Chirag International, an Indian company based in Coimbatore in Tamil Nadu, manufactures and supplies a variety of building products and exhibits a high degree of professionalism. In this endeavour, the company has set up state-of-the-art production lines and are operated by highly motivated thoroughly trained employees. Beyond concrete blocks, pavers and other products used in garden design and landscaping, the company also manufactures windows, doors, Styrofoam panels, sandwich units and system components used for roof coverings.

Overall, ten different categories of construction products are manufactured. The manufacturing capacity for concrete blocks has been expanded by the installation of a new production line. The fundamental requirements determined for this investment included a cost-efficient production line offering a very high degree of flexibility and maximum availability whilst also complying with the exceedingly high quality standard implemented by Chirag. An extremely low capital expenditure, small footprint and a very high degree of production flexibility are some of the key benefits offered by this multilayer system, which has been improved continuously.

In addition, only one machine operator and one forklift driver is needed, keeping the number of staff at a minimum level. Further advantages include the low degree of maintenance and spare parts required. The machine is operated from a soundproof control room equipped with a state-of-the-art Siemens S7 control unit and visualisation via a user-friendly, self-explanatory, menu-based touch panel. Production parameters are entered and stored according to separate machine section visualisations. The touch panel is used to enter mix designs and machine parameters for most diverse moulds and production schedules. The production line features a pallet magazine, a pusher conveyor for the pallets and a roller conveyor for the finished cubes. As the biggest multilayer machine offered by Chirag, the 12 model has been mainly designed to manufacture concrete paving stones, kerbstones and a large number of similar products used in garden design and landscaping in heights from 50 to 300 mm.

The required constant stone heights are ensured by a twin-section vibration table and an individually adjustable frequency control for the vibrator drives. In this respect, it is also important that the moulds be filled uniformly via an accurately routed filler car with adjustable scrapers. At Chirag, employees are enthusiastic about the favourable cost-output ratio and the high degree of flexibility. Further benefits include the quick and easy cleaning of the machine and its low degree of servicing and maintenance. In this project, all quality requirements on the concrete products have been exceeded by a clear margin.

The design of the Chirag multilayer machine enables an incremental upgrade to implement a fully automatic circulation system. In this respect, the Chirag management has indeed taken a future-proof decision by investing in this machine. The high-performance and easy to operate control unit in touch panel execution is surely one of the highlights. Another improvement is the hydraulic control with proportionally controlled movements of the main axles. The application of digital path measuring is also possible. The multitalented Chirag multilayer machine offers the widest range of production possibilities of all concrete block/paver machines currently available in the world market.

The Chirag multilayer machine can be used as a universal machine as well as special machine for nonstandard products. It is an ideal machine to complete a single pallet plant as it allows economical production of niche products. With a Chirag application, one can always make the right choice.