TL;DR
A broken kiln roller stops tile transport in that zone and risks damaging adjacent tiles. Replace broken rollers as quickly as possible using the hot roller replacement procedure to minimize production loss.
What you might see
- ceramic tiles jamming or deviating off the roller line
- visual break in a roller visible through the kiln inspection window
- tile surface defect correlated to one roller position
- drive motor overload on one roller group
Likely causes
Thermal shock from a cold tile or slug entering the hot zone
Roller overstress from tile jamming and increased lateral load
Roller end bearing failure allowing the roller to sag and contact the kiln refractory
Roller wear over the service campaign reducing the wall thickness below the safe minimum
Required tools
- Hot roller replacement tools (heat-resistant hooks, guides)
- Replacement ceramic kiln roller
- Full heat-resistant PPE
- LOTO kit for drive
Safety first
- Roller kiln interior exceeds 1200 degC. Full heat-resistant PPE and face shield are mandatory.
- Thermal radiation from the kiln opening during roller exchange. Minimize exposure time and use a heat shield.
Procedure
- 1
Identify the location of the broken roller from the tile jam or from visual inspection through the kiln window.
Warning: Roller kiln interior temperatures exceed 1200 degC. Do not open any kiln door or port without full heat-resistant PPE and a face shield. - 2
Stop the kiln conveyor drive in the affected zone and divert tiles before the jam.
- 3
Using the hot roller replacement procedure and heat-resistant tools, remove the broken roller end from the kiln side exit port.[1]
- 4
Insert the replacement roller from the entry side, feed it through the kiln tunnel to the support bearings.[1]
- 5
Connect the roller to the drive chain or belt and verify free rotation.
- 6
Restart the conveyor drive at reduced speed and monitor the new roller for 15 minutes.
- 7
Inspect the downstream tiles for surface defects from the broken roller event.
Sources
Sacmi Sacmi FMS / FMA Roller Kiln (Ceramics) general technical documentation, Sacmi
Sacmi roller kiln operation and maintenance documentation, hot roller replacement procedures (general)
More guides for Sacmi Sacmi FMS / FMA
How to diagnose burner combustion faults on a Sacmi FMS / FMA roller kiln
A burner combustion fault in one zone drops the temperature and causes glaze defects on the tile. Check the gas supply pressure and the air-gas ratio before inspecting the burner nozzle.
How to inspect and repair refractory lining cracks on a Sacmi FMS / FMA roller kiln
A hot spot on the kiln shell means the refractory lining has cracked. Schedule a refractory repair at the next planned stop before the crack propagates and threatens the shell.
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