermal processes inside the drying kiln is transformed into a commercial product at the very end of the line. The final touch that directly defines your plant’s market reputation is the dimensional precision of the boards and the quality of their packaging.
As IPS Makina, we are not merely an equipment manufacturer; we are a turnkey solutions partner optimizing your plant's logistics processes. With our fully automated "End-of-Line" systems—eliminating the need for manual labor and operating seamlessly even at line speeds exceeding 100 m/min—we safeguard the true value of your production. This final segment of the process consists of four fully synchronized main stages:
1. Kiln Outfeed Automation This process safely unloads hot plasterboards exiting the multi-deck dryer at the ideal moisture level onto a single-lane conveyor line.
Temperature and Moisture Control: Specially engineered roller and belt conveyors cool the boards to match ambient conditions, preventing thermal shock.
Synchronized Outfeed Hoist: Boards emerging simultaneously from 8, 10, or 12 dryer decks are gathered into a single stream via pneumatic and servo-driven outfeed hoists without mechanical jams. Laser sensors monitor board flow in real time to regulate line rhythm.
2. Book-Matching and Trimming Once transferred onto a single lane, the boards advance to achieve their final standardized dimensions. This stage is critical for surface protection and millimetric cut accuracy.
Book-Matching: A vital operation preventing scratches to the sensitive front linerboard during packing and transit. Automated turning arms flip every alternating board, pairing two consecutive sheets face-to-face.
Edge Trimming: Advancing in pairs, the boards enter the trimming station equipped with high-speed circular saws. The rough ends cut earlier by the knife are precisely trimmed to nominal standards (e.g., net 1200 x 2400 mm). High-efficiency dust extraction hoods instantly evacuate cutting dust to maintain plant cleanliness and route waste back to recycling.
3. End-Taping After passing through the trimming saws to exact dimensions, the exposed plaster core at both trimmed ends of the face-to-face paired boards must be protected and branded.
Core Protection: The automated end-taping machine applies a specialized self-adhesive protective paper tape over the open edges. This tape reliably shields the board core from ambient moisture ingress and eliminates edge-crumbling impact damage during transit.
Branding and Corporate Identity: The applied tape carries your company logo, production date, CE conformity marks, and barcode data. When the product arrives at the jobsite, this flawless edge tape delivers the initial impression of premium quality.
4. Stacking and Palletizing Taped, paired, and commercially ready boards enter the high-speed stacking unit for warehousing and transport logistics.
Automated Stacking: Boards are stacked on a scissor-lift table according to preset batch counts entered into the SCADA system (e.g., 50 or 60 boards per stack). Retractable fork arms deposit the boards gently using an air-cushion effect, avoiding surface abrasion and edge damage.
Automated Dunnage Feeding System: To facilitate forklift handling, clearance must be provided beneath the stack. In IPS Makina systems, support dunnages cut automatically from production off-cuts/rejects are placed under the stack via robotic arms or pneumatic pushers. This eliminates wooden pallet costs entirely while repurposing scrap material into usable packing assets.
Forklift Transfer: Completed bulk stacks move via heavy-duty chain conveyors to the forklift pickup zone. Automated stretch-wrapping units can be integrated into this section upon request to provide extra weatherproofing against outdoor conditions.
Equipped with advanced engineering from IPS Makina, your high-tonnage production heads to customers with zero labor error and uncompromised packaging quality. Contact our engineering team to explore our turnkey Plasterboard Plants or tailor your next project to your specific capacity requirements.