1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando a qualidade inconsistente dos tijolos, altos custos trabalhistas, e gargalos de produção imprevisíveis? Na fabricação comercial de tijolos, esses desafios operacionais impactam diretamente seus resultados financeiros. Manual material handling and inconsistent compaction can lead to a 1520% rejection rate, consuming both raw materials and energy for reprocessing. Unplanned downtime for mold changes or maintenance on older equipment can halt an entire production line, custando milhares por hora em perda de produção.

Are you asking how to achieve higher daily output without expanding your facility’s footprint? Are you seeking a solution to reduce your dependency on scarce skilled labor while maintaining precise dimensional tolerances? The efficiency of your brick making operation hinges on the reliability and intelligence of your core machinery. Addressing these points requires equipment engineered not just for power, but for precision and predictable performance.

2. VISÃO GERAL DO PRODUTO

This product line encompasses fully automatic stationary brick making machines designed for highvolume production of concrete pavers, blocos ocos, tijolos sólidos, and interlocking landscaping products. These are industrialgrade systems that transform raw aggregate and cement into finished, produtos curados com intervenção manual mínima.

The operational workflow is a continuous cycle:
1. Automatic Batching & Misturando: Preprogrammed recipes ensure consistent raw material proportions are delivered to the mixer.
2. Alimentação de materiais & Compactação: The homogeneous mix is conveyed into the machine’s mold box, where highpressure hydraulic compaction forms the brick.
3. Ejeção & Paletização: The formed block is ejected onto a pallet or directly onto a curing rack.
4. Pallet/Cycle Return: Empty pallets are returned to the loading position automatically.
5. Integração do sistema de cura: The green bricks on pallets are systematically transferred to a controlled curing chamber.

Application scope includes largescale block yards, construction product manufacturers, and municipal infrastructure projects requiring standardized masonry units. Primary limitations include the requirement for a stable electrical supply (typically 380480V), a prepared concrete slab foundation, and an initial capital investment suited for production outputs exceeding 10,000 blocos padrão por turno de 8 horas.

3. RECURSOS PRINCIPAIS

Sistema de vibração inteligente | Base Técnica: Alta frequência, multidirectional vibration combined with hydraulic pressure compaction | Benefício Operacional: Achieves uniform density throughout the brick profile, eliminating weak points and reducing cracking during handling | Impacto do ROI: Field data shows a reduction in product rejection rates by up to 18%, maximizando o rendimento da matéria-prima.

Controle PLC Centralizado | Base Técnica: Programmable Logic Controller with touchscreen HMI managing all machine sequences | Benefício Operacional: Your operators can store dozens of product recipes, change molds via automated sequences, and diagnose faults from a single panel | Impacto do ROI: Reduces mold changeover time by approximately 65%, increasing productive uptime and enabling smaller batch runs economically.

Estrutura Estrutural Pesada | Base Técnica: Fabricated from hightensile steel plate with reinforced weldments at stress points | Benefício Operacional: Maintains critical alignment under constant cyclic loading, ensuring consistent product dimensions over years of service | Impacto do ROI: Estende os intervalos de grandes revisões em um valor estimado 40%, lowering longterm total cost of ownership.

ServoDriven Feed System | Base Técnica: Precision servo motors control the volume of material deposited into the mold cavity | Benefício Operacional: Eliminates over or underfilling, providing exact material weight per unit for consistent quality and color | Impacto do ROI: Reduces raw material waste by an average of 57% compared to volumetric feed systems.

Circulação Automatizada de Paletes | Base Técnica: Integrated roller conveyor or stacker system manages pallet flow without forklift intervention within the machine cycle | Benefício Operacional: Removes a manual labor step, increases cycle speed predictability, and enhances worksite safety | Impacto do ROI: Cuts direct labor requirements for machine operation by an estimated 2 fulltime equivalents per shift.

