1. PEMBUKAAN PAINPOINT DRIVEN

Are inconsistent brick quality and unplanned downtime eroding your plant's profitability? For commercial brick manufacturers, unreliable production equipment translates directly to financial loss. Common operational challenges include:

Kualiti Produk Berubah: Inconsistent raw material mixing and imprecise compaction lead to bricks that fail strength tests, resulting in high rejection rates and wasted materials.
Excessive Downtime: Frequent mechanical failures in key components like the compression system or pallet circulation cause full production lines to halt, missing critical order deadlines.
Kos Operasi yang Tinggi: Inefficient hydraulic systems and outdated controls consume excessive energy, while manual interventions increase labor requirements and the risk of error.
Limited Production Flexibility: Rigid machinery cannot adapt to produce different brick types, saiz, or densities without lengthy, costly changeovers, restricting market responsiveness.

How do you achieve consistent ASTMgrade output while maximizing machine uptime and controlling operational expenses? Penyelesaiannya terletak pada ketepatan kejuruteraan, robust mesin membuat batu bata designed for industrialscale performance.

2. GAMBARAN KESELURUHAN PRODUK

This product line comprises fully automatic, pegun mesin membuat batu bata for highvolume production of concrete pavers, blok, and bricks. The system integrates material handling, pemadatan ketepatan, and automated product handling into a continuous workflow.

Aliran Kerja Operasi:
1. Batching & Mixing: Premeasured aggregates, simen, and pigments are delivered to a central mixer for homogeneous blending.
2. Mold Feeding & Pemadatan: The mix is conveyed into the machine’s mold box. A multistage compression system—combining vibration and highpressure hydraulic force—densifies the material.
3. Stripping & Pengawetan: The formed brick is ejected onto a pallet and transferred via stacker/cuber to a controlled curing environment.

Skop Permohonan: Ideal for permanent plants producing standard concrete masonry units (CMUs), permeable pavers, retaining wall units, and landscaping products at capacities from 10,000 ke 60,000+ units per 8hour shift.

Batasan: This equipment is designed for controlled plant environments with consistent access to graded aggregates and cementitious materials. It is not mobile or suitable for onsite, temporary project use with highly variable raw materials.

3. CIRI TERAS

Sistem Getaran Ketepatan | Asas Teknikal: Frekuensi tinggi, verticallyoriented eccentric shafts with amplitude control | Faedah Operasi: Memastikan pengedaran bahan seragam dan penghapusan lompang untuk ketumpatan dan kekuatan bata yang konsisten | Kesan ROI: Mengurangkan kadar penolakan produk sehingga 15%, directly saving on material waste and reprocessing costs.

Centralized PLC Control | Asas Teknikal: Pengawal logik boleh atur cara industri dengan HMI skrin sentuh | Faedah Operasi: Membenarkan pengendali menyimpan resipi untuk produk yang berbeza, monitor all machine functions in realtime, and diagnose faults quickly | Kesan ROI: Cuts changeover time by up to 50% and reduces meantimetorepair (MTTR) by an average of 30%.

HeavyDuty Hydraulic Pack | Asas Teknikal: Variabledisplacement piston pumps with proportional valve technology | Faedah Operasi: Delivers consistent pressing force with minimal heat generation and energy spikes | Kesan ROI: Lowers energy consumption per cycle by approximately 20% compared to fixedpump systems.

Reinforced Mold & Pakai bahagian | Asas Teknikal: Hardchromed mold liners and tungsten carbidetipped wear plates | Faedah Operasi: Dramatically extends component life in abrasive concrete environments | Kesan ROI: Reduces annual spare parts expenditure by an estimated 2540% and increases productive uptime.

Peredaran Pallet Automatik | Asas Teknikal: Closedloop pallet return system with brush cleaning stations | Faedah Operasi: Maintains clean, stable pallets for perfect brick bottom finish and reduces manual labor | Kesan ROI: Minimizes labor for pallet handling and decreases defects related to pallet debris by over 90%.

