1. PEMBUKAAN PAINPOINT DRIVEN

Adakah kualiti bata yang tidak konsisten dan kadar penolakan yang tinggi menghakis margin projek anda? Is your production line bottlenecked by manual handling, limiting output and increasing labor costs? Do you face excessive downtime due to equipment wear from abrasive raw materials or complex maintenance procedures? Untuk pengurus loji dan kontraktor kejuruteraan, these operational challenges translate directly into lost revenue, tarikh akhir terlepas, and compressed profitability.

Soalan intinya ialah: bagaimana anda mencapai konsisten, highvolume brick production with predictable operating costs and minimal unscheduled downtime? Jawapannya bukan hanya terletak pada mesin, but in a precisionengineered production system designed for industrial endurance. This requires partnering with an OEM factory that understands the rigorous demands of commercialscale brick manufacturing.

2. GAMBARAN KESELURUHAN PRODUK

Our product line comprises industrialgrade High Quality Brick Making Machines, specifically engineered as stationary block production systems for highoutput facilities. These are not portable machines but fixed installations designed for continuous operation in plant environments.

The operational workflow is optimized for efficiency:
1. Pemakanan Bahan Automatik: Bahan mentah pracampuran (simen, agregat, abu terbang, dll.) are conveyed and precisely metered into the machine hopper.
2. Pemadatan Tekanan Tinggi: A combination of hydraulic pressure and mechanical vibration densely compacts the material within a rigid mold box.
3. Precise Ejection & Pemindahan Pallet: The formed brick or block is ejected onto a pallet, which is automatically transferred to the curing area.
4. Kembali & Cycle: The empty pallet system returns, and the cycle repeats with precise interval timing.

Application scope includes the production of solid blocks, bongkah berongga, menurap batu, curbstones, and interlocking bricks using cementbased mixes. Primary limitations involve the requirement for a consistent supply of correctly graded raw materials and the need for a structured curing process postproduction.

3. CIRI TERAS

1. MultiFrequency Vibration System | Asas Teknikal: Dualaxis eccentric vibration heads combined with hydraulic pressurization | Faedah Operasi: Ensures uniform material distribution and eliminates voids for superior compressive strength and dimensional accuracy | Kesan ROI: Mengurangkan kadar penolakan produk sehingga 15%, directly improving material yield and reducing waste disposal costs.

2. Hardened Alloy Mold Box & Pakai bahagian | Asas Teknikal: CADoptimized mold designs fabricated from chromiumalloy steel with specialized heat treatment | Faedah Operasi: Extends component life in abrasive environments, maintaining product tolerances over millions of cycles | Kesan ROI: Lowers longterm spare parts inventory costs and reduces changeover downtime by up to 30%.

3. Sistem Kawalan PLC Berpusat | Asas Teknikal: Pengawal logik boleh atur cara industri dengan antara muka mesin manusia (HMI) skrin sentuh | Faedah Operasi: Enables precise control over cycle times, tekanan, and vibration parameters; simplifies operator training and fault diagnostics | Kesan ROI: Increases overall equipment effectiveness (OEE) through consistent cycle times and faster troubleshooting.

4. Modular Hydraulic Power Unit | Asas Teknikal: Independently housed pump and valve system with advanced filtration and cooling | Faedah Operasi: Isolates heat and contamination from the main frame, enhancing reliability and simplifying maintenance access | Kesan ROI: Improves hydraulic system longevity, reducing fluid change frequency and major overhaul intervals.

5. Automated Pallet Return & Circulation System | Asas Teknikal: Chaindriven or rollerconveyor circuit synchronized with the main machine cycle | Faedah Operasi: Menghapuskan pengendalian palet manual, increases production speed, and enhances floor space utilization | Kesan ROI: Reduces labor requirements per shift by approximately 12 personnel for material handling duties.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Our High Quality Brick Making Machine Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Masa Kitaran (untuk blok standard) | 1822 saat | 1517 saat | ~20% daya pengeluaran lebih pantas |
| Jangka Hayat Acuan (before relining)| 400k 600k cycles| 800k 1M+ cycles| ~70% longer service life |
| Penggunaan Tenaga setiap Blok| Garis dasar (100%)| Optimized hydraulic & drive systems| ~12% reduction in kWh/unit |
| Toleransi Ketekalan Dimensi| ±1.5 mm| ±0.8 mm| ~47% higher precision |

