1. PEMBUKAAN PAINPOINT DRIVEN

Adakah kualiti bata yang tidak konsisten dan masa henti mesin yang kerap menghakis margin dan reputasi projek anda? Menguruskan barisan pengeluaran batu bata memberikan cabaran operasi yang berbeza yang secara langsung memberi kesan kepada keuntungan. Titik kesakitan biasa termasuk:
Kadar Penolakan yang Tinggi: Inconsistent raw material feeding and pressure application lead to dimensional flaws and weak bricks, resulting in waste rates often exceeding 58%.
Buruh Berlebihan & Downtime: Manual mold changes for different brick types can halt production for hours. Unplanned maintenance on hydraulic or vibration systems causes significant schedule overruns.
Kos Operasi Tidak Mampan: Inefficient compression cycles and highpower consumption drive up energy costs per pallet. Premature wear on molds and liners from poor material handling necessitates frequent, penggantian yang mahal.
Fleksibiliti Pengeluaran Terhad: Inability to quickly switch between solid, hampa, or interlocking pavior blocks restricts your ability to respond to market demands and contract opportunities.

Bagaimana anda boleh mencapai konsisten, highvolume output with lower operational overhead and greater agility? The solution lies in specifying a white label brick making machine engineered for reliability and precision.

2. GAMBARAN KESELURUHAN PRODUK

A white label brick making machine is a fully automatic or semiautomatic stationary block production system designed for highvolume manufacturing of concrete bricks, blok, dan penurap. These machines are manufactured by an OEM (Pengilang peralatan asal) and sold under a distributor’s or reseller’s own brand, offering a customizable solution without the R&D overhead.

Aliran Kerja Operasi:
1. Batching & Percampuran: Prepared concrete (vibrated or semidry) is conveyed from the mixer to the machine’s feed hopper.
2. Metered Feeding & Mampatan: A precisely measured volume of material is fed into the mold box. A combination of highfrequency vibration and hydraulic pressure compacts the material to the required density.
3. Ejection & Pengawetan: The freshly formed brick or block is ejected onto a pallet, which is then transported to a curing rack or chamber for final strength development.

Skop Permohonan: Ideal for dedicated block yards, pembekal bahan binaan, dan projek infrastruktur berskala besar yang memerlukan konsisten, standardized output of concrete masonry units (CMU).
Had Utama: Tidak sesuai untuk di tapak, mobile production. Memerlukan asas yang disediakan, bekalan bahan mentah yang konsisten (agregat, simen), and integration into a full plant layout including mixers and handling systems.

3. CIRI TERAS

Sistem Getaran Ketepatan | Asas Teknikal: Frekuensi tinggi, verticallyoriented eccentric weights | Faedah Operasi: Memastikan pengedaran bahan seragam dan penghapusan lompang untuk ketumpatan dan kekuatan bata yang konsisten | Kesan ROI: Mengurangkan penolakan produk sehingga 70%, directly improving yield per batch

Modular QuickChange Mold System | Asas Teknikal: Standardized cartridgestyle mold boxes with integrated liners | Faedah Operasi: Membolehkan pertukaran antara jenis bata (mis., daripada blok pepejal kepada penurap saling mengunci) di bawah 30 minutes with minimal tools | Kesan ROI: Increases plant utilization by enabling smaller, profitable batch runs; reduces labor hours per changeover by 65%

Litar Hidraulik Berkadar | Asas Teknikal: Closedloop system with variable displacement pumps | Faedah Operasi: Menyampaikan lancar, controllable pressure ramping during compression cycles, extending mold life and reducing hydraulic shock failures | Kesan ROI: Lowers maintenance costs by an average of 25% setiap tahun; improves energy efficiency by matching power demand to the cycle stage

Peredaran Pallet Automatik & Pelinciran | Asas Teknikal: Pengawal Logik Boleh Aturcara (Plc)managed conveyor indexing with spray lubrication system | Faedah Operasi: Ensures precise pallet positioning for ejection and applies a consistent film of release agent | Kesan ROI: Minimizes pallet damage and stickingrelated stoppages; reduces manual labor for pallet handling

Antara Muka Kawalan PLC Berpusat | Asas Teknikal: Industrialgrade humanmachine interface (HMI) with recipe storage | Faedah Operasi: Allows operators to monitor all machine functions, adjust cycle parameters, store settings for different products, dan mendiagnosis kerosakan daripada satu panel | Kesan ROI: Reduces operator training time; provides data for production tracking and efficiency analysis

