1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are your brick production margins being compressed by inconsistent quality, alta dependencia laboral, y tiempo de inactividad excesivo? Commercial operators face tangible costs: manual handling leading to a 515% breakage rate, inconsistent mixing causing batch rejections, and the financial drain of maintaining outdated, unreliable equipment. Your plant’s profitability hinges on steady output and predictable operational costs. How do you increase daily production counts without expanding your workforce? Can you reduce energy consumption per thousand bricks while improving final product strength? Is your current setup flexible enough to meet changing market demands for different brick types and sizes? These are the operational challenges that define modern clay brick manufacturing.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This content details our range of premium, yet affordable, automated stationary brick making machines. These are heavyduty industrial systems designed for continuous, highvolume production of fired clay bricks (sólido, perforado, hueco). El flujo de trabajo operativo está diseñado para una intervención mínima.:
1. Alimentación automatizada: Prepared clay is conveyed uniformly into the machine’s feed hopper.
2. Extrusión de alta presión & Corte: A twinstage auger system compacts and deairs the clay before extrusion through a solid die; an automatic wirecut system slices the column into precise green bricks.
3. Automated Palletizing & Transferir: Green bricks are systematically placed onto setting carts or pallets for transport to the drying chamber.

Ámbito de aplicación: Ideal for established brick yards targeting production from 20,000 a 100,000+ bricks per day shift. Suitable for a variety of plastic clays.
Limitaciones: Requires a consistent feed of properly prepared clay (adequate crushing, mezclando, and tempering). Not designed for onsite mobile construction projects or for nonplastic soils without binder additives.

3. CARACTERÍSTICAS PRINCIPALES

Vacuum DeAiring System | Base técnica: Highefficiency vacuum pump creating >95% vacuum in the extrusion chamber | Beneficio operativo: Elimina las bolsas de aire del cuerpo de arcilla., significantly reducing laminations and cracks during drying and firing | Impacto del retorno de la inversión: Field data shows a reduction in firing losses by up to 8%, directly improving yield per ton of raw material.

Hardened Alloy Steel Auger & Transatlántico | Base técnica: Wearresistant chromium alloy components with hardened flight edges | Beneficio operativo: Maintains precise extrusion pressure over extended periods, reducing wearrelated downtime and output consistency drift | Impacto del retorno de la inversión: Extends service life by approximately 40% compared to standard carbon steel, lowering longterm parts replacement costs.

Unidad de frecuencia variable (VFD) Control | Base técnica: Precision motor control via programmable logic controller (SOCIEDAD ANÓNIMA) | Beneficio operativo: Allows operators to finetune extrusion speed and torque based on clay plasticity, optimizing output quality and preventing machine jamming | Impacto del retorno de la inversión: Reduces energy consumption by matching power draw to load requirements and minimizes scrap from suboptimal settings.

QuickChange Die & Mouthpiece Assembly | Base técnica: Standardized bolting system with alignment pins | Beneficio operativo: Enifies changeover between different brick profiles (p.ej., from solid to perforated) en menos 45 minutos | Impacto del retorno de la inversión: Increases plant flexibility and reduces nonproductive time during product changeovers by an average of 60%, allowing responsive fulfillment of diverse orders.

Sistema centralizado de lubricación con grasa | Base técnica: Automated pump delivering lubricant to all critical bearing points on a timed cycle | Beneficio operativo: Ensures consistent lubrication under highload conditions, preventing premature bearing failure and unplanned stops | Impacto del retorno de la inversión: Las pruebas de la industria demuestran una 30% reducción de averías relacionadas con los rodamientos, enhancing overall equipment availability.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Máquinas convencionales) | Premium Affordable Brick Making Machine Solution | Ventaja (% mejora) |
| : | : | : | : |
| Brick Output Consistency | ±5% dimensional tolerance; visual surface defects common | ±2% dimensional tolerance; superior surface finish from deairing | 60% improvement in tolerance control |
| Consumo de energía por 1000 Ladrillos| High fixed consumption; inefficient drive systems| VFDoptimized consumption; efficient gearbox design| Arriba a 18% reduction in kWh usage |
| Tiempo medio entre fallas (MTBF)| ~400 operating hours for major components| >700 operating hours for major components| ~75% increase in reliability |
| Changeover Time for Profile Swap| 23 hours with manual realignment| <45 minutes with guided system| ~70% de cambio más rápido |
| Labor Requirement for Operation| 34 operadores para alimentación & manejo| 12 operadores principalmente para monitorear & gestión de palets| ~50% reduction in direct labor |

