1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérez-vous une qualité de brique incohérente, coûts de main d'œuvre élevés, et des goulots d'étranglement de production imprévisibles? Manual and semiautomated brick forming processes often lead to significant material waste, frequent mold damage, and reliance on skilled operators who are increasingly difficult to retain. These inefficiencies directly impact your bottom line through elevated perunit costs and missed delivery deadlines.

How can you standardize brick density and dimensional accuracy across every production batch?
What solution reduces your dependency on manual labor while increasing output per shift?
Is your current equipment causing excessive downtime for mold changes or maintenance, crippling your plant's overall equipment effectiveness (OEE)?

Addressing these challenges requires a fundamental shift from variable manual processes to precisionengineered, automated production systems.

2. APERÇU DU PRODUIT

Le Machine de fabrication de briques hydrauliques entièrement automatisée is a stationary press system designed for highvolume, production constante de solides, creux, and paving bricks using hydraulic compression. This system transforms raw material—typically a mix of cement, agrégats, and pigments—into finished, cured bricks with minimal human intervention.

Flux de travail opérationnel:
1. Automatic Feeding: A conveyor system delivers a precisely measured volume of raw mix into the feed box.
2. Mold Filling & Precompaction: The mix is distributed into the mold cavity and initially compacted to remove air pockets.
3. Compression hydraulique haute pression: The main hydraulic cylinders apply controlled pressure (mesuré en tonnes) to form the brick to its final density and shape.
4. Éjection & Palettisation: The finished brick is ejected onto a pallet or conveyor belt for transport to the curing area.
5. Automatic Pallet Return: The empty pallet cycles back to the loading position, creating a continuous loop.

Champ d'application: Idéal pour les usines de fabrication de briques de moyenne à grande échelle, concrete product producers, and construction material suppliers requiring output from 10,000 à 30,000+ briques par quart de 8 heures.

Limites: This system is engineered for use with drymix concrete or stabilized earth materials. It is not suitable for wetclay processing (which requires extruders) or very smallbatch, artisanal production where frequent product changeovers are needed.

3. CARACTÉRISTIQUES PRINCIPALES

Proportional Hydraulic System | Base technique: Closedloop servohydraulics with pressure/flow feedback | Avantage opérationnel: Delivers consistent pressing force cycletocycle, ensuring uniform brick density and strength | Impact sur le retour sur investissement: Reduces reject rates by an average of 1525%, directly saving on material costs and rework labor.

Système de moule QuickChange | Base technique: Interface de boulonnage standardisée et broches d'alignement guidées | Avantage opérationnel: Permet un changement complet de moule en moins 30 minutes contre plusieurs heures | Impact sur le retour sur investissement: Increases plant flexibility and OEE by allowing rapid response to different product orders without major downtime.

VibrationAssisted Compaction | Base technique: Highfrequency eccentric vibrators mounted on the feed shoe and mold table | Avantage opérationnel: Ensures complete cavity fill and eliminates voids before final press | Impact sur le retour sur investissement: Improves surface finish and structural integrity, enhancing product marketability and reducing customer complaints.

Panneau de contrôle basé sur un API | Base technique: Automate programmable industriel avec IHM à écran tactile | Avantage opérationnel: Permet aux opérateurs de stocker des recettes pour différents produits, monitor cycle times, and diagnose faults | Impact sur le retour sur investissement: Reduces operator training time and enables datadriven process optimization for peak efficiency.

Cadre soudé robuste | Base technique: Fabriqué à partir de tôle d'acier à haute résistance avec points de contrainte renforcés | Avantage opérationnel: Absorbs operational vibrations completely, extending the service life of all internal components | Impact sur le retour sur investissement: Minimise les ruptures de fatigue structurelle, leading to lower longterm maintenance costs and higher asset longevity.

