1. PAINPOINT DRIVEN OPENING

Are your brick production margins being compressed by inconsistent quality, high labor dependency, and excessive downtime? 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leading to a 515% breakage rate, inconsistent mixing causing batch rejections, and the financial drain of maintaining outdated, unreliable equipment.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. PRODUCT OVERVIEW

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 (solid, perforated, hollow). The operational workflow is engineered for minimal intervention:
1. Automated Feed: Prepared clay is conveyed uniformly into the machine’s feed hopper.
2. HighPressure Extrusion & Cutting: 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 & Transfer: Green bricks are systematically placed onto setting carts or pallets for transport to the drying chamber.

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

3. CORE FEATURES

Vacuum DeAiring System | Technical Basis: Highefficiency vacuum pump creating >95% vacuum in the extrusion chamber | Operational Benefit: Removes air pockets from the clay body, significantly reducing laminations and cracks during drying and firing | ROI Impact: Field data shows a reduction in firing losses by up to 8%, directly improving yield per ton of raw material.

Hardened Alloy Steel Auger & Liner | Technical Basis: Wearresistant chromium alloy components with hardened flight edges | Operational Benefit: Maintains precise extrusion pressure over extended periods, reducing wearrelated downtime and output consistency drift | ROI Impact: Extends service life by approximately 40% compared to standard carbon steel, lowering longterm parts replacement costs.

Variable Frequency Drive (VFD) Control | Technical Basis: Precision motor control via programmable logic controller (PLC) | Operational Benefit: Allows operators to finetune extrusion speed and torque based on clay plasticity, optimizing output quality and preventing machine jamming | ROI Impact: Reduces energy consumption by matching power draw to load requirements and minimizes scrap from suboptimal settings.

QuickChange Die & Mouthpiece Assembly | Technical Basis: Standardized bolting system with alignment pins | Operational Benefit: Enifies changeover between different brick profiles (e.g., from solid to perforated) in under 45 minutes | ROI Impact: Increases plant flexibility and reduces nonproductive time during product changeovers by an average of 60%, allowing responsive fulfillment of diverse orders.

Centralized Grease Lubrication System | Technical Basis: Automated pump delivering lubricant to all critical bearing points on a timed cycle | Operational Benefit: Ensures consistent lubrication under highload conditions, preventing premature bearing failure and unplanned stops | ROI Impact: Industry testing demonstrates a 30% reduction in bearingrelated breakdowns, enhancing overall equipment availability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Machines) | Premium Affordable Brick Making Machine Solution | Advantage (% improvement) |
| : | : | : | : |
| Brick Output Consistency | ±5% dimensional tolerance; visual surface defects common | ±2% dimensional tolerance; superior surface finish from deairing | 60% improvement in tolerance control |
| Energy Consumption per 1000 Bricks| High fixed consumption; inefficient drive systems| VFDoptimized consumption; efficient gearbox design| Up to 18% reduction in kWh usage |
| Mean Time Between Failures (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% faster changeover |
| Labor Requirement for Operation| 34 operators for feeding & handling| 12 operators primarily for monitoring & pallet management| ~50% reduction in direct labor |

5. TECHNICAL SPECIFICATIONS

Production Capacity: Configurable models from 12,000 to over 36,000 standard bricks per hour.
Power Requirements: Main extruder motor from 90 kW to 160 kW (depending on model); total connected load includes vacuum pump (~15 kW) and conveyor systems.
Material Specifications: Accepts clay with plasticity index (Atterberg Limits) suitable for extrusion; maximum feed particle size ≤8mm.
Physical Dimensions: Typical footprint ranges from L12m x W4m x H3m (for core unit).
Environmental Operating Range: Designed for ambient temperatures of 10°C to +45°C with appropriate weather protection; requires a stable, level concrete foundation.

6. APPLICATION SCENARIOS

MediumSized Brick Yard Expansion

Challenge: 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.
Solution: Implementation of a midrange premium affordable brick making machine with automated palletizing and VFD control.
Results: 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

Challenge: An engineering contractor secured a project requiring specific perforated bricks on a tight timeline but lacked specialized equipment.
Solution: Procurement of a premium affordable brick making machine equipped with quickchange die systems for both solid and perforated profiles.
Results: 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. COMMERCIAL CONSIDERATIONS

Pricing Tiers: 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 & basic automation.
HighCapacity System (~30k+ bricks/hour): Fullfeatured with advanced PLC automation and telemetry options.
Optional Features: Upgrades include remote monitoring packages, specialized alloy wear parts packages for abrasive clays, or integrated autostacking systems.
Service Packages: Choose from annual preventive maintenance contracts offering guaranteed response times or payperservice technical support plans tailored based on expected annual operating hours.
Financing Options: 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. FAQ

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 What is the typical installation commissioning timeline?
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