1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing brick production while navigating increasingly stringent environmental regulations and volatile material costs? The pressure to maintain output while controlling operational risk is intensifying. Cabaran biasa termasuk:

Risiko Penutupan Peraturan: Noncompliant machinery can lead to fines, production stoppages, and reputational damage in markets with strict substance controls like the EU, Amerika Utara, and parts of Asia.
Kualiti Produk Tidak Konsisten: Variations in hydraulic pressure and vibration frequency from aging or poorly calibrated machines result in bricks with compromised structural integrity, leading to higher rejection rates.
Masa Henti Tidak Berjadual: Frequent mechanical failures in highstress components cause unpredictable production halts, directly impacting your ability to fulfill contracts.
Kos Operasi yang Tinggi: Inefficient energy consumption per brick and excessive wear on nondurable parts erode your profit margins over thousands of production cycles.
Supply Chain Complexity: Sourcing replacement parts that meet both performance and compliance standards can be slow and costly.

How do you select a brick making machine that delivers reliable performance, ensures longterm market access, dan memberikan pulangan pelaburan yang jelas? The solution lies in purposebuilt engineering that prioritizes both compliance and commercial durability.

2. GAMBARAN KESELURUHAN PRODUK

Kami RoHS Compliant Brick Making Machines are heavyduty, automated stationary systems engineered for the continuous production of highdensity concrete blocks, penurap, and related masonry products. These machines are constructed to adhere to the European Union's Restriction of Hazardous Substances (RoHS) Directive 2015/863, ensuring no controlled substances like lead, kadmium, merkuri, or specific phthalates are used in electrical components, pendawaian, hydraulic seals, or surface coatings.

Aliran Kerja Operasi:
1. Batching & Memberi makan: Prepared drymix concrete (agregat, pasir, simen) is automatically metered into the machine's feed hopper.
2. pengacuan & Mampatan: Material is distributed into a mold box where it undergoes highfrequency vibration and substantial hydraulic pressure for compaction.
3. Pengawetan & Ejection: The formed brick is raised onto a pallet and transferred to a curing rack or conveyor system, while the cycle repeats.

Skop Permohonan: Ideal for medium to largescale block yards and precast concrete product manufacturers supplying commercial construction, municipal projects, and export markets with strict compliance requirements.

Batasan: These are not smallscale manual machines. They require a prepared concrete mix feedstock, stable threephase power supply, and adequate space for operation and product curing.

3. CIRI TERAS

RoHSCertified Component Architecture | Asas Teknikal: Full material declaration from suppliers & controlled substance testing | Faedah Operasi: Eliminates regulatory barriers for selling into RoHSregulated regions; futureproofs your investment against expanding global substance laws. | Kesan ROI: Avoids potential fines per incident; protects access to highermargin export contracts.

Sistem ServoHidraulik Ketepatan | Asas Teknikal: Closedloop servo valves controlling hydraulic pressure within ±0.5% tolerance | Faedah Operasi: Delivers consistent compaction force for uniform brick density and strength (minimum variance), reducing product rejection rates. | Kesan ROI: Field data shows a reduction in waste material by up to 3% annually through improved consistency.

HighEfficiency Vibration Array | Asas Teknikal: Multiple synchronized eccentric shafts generating directed vertical vibration | Faedah Operasi: Ensures complete mold fill and optimal particle interlock even with variable aggregate sizes, enhancing final product durability. | Kesan ROI: Increases production speed by up to 15% per cycle compared to singleshaft systems by achieving required density faster.

Durable AbrasionResistant Mold System | Asas Teknikal: Hardened steel molds with RoHScompliant surface treatments (mis., nitriding) | Faedah Operasi: Extends mold life significantly under abrasive concrete mix conditions; ensures dimensional accuracy over millions of cycles. | Kesan ROI: Reduces mold replacement frequency by an estimated 40%, lowering perunit tooling costs.

Antara Muka Kawalan Pintar | Asas Teknikal: PLCbased system with touchscreen HMI for parameter storage (tekanan, masa kitaran) per product type | Faedah Operasi: Your operators can change product specifications with onetouch recall, minimizing setup errors and downtime during changeovers. | Kesan ROI: Cuts changeover time by approximately 50%, increasing overall equipment effectiveness (OEE).