5. SPESIFIKASI TEKNIKAL

Kapasiti pengeluaran: Model boleh dikonfigurasikan daripada 6,000 ke atas 20,000 blok standard (400x200x200mm) setiap syif 8 jam.
Keperluan kuasa: Main drive power from 30 kW kepada 75 kw; total installed power dependent on automation level.
Spesifikasi Bahan: Compatible with standard cementitious mixes; maximum aggregate size typically ≤8mm.
Dimensi Fizikal: Machine footprint ranges from approx. 6m x 3m to 10m x 5m (L x W), tidak termasuk sistem penghantar.
Julat Operasi: Direka untuk suhu ambien +5°C hingga +40°C; komponen elektrik dinilai untuk tahap kelembapan industri standard.

6. SENARIO APLIKASI

Construction Materials Producer – Urban Infrastructure

Cabaran: A producer supplying municipal paving projects faced strict dimensional tolerances on interlocking pavers. High rejection rates from older equipment were causing contract penalties.
Penyelesaian: Implementation of a fully automated High Quality Brick Making Machine with our hardened alloy mold system and PLCcontrolled vibration/pressure profiles.
Keputusan: Dimensional compliance reached consistently above standards; rejection rates fell from >8% ke bawah <2%. The producer secured two additional municipal contracts based on demonstrated quality control.

Industrial Plant – Fly Ash Utilization

Cabaran: A thermal power plant sought to monetize fly ash byproduct but struggled with mix consistency affecting block strength in their onsite brick yard.
Penyelesaian: Installation of our machine equipped with precise automated batching feed integration and multifrequency vibration to handle lightweight flyashrich mixes.
Keputusan: Achieved consistent compressive strength exceeding required grades by >15%, creating a profitable secondary revenue stream while reducing landfill costs.

7. PERTIMBANGAN KOMERSIL

Our pricing structure reflects build quality and automation level:
Peringkat Standard: Semiautomatic machines focusing on core compaction technology for operations prioritizing capex control.
Peringkat Prestasi: Fully automatic machines with integrated pallet circulation systems for balanced output efficiency.
Peringkat Tumbuhan: Turnkey production line solutions including conveyors, sistem batching, robotic stacking/curing management.

Optional features include specialized mold designs for unique products color dosing systems custombranded block faces extended warranty packages

We offer comprehensive service agreements covering scheduled maintenance parts supply priority technical support Financing options including leasing arrangements are available through partners facilitating capital expenditure planning

Soalan Lazim

S1: Are your machines compatible with our existing raw material mix design?
A1 Our engineering team can review your mix proportions including cement fly ash slag or aggregate types We provide recommendations to ensure optimal performance on our systems often requiring only minor adjustments

Q2 What is the typical installation timeline from delivery to commissioning?
A2 For a standalone machine installation electrical connection basic training typically requires weeks depending on site readiness Full turnkey line commissioning may require weeks Our project managers provide detailed schedules upfront

Q3 How does this equipment impact our overall labor requirements?
A3 By automating feeding compaction ejection most clients reallocate labor from direct machine operation to quality control maintenance material preparation stacking resulting in higher productivity per employee

Q4 What are the key maintenance routines required?
A4 Daily lubrication visual checks weekly bolt tightening hydraulic inspections Quarterly filter changes wear part measurement Annual comprehensive inspection Field data shows adherence prevents unplanned stoppages

Q5 Do you offer training for our operators maintenance staff?
A5 Yes we provide onsite operational training during commissioning as well as optional advanced technical training at our facility covering troubleshooting PLC programming preventive maintenance procedures

Q6 Can we produce different block types on one machine?
A6 Yes quickchange mold systems allow transition between compatible block styles within minutes Modular designs facilitate this flexibility ensuring minimal downtime during product changeovers

Q7 What are your payment terms lead times?
A7 Standard terms involve progress payments tied to manufacturing milestones shipping Lead times vary by model complexity typically ranging from weeks upon receipt of deposit confirmed order