I. Introduction of Roman candles fireworks 

Roman candles fireworks, also known as shooting or thomsonae fireworks, are a type of fireworks that shoot flaming projectiles into the air. When ignited, they eject one or more stars through the open end of the paper tube. Roman candle come in a variety of sizes and can contain anywhere from several to many stars inside the tube that shoot out in rapid succession.

II. Reason for designing roman candle automatic production line

Manual roman candle making is laborious, risky and prone to waste:   

Labor intensity and low efficiency

Manual production in fireworks supplier factory requires workers to roll each tube, insert lift charges and delay fuse, fill in stars, and seal the tube. This is a slow, repetitive process with low output.

High safety risks

Workers must directly handle black powder and other pyrotechnic substances, posing serious burn and explosive risks. Even with protective equipment, manual work lacks the inherent safety of automation.  

High material wastage

Without precise mechanized controls, excess black powder, stars and other materials are often wasted during roman candle filling. This significantly raises production costs.

Inconsistent quality

The human error and variability inherent in manual work leads to inconsistent roman candle performance. Candles may fail to ignite properly or provide unreliable duration and special effects.     

Automation addresses these issues by

– Expediting tasks through mechanical processes    

– Separating workers from pyrotechnic substances  

– Enabling precise, repeatable material loading  

– Utilizing programmable controls for consistent quality

The result is dramatic improvements in:

– Throughput: 3 to 6 times higher productivity     

– Safety: Near-elimination of burns and explosions      

– Cost: Lower material waste cuts expenses by up to 80%   

– Reliability: More consistent ignition and performance      

For these reasons, roman candle automation has been widely adopted by manufacturers seeking greater efficiency, higher safety and reduced costs. Comprehensive production line solutions can be configured to match your specific production goals and budget.

III. Features of the roman candle firework machines

Separation of humans and substances

The production line uses mechanical and pneumatic systems to handle all pyrotechnic filling tasks, completely separating workers from substances like black powder. This provides the highest level of safety by eliminating direct contact.  

Man-machine isolation

The powder filling machines, tube feeders, charging heads and other equipment operate behind safety guards to protect workers. Pneumatic operations and powered conveyors keep human hands away from moving parts.     

Automated quality control

Inspection cameras and sensors within the line detect defects in tubes, fuse placement and star loading in real time. Nonconforming candles are automatically discarded while meeting specifications. This ensures consistent product quality.

Remote monitoring and control

The entire production process can be monitored and adjusted from a central control panel. Operators are not exposed to pyrotechnic explode risks while making changes to line parameters.  

High productivity

Automated roman candle making machines can fill tubes at rates up to 300 per hour – 6 times faster than manual methods. This massive throughput boost translates into big cost savings for manufacturers.

Precise material loading

Programmable fill weights and pneumatic charges enable highly precise loading of lift charges and stars into each roman candle. This uniformity drives more reliable ignition and performance.

Customizable settings

Many automated lines allow adjustment of settings for different tube sizes, star loads, lift charges and other parameters. This flexibility suits diverse candle specifications and changing product needs.

These features combine to deliver the benefits roman candle producers seek: dramatic increases in safety, productivity, quality and cost-effectiveness. Automation removes the human limitations of manual production for significantly superior results.

IV.Structure and working principle

The roman candle automation line incorporates several key systems:   

Mechanical systems

Tube feeders load cardboard tubes onto a conveyor belt at rates from 50 to 300 tubes per hour in basic, advanced and heavy-duty systems. Stacking machines arrange filled candles onto trays by size.       

Pneumatic systems

Charging heads utilize compressed air to precisely insert 3 to 37 grams of powder lift charge into the base of tubes, based on candle specifications. Pneumatic tube presses then seal the open end after filling with 8 to 55 glitter stars.

Programmable logic control 

An industrial PLC controls the entire process. It synchronizes the tube feeder, star filler, lift charger, tube hydraulic press and stacking machine through programmed production cycles. The PLC ensures precise filling of each roman candle per requirements.   

The automated work flow

1) Tube feeders load 50-300 cardboard tubes per hour onto a conveyor belt.

2) A lift charger inserts 3-37 grams of black powder into tube bases using pneumatics.  

3) Star fillers load 8-55 glitter stars into tubes as they move on the conveyor.    

4) A pneumatic tube press seals the open end, containing lift charge and stars.

5) Stacking machinery arrange filled candles by size onto trays.   

6) Inline cameras integrated with the PLC identify and reject 2-5% of defective candles.

The automation utilizes programmed cycles and pneumatic actuation to achieve consistent filling rates up to 6 times faster while reducing material waste by up to 80%.

System configurations vary based on tube capacity, lift charge weight and number of stars per candle.