Système de lubrification automatique | Base technique: Centralized grease pump with distribution lines to all bearing points | Avantage opérationnel: Provides scheduled lubrication without operator intervention | Impact sur le retour sur investissement: Empêche l'usure prématurée des tiges de guidage et des roulements, a leading cause of unplanned stoppages.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (SemiAutomatic Press) | Fully Automated Hydraulic Brick Making Machine Solution | Avantage (% amélioration) |
| : | : | : | : |
| Output per Operator Shift| 2,500 4,000 briques | 10,000 12,000 briques | +250% |
| Cohérence de la densité des briques| ±5% variance due to manual filling/pressure control| ±1.5% variance via automated process control| +70% plus cohérent |
| Temps de changement de moule| 120 180 minutes| 75% plus rapide |
| Consommation d'énergie par 1000 Briques| Based on older pump technology| Variabledisplacement pumps reduce idle power draw| Jusqu'à 20% inférieur |
| Temps moyen entre les pannes (MTBF)| ~400 heures de fonctionnement| >800 heures d'ouverture (données de terrain)| +100% amélioration |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de production: Modèles configurables à partir de 1,200 à 1,800 briques par heure.
Pression nominale: Main hydraulic pressure adjustable from 120 à 220 tonnes.
Exigences d'alimentation: Moteur d'entraînement principal(s): 18.5 kW 30 kW; Vibrator motors: Additional total of ~5 kW; Standard supply voltage is threephase AC at either standard regional voltages.
Spécifications matérielles: Compatible with aggregates up to ≤6mm; Cement content typically ≥10%; Moisture content ≤8%.
Dimensions physiques (Typique): L x W x H ≈4500mm x1800mm x2200mm; Poids env.: ~810 metric tons.
Plage de fonctionnement environnementale: Conçu pour une installation en intérieur; Ambient temperature range recommended between +5°C / +40°C; Humidity noncondensing.

6. SCÉNARIOS D'APPLICATION

Fournisseur de matériaux de construction urbaine

Challenge A supplier faced volatile demand for different brick types (solid blocks today paving stones tomorrow). Their old multimachine setup caused long changeovers high workinprogress inventory tying up capital.
Solution Implementation of two fully automated hydraulic brick making machines with quickchange molds.
Results Changeover time reduced from half a shift to under an hour enabling justintime production models Inventory levels were cut by40% while fulfilling15% more customer orders monthly due increased flexibility

LargeScale Infrastructure Project Contractor

Challenge A contractor building a remote highway needed an onsite brick production plant ensure supply but local labor was unskilled in traditional methods leading poor quality control
Solution Deployment of a containerized automated brick making plant featuring one primary hydraulic press machine
Results The project achieved consistent ASTMgrade concrete bricks directly at site eliminating transport costs Operator training focused on machine interface not craft skills reducing quality dependence on individual skill Project reported22% lower material cost versus sourcing externally

Considérations commerciales

Equipment pricing tiers are primarily determined by the degree of automation press capacity:
EntryLevel SemiAutomatic Systems require more operator involvement starting range
Standard Fully Automated SinglePallet Machines represent core offering detailed here midrange investment
HighCapacity TwinPallet or Rotary Table Systems designed for maximum output premium price point

Optional features include robotic pallet stackers color dosing systems integrated water spray units advanced data logging packages

Forfaits de services généralement offerts:
1 Annual Preventive Maintenance Inspection includes parts discount
2 Comprehensive Service Contract covering all labor travel parts excluding consumables like molds
3 Remote Monitoring Support providing realtime diagnostics via PLC connectivity

Financing options available through partner institutions include standard leasing structures milestonebased project financing or renttoown agreements tailored capital expenditure cycles

FAQ

Q What raw material preparation system is required upstream of this machine?
A An efficient pan mixer capable producing homogeneous drymix essential Optimal performance requires consistent aggregate size moisture content within specified ranges We provide guidelines for upstream equipment compatibility

Q How does this machine impact our overall plant footprint?
A As stationary system it requires fixed foundation However by consolidating multiple forming curing stages into one continuous automated line many operators find total plant layout becomes more efficient reducing material handling space

Q Quel est le délai de livraison typique à partir de la mise en service de la commande?
A For standard configurations lead time averages weeks Customized solutions may require additional time Detailed project planning including foundation preparation electrical hookups conducted parallel delivery minimize implementation timeline

Q Les pièces de rechange sont-elles facilement disponibles?
A We maintain global inventory critical wear items like hydraulic seals cylinder components Control system built using industrystandard PLCs HMIs ensuring component availability locally most regions

Q Can existing mold designs be adapted fit your machine?
A Potentially yes Our engineering team can evaluate current mold designs adapt them our quickchange mounting interface This often represents significant cost saving versus complete retooling