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Mesin Pembuat Bata Label Putih | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Kitaran setiap Blok Standard | 1822 saat | 1517 saat | ~20% daya pengeluaran lebih pantas |
| Mold Liner Lifespan (Production Cycles) | 80,000 100,000 kitaran| 120,000 150,000 kitaran| Hingga 50% hayat perkhidmatan yang lebih lama |
| Penggunaan Tenaga setiap Pallet (kWj) | Berbeza secara meluas; selalunya tidak dioptimumkan| Metered consumption reduced via efficient hydraulics & pemacu| Documented savings of 1522% boleh dicapai |
| Masa Min Antara Kegagalan (MTBF) – Hydraulic System| ~1,200 waktu operasi| >1,800 waktu operasi| >50% peningkatan dalam kebolehpercayaan |

5. SPESIFIKASI TEKNIKAL

Kapasiti pengeluaran: Model boleh dikonfigurasikan daripada 1,800 ke atas 6,000 blok standard (200mm x 100mm x 400mm) setiap syif 8 jam.
Keperluan kuasa: Main drive powered by a 18.5kW 45kW electric motor (Bergantung pada model). Requires standard industrial threephase power supply.
Spesifikasi Bahan: Designed for semidry concrete mixes with slump typically between 020mm. Compatible with cementtoaggregate ratios standard in block production.
Dimensi Fizikal (Stesen Biasa): Lebih kurang. Panjang: 4m x Lebar 2m x Tinggi 3m (excluding conveyor feed/discharge).
Julat Operasi Persekitaran: Direka untuk pemasangan tumbuhan dalaman. Julat suhu persekitaran: 5°C to 40°C. Requires dust management in feeding area.

6. SENARIO APLIKASI

LargeScale Construction Material Supplier

Cabaran: A regional supplier needed to expand its product line from standard blocks to include decorative pavers but faced prohibitive downtime estimates of one full day per mold changeover on older equipment.
Penyelesaian: Implementation of a white label brick making machine with the modular quickchange mold system.
Keputusan: Reduced changeover time to under 30 minutes allowed the supplier to run multiple product batches daily. Within six months they captured 15% new market share in landscaping supplies without increasing labor costs.

Government Infrastructure Project Contractor

Cabaran: A contractor building lowcost housing faced strict quality audits and penalties for dimensional inconsistencies in supplied blocks, causing project delays.
Penyelesaian: Onsite installation of a dedicated white label plant featuring the precision vibration system and PLCcontrolled operation.
Keputusan: Achieved consistent dimensional tolerance within ±1mm across all batches. Rejection rates fell from an industryaverage ~7% to below 2%, ensuring steady supply and eliminating penalty clauses.

7. PERTIMBANGAN KOMERSIL

White label solutions offer significant value through flexible commercial structuring:
Peringkat Harga: Based on automation level (semiauto vs fully automatic), kapasiti pengeluaran (blocks/hour), and control system sophistication (basic PLC vs advanced HMI).
Ciri Pilihan: Upgrades can include automated color feeder systems for layered bricks robotic pallet stackers/desstackers enhanced vibration isolation frames
Pakej Perkhidmatan: Tiered annual maintenance contracts are available covering scheduled parts replacement technical support response times preventive maintenance visits
Pilihan Pembiayaan: Many distributors offer equipment leasing plans or partnershipbased financing through thirdparty providers easing capital expenditure requirements

8.Soalan Lazim

Q1 Are these machines compatible with our existing batching plant?
Field data shows successful integration is standard practice provided feed conveyor heights discharge mechanisms are aligned during site planning Our technical team provides interface specifications

Q2 What is the typical lead time from order commissioning?
Lead times vary based on model customization but industrystandard delivery ranges from 60 90 days exworks excluding shipping

Q3 How does this solution impact our overall labor requirements?
A fully automatic white label system typically reduces direct manual labor at the pressing station by 60 allowing personnel reallocation to quality control logistics roles

Q4 What are the commercial terms regarding spare parts availability?
We maintain certified spare parts inventories locally Critical wear items like mold liners hydraulic seals are guaranteed available within 48 jam di bawah pelan perkhidmatan premium kami

Q5 Can you provide specific ROI calculations based on our current production figures?
Yes Our commercial team will conduct an operational analysis using your current output waste rates energy costs labor inputs This generates a projected payback period report based on documented performance metrics