1. PEMBUKAAN PAINPOINT DRIVEN

Managing a commercial brick production line requires balancing output, kualiti, and cost under constant pressure. Common operational challenges include inconsistent raw material feed leading to variable brick density and strength, frequent mold changes causing excessive production downtime, and high energy consumption per unit that erodes profit margins. Manual handling and stacking not only limit throughput but also contribute to a higher rate of product damage before curing. Are you facing rising labor costs, unpredictable maintenance cycles on older equipment, or an inability to scale production to meet contract demands without significant capital outlay? These bottlenecks directly impact your plant’s profitability and competitive positioning.

2. GAMBARAN KESELURUHAN PRODUK

This content details our range of industrial Mesin Pembuat Bata, specifically automated stationary block machines designed for highvolume production. Aliran kerja operasi direka bentuk untuk keluaran berterusan: (1) Automated batching and mixing of raw materials (simen, agregat, abu terbang), (2) Precision feeding and highpressure compaction within a rigid mold system, (3) Automated ejection and transfer of green bricks onto pallets, (4) Accumulation and indexing for efficient transport to the curing chamber. These systems are scoped for largescale commercial yards, concrete product manufacturers, and construction material suppliers producing solid, hampa, and interlocking concrete blocks. Limitations include requirements for a stable power supply, prepared foundation pads, and consistent raw material grading to achieve specified performance.

3. CIRI TERAS

ServoDriven Hydraulic System | Asas Teknikal: Closedloop proportional valve control with feedback sensors | Faedah Operasi: Delivers precise pressure ramping and dwell time, ensuring uniform brick density with minimal hydraulic shock or heat generation | Kesan ROI: Reduces energy consumption by up to 25% compared to standard systems and lowers longterm maintenance costs
Sistem Katrij Acuan QuickChange | Asas Teknikal: Standardized subplate mounting with guided alignment pins | Faedah Operasi: Membolehkan penukaran acuan lengkap di bawah 15 minutes by two operators without specialized tools | Kesan ROI: Increases machine utilization rate by reducing downtime, allowing smaller batch runs to be economically viable
Intelligent Vibration Platform | Asas Teknikal: Multidirectional eccentric weights with variable frequency drives (VFD) | Faedah Operasi: Optimizes material consolidation for different mix designs, eliminating voids and achieving superior surface finish from the first brick | Kesan ROI: Lowers rejection rates by ensuring consistent quality compliance from startup
Pelinciran Berpusat & Pemantauan Keadaan | Asas Teknikal: Automated greasing points with flow sensors connected to machine PLC | Faedah Operasi: Provides scheduled lubrication to all critical wear points and alerts operators to any blockage or deviation | Kesan ROI: Prevents unscheduled downtime due to bearing or guide failures, memanjangkan selang baik pulih utama
Pemulangan Pallet & Circulation Conveyor | Asas Teknikal: Integrated steelbelt conveyor loop with synchronized drive | Faedah Operasi: Automatically returns empty pallets to the loading station in a continuous cycle without manual intervention | Kesan ROI: Reduces labor requirements for material handling and minimizes pallet damage, mengurangkan kos boleh guna

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Mesin Pembuat Bata Kami | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Cycles per Hour (Blok Standard) | 1,800 2,200 cycles/hr | 2,400 2,600 cycles/hr| +15% Output |
| Penggunaan Tenaga per 1000 Batu bata| 85 100 kWj / 1000 batu bata| 65 75 kWj / 1000 batu bata| 22% Kos Tenaga |
| Masa Pertukaran Acuan| 45 60 minit| <15 minit| 70% Downtime |
| Penggunaan Campuran (Waste) | 35% Reject/Material Loss| <1.5% Reject/Material Loss| Reduced Raw Material Cost |

5. SPESIFIKASI TEKNIKAL

Kapasiti/Penilaian: Production output of 2,400 – 2,600 blok standard (400x200x200mm) per hour under optimal conditions.
Keperluan kuasa: Pemacu utama dikuasakan oleh a 55 motor elektrik kW; total connected load approximately 90 kw (including vibrators, penghantar).
Spesifikasi Bahan: Constructed from hightensile steel plate at stress points; hardened alloy steel liners in the compaction chamber; industrialgrade hydraulic components.
Dimensi Fizikal: Jejak mesin lebih kurang. 8m (L) x 4m (W) x 3.5m (H). Total system length with conveyor typically requires a 25m bay.
Julat Operasi Persekitaran: Direka untuk operasi dalam suhu ambien dari +5°C hingga +45°C. Electrical components rated for IP54 protection against dust and water spray.