Sistema de molde QuickChange | Base Técnica: Standardized mold clamping with guided alignment pins and singlepoint release mechanisms | Benefício Operacional: Enables your crew to switch brick profiles or sizes in under 15 minutes with basic tools | Impacto do ROI: Minimizes downtime between production runs, allowing greater responsiveness to order changes.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Our Automatic Brick Making Machine Solution | Vantagem (% melhoria) |
|||||
| Tempo de ciclo (para bloco padrão) | 1822 segundos | 1416 segundos | ~25% mais rápido |
| Tolerância Dimensional | ±1,5 mm | ±0,8 mm | 47% mais preciso |
| Consumo de Energia por Bloco (kWh) | 0.085 kWh | 0.072 kWh | 15% mais eficiente |
| Tempo médio entre falhas (MTBF) | ~450 horas de operação | ~720 operating hours | 60% aumento na confiabilidade|
| Labor Required (Operadores por linha) | 34 | 12 | Redução de aproximadamente 50% |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de produção: Configurável de 12,000 acabar 30,000 blocos sólidos padrão (200mm x 100 mm x 60 mm) por turno de 8 horas.
Requisitos de energia: Unidade principal alimentada por um 4575 motor elétrico kW; carga total conectada dependente da configuração (mixer + transportador). Fornecimento padrão: 400V/50Hz/3phase.
Especificações de materiais: Compatível com misturas de concreto padrão (C20/25 to C30/37). Tamanho máximo agregado: ≤10 mm.
Dimensões Físicas: Machine footprint approximately ranges from L8m x W4m x H3m to L15m x W6m x H4m based on automation level.
Faixa operacional ambiental: Designed for indoor installation or under shelter; faixa de temperatura ambiente: +5°C a +40°C; umidade relativa até 80% sem condensação.

6. CENÁRIOS DE APLICAÇÃO

Empreiteiro de projeto de infraestrutura municipal

Desafio: A contractor needed to produce over 500k paving stones locally for a city renewal project within six months at lower cost than purchasing imported units.
Solução: Installation of one fully automatic brick making machine with multiple paver molds at their site batching plant.
Resultados: Achieved inhouse production of all required pavers within five months at a verified cost saving of $0.22 por unidade ($110k total), while meeting strict municipal compressive strength specifications.

Expanding Block Yard Manufacturer

Desafio: A familyowned block yard faced inconsistent quality between shifts due to manual operations and could not meet demand from new large construction clients without excessive overtime.
Solução: Upgraded from semiautomatic machines to two synchronized automatic brick making lines with central PLC control.
Resultados: Output increased by over threefold while reducing workforce fatiguerelated defects by nearly half; they secured two major annual supply contracts due to demonstrable capacity and quality consistency.

7. CONSIDERAÇÕES COMERCIAIS

Equipment pricing is structured across three primary tiers:
1. EntryLevel Automatic Line ($150k $250k): Core machine with basic PLC control and semiautomatic pallet return.
2 .Linha de produção padrão ($250k $400k): Fully integrated system including automatic pallet circulation,
recipe management software,
one set of standard molds,
optional mixer integration package available separately ($25k).
3 .Turnkey HighCapacity Line ($400k+): Includes heavyduty mixer,
automated curing rack handling system,
extended warranty,
comprehensive operator training program onsite

Optional features include robotic stacking arms,
custom mold design services,
remote monitoring via SCADA system integration,
and dust suppression hoods

Service packages offered:
• Garantia Básica:
12 meses peças/mão de obra
• Premium Service Contract:
36month extended coverage including annual preventive maintenance visits
• PayPerService Hour Plans available

Financing options include capital lease agreements operating leases through our partners direct financing programs typically structured over three five years subject credit approval

8.Perguntas frequentes

Q What existing batching/mixing equipment is compatible?
A Our machines are designed integrate any industrial pan or planetary mixer capable delivering consistent slump concrete Most clients use existing mixers successfully

Q How does implementation affect my current production during installation?
A We recommend planning installation during scheduled plant shutdown typical commissioning process takes days once foundation prepared Our team works minimize disruption

Q What ongoing maintenance skills are required?
A Daily lubrication weekly bolt tightening checks performed your staff Annual hydraulic filter changes bearing inspections recommended complex repairs handled our service technicians

Q As peças sobressalentes estão prontamente disponíveis?
A We maintain regional inventory critical wear parts vibration motors hydraulic seals PLC components Standard lead time nonstock items weeks not months

Q Can produce different block types same day?
A Yes quickchange mold system allows switching between compatible product profiles minutes enabling efficient small batch production

Q What training provided operators?
A Comprehensive onsite training covers machine operation basic troubleshooting recipe programming safety procedures included all installations Additional training modules available

Q What typical return investment period?
A Based historical data clients producing at capacity achieve ROI through labor savings reduced waste increased output months depending local market conditions production volume