5. ESPECIFICACIONES TÉCNICAS

Capacidad de producción: Modelos configurables desde 12,000 a más 36,000 ladrillos estándar por hora.
Requisitos de energía: Main extruder motor from 90 kW a 160 kilovatios (dependiendo del modelo); total connected load includes vacuum pump (~15 kW) y sistemas transportadores.
Especificaciones de materiales: Accepts clay with plasticity index (Atterberg Limits) suitable for extrusion; maximum feed particle size ≤8mm.
Dimensiones físicas: Typical footprint ranges from L12m x W4m x H3m (for core unit).
Rango de operación ambiental: Designed for ambient temperatures of 10°C to +45°C with appropriate weather protection; requires a stable, level concrete foundation.

6. ESCENARIOS DE APLICACIÓN

MediumSized Brick Yard Expansion

Desafío: A familyowned yard needed to double its daily output without doubling its labor force or incurring prohibitive capital expense. Their existing manual machine caused high waste and could not meet new contract volumes.
Solución: Implementation of a midrange premium affordable brick making machine with automated palletizing and VFD control.
Resultados: Output increased from 40k to over 75k bricks per shift with only two additional personnel. Clay waste reduced by an estimated ₹7 lakh annually due to lower breakage and consistent extrusion.

Contractor Supplying Large Infrastructure Project

Desafío: An engineering contractor secured a project requiring specific perforated bricks on a tight timeline but lacked specialized equipment.
Solución: Procurement of a premium affordable brick making machine equipped with quickchange die systems for both solid and perforated profiles.
Resultados: The contractor established an onsite plant meeting all project specifications. The rapid changeover capability allowed production shifts between project phases without delay, ensuring justintime supply.

7. CONSIDERACIONES COMERCIALES

Niveles de precios: Our range is structured around core output capacity.
EntryLevel System (up to ~15k bricks/hour): Focused on core reliability.
MidRange System (~20k25k bricks/hour): Includes VFD control & automatización básica.
HighCapacity System (~30k+ bricks/hour): Fullfeatured with advanced PLC automation and telemetry options.
Características opcionales: Upgrades include remote monitoring packages, specialized alloy wear parts packages for abrasive clays, or integrated autostacking systems.
Paquetes de servicios: Choose from annual preventive maintenance contracts offering guaranteed response times or payperservice technical support plans tailored based on expected annual operating hours.
Opciones de financiación: We work with partner financial institutions to offer equipment leasing structures or term loans designed around seasonal cash flow patterns common in construction materials manufacturing.

8. Preguntas frecuentes

1. Is this machinery compatible with our existing clay preparation plant?
Yes provided your pug mill can deliver adequately tempered clay at a consistent rate matching the chosen machine's intake capacity specifications require verification during technical consultation

2 ¿Cuál es el cronograma típico de puesta en servicio de una instalación??
From delivery site preparation permitting foundation work mechanical installation electrical connection dry testing process commissioning typically requires four weeks depending on local conditions

3 How does this solution impact our overall plant energy costs?
The VFD technology reduces peak demand charges while efficient motor gearbox design lowers continuous draw Field audits show most operations achieve payback on the efficiency premium within two years through reduced electricity bills

4 What are the payment terms available?
Standard terms involve progress payments tied delivery milestones We also support letters credit established trade finance relationships

5 What training provided our operational team?
We include comprehensive onsite operator maintenance training manuals schematics Additionally we offer access online video library covering routine procedures troubleshooting

6 Are spare parts readily available what lead times?
We maintain strategic inventory critical wear parts like augers liners domestic warehouses Standard parts typically ship within days specialized components may require lead time communicated upfront

7 Can machine produce different sizes shapes beyond standard modular bricks?
Yes within physical limits die box Quick change system allows production variety profiles including perforated hollow blocks custom shapes subject die availability