6. SENARIO APLIKASI

Precast Concrete Products Plant Expansion
Cabaran: A manufacturer needed to fulfill a large infrastructure contract but was constrained by the slow cycle time and high waste rate of their existing brick making machines.
Penyelesaian: Implementation of a highcycle servohydraulic brick making machine with an intelligent vibration system tailored for their specific aggregate mix.
Keputusan: Achieved a quantified output increase of overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity by overproduction capacity20%, reduced product waste from ~4% to below .8%, meeting the project timeline.
Fly Ash Utilization Facility
Cabaran: A power plant’s downstream operation sought to increase commercial use of fly ash but struggled with mix consistency using older compaction equipment.
Penyelesaian: Installation of a brick making machine with precise moisture sensing and adaptive pressure control optimized for high flyash content mixes.
Keputusan: Consistently produced ASTMcompliant bricks with >60% kandungan abu terbang; data lapangan menunjukkan a % improvement in final compressive strength uniformity.

Pembekal Bahan Binaan Bandar
Cabaran: Frequent custom orders necessitated multiple short production runs on a single machine line , leading t o prohibitive downtime f or mold changes .
Penyelesaian : Procurement o f abrick making machine equipped wit h th e quickchange mold cartridge system .
Keputusan : Reduced nonproductive time b y approximately hours pe r week , enabling th e supplier t o profitably accept smaller , specialized orders while maintaining core production .

Pertimbangan Komersial

Ourbrick making machines are offered i n three primary tiers t o match operational scale an d investment plans :

Tahap : Standard Production Model – Includes core servohydraulic system , basi c vibration platform , an d manual pallet feed .
Tahap : HighOutput Model – Adds th e quickchange mold system , integrate d pallet circulation conveyor , an d enhanced diagnostics .
Tahap : Fully Automated Line – Incorporates robotic stacking , automatic mix feed from batching plant , an d full plant SCADA integration .

Optional features include specifi c mold libraries , dedusting shrouds , an d alternative liner materials fo r abrasive mixes . Comprehensive service packages range fro m preventative maintenance plans t o fullsite operational training an d remote monitoring support . Financing options including equipment leasing an d term loans ar e available t o hel p manage capital expenditure .

Soalan Lazim

Q What ar e th e infrastructure requirements fo r installing thi s brick making machine ?
A successful installation requires reinforced concrete foundation capable o f supporting dynamic loads , stable V threephase power supply wit h appropriate transformer capacity , an d compressed air fo r auxiliary functions . Detailed site preparation guidelines ar e provided .

Q How does thi s machin e handle variations i n raw material moisture content ?
Th e syste m can b e equipped wit h optional inline moisture probes tha t provide dat ato th e PLC allowing fo r minor automatic compensation i n vibration timetomaintain density ; however consistent premix conditioning remains critical fo r optimal results .

Q What i s th e expected lifespan o f critical wear parts likemoldsan d liners ?
Unde r normal operating conditions wit h proper maintenance hardened steel liners typically last fo r million cycles before requiring refurbishment while molds themselves depending on design can produce several million units .

Q Are these machines compatible wit h existing batching plantsan dcuring systems ?
Yes thesebrick making machines ar e designed fo r integration into complete plants They feature standardized interface heightsan dreceive signals fro m upstreamdownstream equipment ensuring synchronized operation .

Q What training isprovidedforour operatorsandmaintenance staff ?
We provide comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting common faultsandmold changeover protocols Documentation includes detailed manuals part listsand schematic diagrams .

Q Whataretheleadtimesfor deliveryinstallation?
Lead times vary basedonmodel configurationandcurrent production schedule Typically delivery occurs within weeks following order confirmationwith installation commissioning requiring approximately weeks onsite dependingonpreparedness .

7 PERTIMBANGAN KOMERSIL

8 Soalan Lazim