1. ABERTURA ACIONADA POR PAINPOINT

Suas margens de produção de tijolos estão sendo comprimidas por qualidade inconsistente?, alta dependência trabalhista, e tempo de inatividade excessivo? Commercial operators face tangible costs: manual handling leading to a 515% breakage rate, inconsistent mixing causing batch rejections, and the financial drain of maintaining outdated, unreliable equipment. Your plant’s profitability hinges on steady output and predictable operational costs. How do you increase daily production counts without expanding your workforce? Can you reduce energy consumption per thousand bricks while improving final product strength? Is your current setup flexible enough to meet changing market demands for different brick types and sizes? These are the operational challenges that define modern clay brick manufacturing.

2. VISÃO GERAL DO PRODUTO

This content details our range of premium, yet affordable, automated stationary brick making machines. These are heavyduty industrial systems designed for continuous, highvolume production of fired clay bricks (sólido, perfurado, oco). O fluxo de trabalho operacional é projetado para intervenção mínima:
1. Feed automatizado: Prepared clay is conveyed uniformly into the machine’s feed hopper.
2. Extrusão de alta pressão & Corte: A twinstage auger system compacts and deairs the clay before extrusion through a solid die; an automatic wirecut system slices the column into precise green bricks.
3. Automated Palletizing & Transferir: Green bricks are systematically placed onto setting carts or pallets for transport to the drying chamber.

Escopo de aplicação: Ideal for established brick yards targeting production from 20,000 para 100,000+ bricks per day shift. Suitable for a variety of plastic clays.
Limitações: Requires a consistent feed of properly prepared clay (adequate crushing, misturando, and tempering). Not designed for onsite mobile construction projects or for nonplastic soils without binder additives.

3. RECURSOS PRINCIPAIS

Vacuum DeAiring System | Base Técnica: Highefficiency vacuum pump creating >95% vacuum in the extrusion chamber | Benefício Operacional: Remove bolsas de ar do corpo de argila, significantly reducing laminations and cracks during drying and firing | Impacto do ROI: Field data shows a reduction in firing losses by up to 8%, directly improving yield per ton of raw material.

Hardened Alloy Steel Auger & Forro | Base Técnica: Wearresistant chromium alloy components with hardened flight edges | Benefício Operacional: Maintains precise extrusion pressure over extended periods, reducing wearrelated downtime and output consistency drift | Impacto do ROI: Extends service life by approximately 40% compared to standard carbon steel, lowering longterm parts replacement costs.

Unidade de frequência variável (VFD) Controlar | Base Técnica: Precision motor control via programmable logic controller (CLP) | Benefício Operacional: Allows operators to finetune extrusion speed and torque based on clay plasticity, optimizing output quality and preventing machine jamming | Impacto do ROI: Reduces energy consumption by matching power draw to load requirements and minimizes scrap from suboptimal settings.

QuickChange Die & Mouthpiece Assembly | Base Técnica: Standardized bolting system with alignment pins | Benefício Operacional: Enifies changeover between different brick profiles (por exemplo, from solid to perforated) em baixo 45 minutos | Impacto do ROI: Increases plant flexibility and reduces nonproductive time during product changeovers by an average of 60%, allowing responsive fulfillment of diverse orders.

