Knife and Transfer Group

Flawless Precision and Uninterrupted Flow at High Speed

The continuous plaster board, which takes shape on the forming table and sets on the long hydration belt (setting belt), reaches the most critical stage that determines the line’s mechanical speed and efficiency: cutting and distribution. At IPS Makina, we are not merely a machine or automation supplier during this dynamic phase of the plant; we stand by your side as a turnkey solution partner, guaranteeing zero waste, continuous flow, and millimeter-level synchronization.

Even on our high-speed lines, which reach speeds ranging from 15 m/min to over 100 m/min, we produce advanced mechatronic systems that ensure the panels are cut without crumbling, with smooth edges, and fed flawlessly into multi-layer drying ovens.

High-Speed Rotary Shearing Technology

Performing operations without stopping a continuously flowing production line requires immense mechanical precision. Our fully automatic rotary shears, designed by IPS Machinery engineers, operate 100% in sync with the sheet flow speed to cut continuous sheets into lengths compliant with international standards (2000 mm, 2400 mm, 2500 mm, 3000 mm, etc.).

• Smooth Edge Quality: Thanks to specially alloyed blade designs and synchronized blade drum movements, it ensures a clean cut without causing bursting, crushing, or crumbling in the sheet core.
• Instant Size Change: New cutting dimensions entered by the operator via the SCADA system are instantly reflected in production via servo motors without reducing the line’s speed.
• Scrap Detection and Ejection: By detecting potential production defects or scrap from the beginning or end of cuts using optical sensors, the system automatically ejects them to the scrap area before they enter the production line.

Smart Acceleration and Inverting Units

To prevent cut panels from colliding with one another and to ensure they enter the drying oven in an orderly manner, the distance between the panels must be increased. Panels exiting the cutting shears are separated from one another by being accelerated to a speed higher than the main line speed via accelerating belts.

Additionally, to protect the sensitive front surface (face paper) of the plaster board from friction with the oven rollers and to ensure even heat transfer, the boards are flipped in pairs (book-to-book) by high-speed automatic flipping (inverter/flipper) units before entering the oven.

Dryer Feeding and Distribution (Tipple & Feeding)

The rotated and spaced-apart plates reach the distribution (tipple) table, which distributes the output from a single line across the multi-deck kiln architecture.

• Synchronized Distribution Table: A pneumatic and servo-assisted elevator conveyor directs the plates to the kiln’s 8th, 10th, or 12th levels, respectively, within seconds.
• Mechanical Jam Protection: Advanced laser and photocell sensor networks in the distribution unit continuously monitor the alignment and passage of the plates. In the event of any synchronization error, the system activates its protective mechanism to prevent mechanical jams inside the oven.