Reka Bentuk Bingkai Modular | Asas Teknikal: Fabricated steel frame with bolted stress points for localized reinforcement | Faedah Operasi: Simplifies maintenance access to key components like the vibration table or hydraulic manifold | Kesan ROI: Reduces scheduled maintenance duration by 20%, meningkatkan waktu pengeluaran tahunan yang tersedia.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Mesin Pembuat Bata Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Cycle Time Consistency (Standard Block) | ±0.3 seconds variance per cycle due to hydraulic lag or control drift. Our solution maintains ±0.05 seconds variance through closedloop servo control on key movements.| More than 80% improvement in consistency |
| Mold Lifespan (Abrasive Mix) Typically requires liner replacement after ~150k cycles under standard abrasive conditions.| Field data shows lifespan extension to ~250k cycles before refurbishment is needed.| ~67% increase in lifespan |
| Penggunaan Tenaga per 1000 Bricks Average draw of ~85 kWh/1000 units for comparable output machines.| Documented average draw of ~68 kWh/1000 units under similar production conditions.| ~20% reduction in energy use |
| Masa Min Antara Kegagalan (MTBF) Major component failures often occur within 68 months of continuous operation.| Core hydraulic & vibration systems demonstrate MTBF exceeding 14 months in documented installations.| Over 75% improvement in reliability |

5. SPESIFIKASI TEKNIKAL

Kapasiti pengeluaran: Boleh dikonfigurasikan daripada 1,800 ke atas 7,500 blok standard (200mm x 200mm x 400mm) per hour.
Keperluan kuasa: Pemacu utama dikuasakan oleh motor elektrik tugas berat; jumlah beban bersambung biasanya antara 90 160 kW bergantung pada konfigurasi.
Spesifikasi Bahan: Compatible with standard concrete mixes with aggregate size up to 10mm; designed for compressive forces exceeding 350 tan.
Dimensi Fizikal: Machine footprint approximately varies from L12m x W4m x H3m; total plant layout must include space for pallet return conveyor.
Julat Operasi Persekitaran: Direka untuk pemasangan tumbuhan dalaman; operating ambient temperature range of +5°C to +40°C; requires a level foundation (±2mm tolerance).

6. SENARIO APLIKASI

Municipal Paver Supplier Challenge:

A supplier faced increasing rejection rates from city contracts due to failing freezethaw durability tests on interlocking concrete pavers. Inconsistent compaction was identified as the root cause.

Penyelesaian:

Implementation of our brick making machine featuring the precision vibration system with amplitude feedback control paired with the heavyduty hydraulic pack.

Keputusan:

Brick density CV (Coefficient of Variance) improved from >8% down 98%. This secured two major municipal contracts worth over $2M annually.

Block Plant Expansion Challenge:

A block manufacturer needed a second production line but was constrained by high energy costs limiting profitability on new capital investments.

Penyelesaian:

Installation of our energyoptimized brick making machine configuration featuring variabledisplacement hydraulics an automated curing rack management system

Keputusan:

The new line achieved a documented reduction o22% in specific energy consumption (kWj/blok) compared tthe plant's older line Annual energy savings exceeded $45 allowing payback period reduction b18 months

7 PERTIMBANGAN KOMERSIL

Our brick making machines are offered i three primary tiers based o automation level ancapacity:

1. HighPerformance Standard Line
2 Premium Line witAdvanced Controls
3 Custom Configured Plant Solutions

Optional features include robotic layer picking systems color feeder integration anremote diagnostic portals Service packages range frobasic preventive maintenance plans tcomprehensive performance contracts witguaranteed uptime levels Financing options including equipment leasing anprojectbased loans are available through partner institutions tfacilitate capital expenditure planning

8 Soalan Lazim

What raw material preparation system is required?
Our machines require consistently proportioned anmixed concrete delivered at specified slump Astandard industrial pan mixer ocontinuous mixer i typically used upstream We can provide specifications fooptimal feed consistency

Can one machine produce multiple brick sizes anshapes?
Yes Thcentralized PLC stores recipes fordifferent molds Changeover involves swapping thmold box anselecting thcorresponding program which trained crew cacomplete iunder minutes

What is thtypical installation anc commissioning timeline?
From delivery onsite tomachine commissioning requires approximately weeks depending osite readiness This includes foundation verification mechanical assembly electrical connection ansupervised test runs wityour material

What training id provided foour operators?
We include comprehensive onsite operator training focore machine functions basic troubleshooting ansafety procedures along witdetailed manuals Additional training modules formaintenance staff are available

Adakah anda menawarkan jaminan prestasi?
Yes Oucontracts includeguarantees forminimum production capacity atspecified quality levels based ostandardized mix designs These are validated during thacceptance test run period