Table: Types of roman candle automatic systems

Model	Tubes/hr	Stars/tube	Lift charge (g)
Basic	50	8 – 15	3 – 9
Advanced	100	15 – 28	9 – 22
Heavy-duty	300	30 – 55	18 – 37

V. Operation of the roman candle automation line

The production process involves the following key steps:

Loading tubes onto carriers

A tube feeder automatically grips cardboard tubes via suction cups or mechanical clamps and precisely spaces them on an elevating conveyor belt at a rate of 50-300 tubes per hour. This evenly positions candles for filling.

Automatic fuse and lift charge insertion

Pneumatically operated charging heads insert both the time fuse and initial combustible lift charge of 3-37 grams  into the base of each tube  at programmed weight specifications. Compressed air drives the charges into place.

Loading of glitter stars into tubes

Star filling machines utilize feed screws or vibratory feeders to deliver  8-55 glitter stars  into the moving cardboard tubes on the conveyor belt. Fill weight is determined by the PLC program.    

Sealing of filled tubes 

Pneumatic tube presses activate to seal the open end of each shell after it is filled with stars and lift charge. The aerial powered metal dies crimp the cardboard edge to prevent spillage and ensure a tight seal.      

Stacking of finished roman candles

An unloading machine grips filled tubes from the conveyor and arranges them into ordered stacks within trays according to size. Bar code readers ensure candles are stacked in correct sequences.

Inline inspection and rejection

Cameras and sensors integrated with the PLC detect lift charge placement errors, blocked or jammed container, improper star loading and other defects. Software automatically removes 2-5% of nonconforming candles from the line.

The automation line runs continuously, performing each subprocess at its optimal rate while the PLC coordinates the overall manufacturing cycle. Proper programming and adjustment of line settings are essential for high yields of quality roman candles in bulk quantities. Experienced engineers can develop a custom production line optimized around your specific production needs.

VI. Applications

Roman candle automation lines are commonly used by bulk roman candle manufacturers seeking higher productivity, throughput and quality consistency. 

Typical users include

– Fireworks production companies that specialize in roman candle firecrackers 

– Wholesale fireworks distributors relying on roman candles as a product mainstay   

– Industrial enterprises with in-house roman candle manufacturing needs for large flammable fireworks shows and events

The automated lines enable these businesses to

– Produce roman candles in commercial quantities of 10,000 to 100,000 units or more annually   

– Lower costs through materials savings, reduced labor requirements and higher yields  

– Offer more competitive pricing compared to candles made through manual processes    

– Improve product image with higher reliability and performance consistency   

– Reduce safety risks by removing workers from black powder and pyrotechnic filling tasks   

Roman candle automation increases efficiency, yields and throughput while lowering costs for fireworks manufacturers. The produced roman candles can then be sold:

– To wholesalers for distribution to retail shops   

– To event coordinators and show producers    

– Directly to consumers for personal use  

The applications are widespread, from commercial production for cracker retailers to on-demand manufacturing for demand displays. Automation provides the means for roman candle producers to scale up operations profitably while ensuring worker safety throughout the process.

VII.Conclusion

In conclusion, an automated roman candle production line has numerous benefits that any fireworks manufacturer should seriously consider:

• Productivity can be increased by up to 6 times compared to manual filling processes. Throughput of 50 to 300 roman candles per hour is routine.

• Material costs go down by as much as 80% due to reduced waste, tight fill weights and accurate timing of lift charges.      

• Labor costs are reduced since the line needs only a few operators instead of many manual fillers.      

• Product quality consistency improves dramatically from programmed filling sequences and precise charging of lift weights and pyrotechnic stars.

• Worker safety is greatly enhanced by removing humans from direct handling of pyrotechnic lift charges and black powder during filling tasks.   

• Cost of ownership is lower in the long run due to higher yields, less waste and reduced labor costs versus employees filling roman candles by hand.

For any fireworks or pyrotechnics supplier manufacturer looking to scale up roman candle production while improving safety, efficiency and margins, automation offers a tangible solution.  

If you’d like to learn more about roman candle automation  systems and solutions for your production needs, feel free to contact PyroEquip engineers. Our team of specialists can provide guidance on selecting the optimal equipment configuration based on your requirements.

Let’s discuss how we can help grow your roman candle business profitably and responsibly through  smart automation technology.

Reference

• Part 2: Roman candles — Specification and test methods
• JEETON – Fireworks
• ROMAN CANDLE
• Noise Testing of Fireworks
• HISTORY OF WAX-CANDLES IN INDIA (A. D. 1500-1900)
• Pyrotechnic Families Guidance – Category F1-F3 fireworks
• Firework Displays: Explosive Entertainment
• Pyrotechnics in Stadia
• UN/SCETDG/25/INF.69
• Explosives (Fireworks) Regulations (Northern Ireland) 2002
• Roman wheel-made lamps from Carthago Nova
• 2021 Fireworks Annual Report
• Early Candle Making
• ROMAN CANDLE
• The Roman Candle at Knickerbocker Place