Regenerative Energy Recovery Circuit | Asas Teknikal: Hydraulic system design that captures energy during decompression and ram retraction phases | Faedah Operasi: Lowers peak power demand and reduces overall energy consumption per thousand bricks produced. | Kesan ROI: Industry testing demonstrates average energy cost savings of 1822% compared to standard hydraulic circuits.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Mesin Pembuat Bata Patuh RoHS | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Pematuhan peraturan| separa / Selfdeclared| Full componentlevel certification & dokumentasi| Mitigates 100% of RoHSbased entry risk |
| Ketekalan Masa Kitaran| ±3% variance due to hydraulic drift| ±0.5% variance via servocontrol| ~80% more consistent output |
| Jangka Hayat Acuan| 500k – 800k cycles before refurbishment| 1.2M – 1.5M cycles before refurbishment| ~70% longer service life |
| Penggunaan tenaga| Baseline kWh/1000 bricks| Regenerative circuit design| ~20% lower operating cost |
| Masa Pertukaran| Manual adjustment (2535 min)| Programmed recipe recall (1215 min)| ~55% faster product switching |

5. SPESIFIKASI TEKNIKAL

Kapasiti pengeluaran: Model boleh dikonfigurasikan daripada 1,800 ke 6,000 blok standard (200x100x400mm) setiap syif 8 jam.
Keperluan kuasa: 380480VAC / 5060Hz / Threephase; Installed power range from 45 kW – 75 kW bergantung kepada model.
Spesifikasi Bahan: Compatible with standard drycast concrete mixes with aggregate size up to 10mm; Mold sizes customizable for block thicknesses from 50mm to 300mm.
Dimensi Fizikal (Stesen Biasa): Length ≈12m; Width ≈4m; Height ≈3m (excluding conveyor lines).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari +5°C hingga +40°C; Electrical enclosures rated IP54 for dust/moisture protection.
Control System Compliance: PLCS & HMIs sourced from manufacturers with full RoHS compliance documentation packages.

6. SENARIO APLIKASI

Precast Concrete Exporter Serving EU Markets

Cabaran: A manufacturer faced rejected shipments due to trace amounts of restricted substances found in control panel wiring of their existing plant equipment.
Solution Implementation of a fully documented RoHS compliant brick making machine as the core of their new production line.
Results Eliminated customs compliance issues entirely; secured a longterm supply contract with a European distributor based on guaranteed compliance protocols.

Municipal Paver Production Facility

Challenge High maintenance costs from frequent hydraulic seal failures and inconsistent paver quality leading to onsite breakage during installation.
Solution Upgraded two older machines with new RoHS compliant models featuring servohydraulics hardened molds
Results Achieved consistent compressive strength (+15%), reduced maintenance downtime by an average of two days/month cut annual seal replacement costs by over $8

LargeScale Block Yard Modernization

Challenge An aging fleet of machines caused high energy bills unpredictable downtime making costperblock calculations unreliable
Solution Phased replacement program installing three highcapacity RoHS compliant brick making machines over two years
Results Standardized maintenance protocols reduced total energy consumption across the yard by established predictable output schedules allowing more competitive bidding

PERTIMBANGAN KOMERSIL

Peringkat Harga:
Tier EntryLevel SemiAutomatic Models suitable for lowervolume specialized products Tier MidRange Fully Automatic Standard models formost block yard operations Tier HighCapacity Fully Automatic Systems designedfor continuous multishift operation

Ciri Pilihan:
• Automated pallet return conveyor systems • Advanced moisture sensorsfor mix optimization • Remote monitoring diagnostics package • Custom branding platesfor molded products

Pakej Perkhidmatan:
• Basic Warranty covering parts labor formonths • Extended Performance Plan including annual inspections critical wear parts coverage • Comprehensive Plant Support offering scheduled maintenance training spare parts inventory management

Pilihan Pembiayaan:
We workwith established industrial equipment financiers offer solutions including straight leasepurchase plans seasonal payment structures tailoredto your project cash flow requirements

FREQUENTLY ASKED QUESTIONS FAQ

Q Are these machines only usefulfor companies exportingto Europe?
A No WhileRoHs compliance is criticalfor EU market access it also demonstratesa commitmentto environmental safety reduces future retooling risks as similar regulationsare adopted globally It also often correlateswith higherreliability components

Q How do you verifyand documentcompliance?
A We providea full technical file including material declarationsfrom all component suppliers certificatesof conformityfor the completed assembly anda traceability matrix This documentationis what buyers regulatorsrequire

Q What happensif we needa replacementpart yearsfrom now?
A We maintainan inventoryof certifiedspare parts guarantee their continuedRoHs compliance All part numbersare crossreferencedin our system ensuringyou receivea direct equivalentnot justa functional substitute

Q Can your machine integratewith our existing batchingand curing systems?
A Yes Our machinesare designedwith standardinterfacesfor feed conveyorsand pallet handling Systems integrationis a key partof our predelivery engineeringassessmentto ensure compatibility

Q What isthe typicalpayback periodon this investment?
A Payback variesbasedon scale utilizationand previousmachine efficiency Most clientsseea full returnon investmentwithin months through combined savingsin energy waste reduction maintenanceand increasedoutput Consultour team fora detailedanalysisbasedon your specificproduction figures