Sistema centralizado de lubrificação com graxa | Base Técnica: Automated pump delivering lubricant to all critical bearing points on a timed cycle | Benefício Operacional: Ensures consistent lubrication under highload conditions, preventing premature bearing failure and unplanned stops | Impacto do ROI: Os testes da indústria demonstram uma 30% reduction in bearingrelated breakdowns, enhancing overall equipment availability.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Máquinas Convencionais) | Premium Affordable Brick Making Machine Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Brick Output Consistency | ±5% dimensional tolerance; visual surface defects common | ±2% dimensional tolerance; superior surface finish from deairing | 60% improvement in tolerance control |
| Consumo de energia por 1000 Tijolos| High fixed consumption; inefficient drive systems| VFDoptimized consumption; efficient gearbox design| Até 18% reduction in kWh usage |
| Tempo médio entre falhas (MTBF)| ~400 operating hours for major components| >700 operating hours for major components| ~75% increase in reliability |
| Changeover Time for Profile Swap| 23 hours with manual realignment| <45 minutes with guided system| ~70% faster changeover |
| Labor Requirement for Operation| 34 operadores para alimentação & manuseio| 12 operadores principalmente para monitoramento & gerenciamento de paletes| ~50% reduction in direct labor |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de produção: Modelos configuráveis ​​de 12,000 acabar 36,000 tijolos padrão por hora.
Requisitos de energia: Main extruder motor from 90 kW para 160 kW (dependendo do modelo); total connected load includes vacuum pump (~15 kW) e sistemas de transporte.
Especificações de materiais: Accepts clay with plasticity index (Atterberg Limits) suitable for extrusion; maximum feed particle size ≤8mm.
Dimensões Físicas: Typical footprint ranges from L12m x W4m x H3m (for core unit).
Faixa operacional ambiental: Designed for ambient temperatures of 10°C to +45°C with appropriate weather protection; requires a stable, level concrete foundation.

6. CENÁRIOS DE APLICAÇÃO

MediumSized Brick Yard Expansion

Desafio: A familyowned yard needed to double its daily output without doubling its labor force or incurring prohibitive capital expense. Their existing manual machine caused high waste and could not meet new contract volumes.
Solução: Implementation of a midrange premium affordable brick making machine with automated palletizing and VFD control.
Resultados: Output increased from 40k to over 75k bricks per shift with only two additional personnel. Clay waste reduced by an estimated ₹7 lakh annually due to lower breakage and consistent extrusion.

Contractor Supplying Large Infrastructure Project

Desafio: An engineering contractor secured a project requiring specific perforated bricks on a tight timeline but lacked specialized equipment.
Solução: Procurement of a premium affordable brick making machine equipped with quickchange die systems for both solid and perforated profiles.
Resultados: The contractor established an onsite plant meeting all project specifications. The rapid changeover capability allowed production shifts between project phases without delay, ensuring justintime supply.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Our range is structured around core output capacity.
EntryLevel System (up to ~15k bricks/hour): Focused on core reliability.
MidRange System (~20k25k bricks/hour): Includes VFD control & automação básica.
HighCapacity System (~30k+ bricks/hour): Fullfeatured with advanced PLC automation and telemetry options.
Recursos opcionais: Upgrades include remote monitoring packages, specialized alloy wear parts packages for abrasive clays, or integrated autostacking systems.
Pacotes de serviços: Choose from annual preventive maintenance contracts offering guaranteed response times or payperservice technical support plans tailored based on expected annual operating hours.
Opções de financiamento: We work with partner financial institutions to offer equipment leasing structures or term loans designed around seasonal cash flow patterns common in construction materials manufacturing.

8. Perguntas frequentes

1. Is this machinery compatible with our existing clay preparation plant?
Yes provided your pug mill can deliver adequately tempered clay at a consistent rate matching the chosen machine's intake capacity specifications require verification during technical consultation

2 Qual é o cronograma típico de comissionamento da instalação?
From delivery site preparation permitting foundation work mechanical installation electrical connection dry testing process commissioning typically requires four weeks depending on local conditions

3 How does this solution impact our overall plant energy costs?
The VFD technology reduces peak demand charges while efficient motor gearbox design lowers continuous draw Field audits show most operations achieve payback on the efficiency premium within two years through reduced electricity bills

4 Quais são as condições de pagamento disponíveis?
Standard terms involve progress payments tied delivery milestones We also support letters credit established trade finance relationships

5 What training provided our operational team?
We include comprehensive onsite operator maintenance training manuals schematics Additionally we offer access online video library covering routine procedures troubleshooting

6 Are spare parts readily available what lead times?
We maintain strategic inventory critical wear parts like augers liners domestic warehouses Standard parts typically ship within days specialized components may require lead time communicated upfront

7 Can machine produce different sizes shapes beyond standard modular bricks?
Yes within physical limits die box Quick change system allows production variety profiles including perforated hollow blocks custom shapes subject die availability