1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Are inconsistent raw materials and manual feeding processes causing unacceptable levels of product variation and waste in your brick production? Is unplanned downtime due to abrasive wear on mixing and extrusion components eroding your plant’s profitability? Are you struggling to scale output or introduce new brick profiles without major capital investment in entirely new production lines?

Эти операционные проблемы напрямую влияют на вашу прибыль.. Inconsistent density and strength lead to higher rejection rates. Frequent component replacement halts production and increases maintenance costs. Inflexible systems prevent you from capitalizing on new market opportunities.

Центральный вопрос для руководителей предприятий заключается в следующем.: как ты можешь достичь большего, more consistent output with lower operational expenditure and greater flexibility? The answer lies in the engineering precision of a modern Завод по переработке машин для производства кирпича.

2. ОБЗОР ПРОДУКТА

А Завод по переработке машин для производства кирпича is an integrated industrial system designed to automate the transformation of raw materials (глина, сланец, летучая зола, и т. д.) into finished, highdensity bricks or blocks. It moves beyond a single machine to a coordinated production line.

Основной рабочий процесс обычно включает в себя:
1. Подготовка сырья: Первичное дробление, скрининг, and controlled feeding into the mixing system.
2. Precision Mixing & Кондиционирование: Homogenizing raw materials with water/additives to achieve exact moisture content and plasticity for optimal extrusion.
3. ​HighPressure Extrusion & Формирование: Compacting the conditioned material through a deairing extruder and die to form a continuous column of precise shape and density.
4. ​Automatic Cutting & Умение обращаться: Cutting the extruded column to precise brick lengths and transferring them to downstream dryers or kilns via automated systems.
5. Централизованное управление & Мониторинг: Orchestrating the entire process from a single control panel for consistency and efficiency.

Application scope includes largescale production of solid, perforated, hollow bricks, and pavers for construction and landscaping. Key limitations involve the requirement for a consistent power supply, structured raw material feedstock management, and significant floor space for the complete line.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Intelligent Feed System | Техническая основа: Gravimetric or volumetric feeding with loadcell feedback | Операционная выгода: Eliminates guesswork, ensures perfect raw material ratios batch after batch | Воздействие на рентабельность инвестиций: Снижает количество отходов материала до 8% and guarantees uniform product quality

Vacuum DeAiring Extrusion Chamber | Техническая основа: Highcapacity vacuum pump removing air from the pugmill | Операционная выгода: Dramatically increases brick density and mechanical strength while reducing cracking during drying/firing | Воздействие на рентабельность инвестиций: Enables production of premiumgrade bricks with higher market value and lower firing losses

HardFaced Alloy Wear Parts | Техническая основа: Tungsten carbide or specialized steel liners in mixer shafts, extrusion auger, and die mouth | Операционная выгода: Withstands highly abrasive materials, extending service life by multiples compared to standard parts | Воздействие на рентабельность инвестиций: Cuts replacement part costs by over 60% and reduces downtime for maintenance

Модульная матрица & Cutter System | Техническая основа: Quickchange mechanisms for profile dies and cutting heads | Операционная выгода: Allows shift change between different brick types or sizes in under 30 минуты | Воздействие на рентабельность инвестиций: Maximizes line utilization, enabling smallbatch custom orders without sacrificing overall plant throughput

PLC with HMI Touchscreen Control | Техническая основа: Programmable Logic Controller with HumanMachine Interface storing recipes for all products | Операционная выгода: Operators manage the entire Завод по переработке машин для производства кирпича from one station; parameters are locked in for repeatability | Воздействие на рентабельность инвестиций: Lowers skill barrier for operation, reduces human error, and provides diagnostic data to preempt failures

Integrated Energy Recovery | Техническая основа: Heat exchange systems capturing thermal energy from motors/hydraulics | Операционная выгода: Redirects waste heat to prewarm process water or facility spaces | Воздействие на рентабельность инвестиций: Lowers total energy consumption of the plant by an estimated 1015%

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (Average Plant) | Наш Brick Making Machines Processing Plant Решение | Преимущество (% Улучшение) |
| : | : | : | : |
| Согласованность продукта (Изменение плотности) | ±5% tolerance common due to manual feed control maintained within ±1.5% via automated gravimetric systems improves quality control by ~70% |
| Среднее время между отказами (Изнашиваемые детали) requires replacement every 400600 operating hours engineered wear parts last 1,500+ hours extends service life by ~150% |
| Время переключения (Brick Profile) can take half a shift (4 часы) modular system completes changeover in <45 minutes reduces downtime by over 80% |
| Общая эффективность оборудования (ОЕЕ) typically ranges from 6575% field data supports OEE consistently above 85% boosts productive capacity by ~15% |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Номинальная мощность: Настраивается из 12,000 слишком 40,000 стандартный эквивалент кирпича за 8-часовую смену.
Требования к питанию: Total connected load between 180 кВт 450 кВт в зависимости от конфигурации; requires stable 3phase supply.
Характеристики материала: Processes natural clay, сланец, промышленные побочные продукты (летучая зола), and mixed aggregates with particle size up to 8mm.
Физические размеры: Typical footprint for a complete line ranges from 30m (л) х 8м (Вт) х 5 м (ЧАС) to 50m (л) x 10m (Вт) х 6 м (ЧАС).
Экологический рабочий диапазон: Предназначен для установки внутри помещений.; ambient temperature range 5°C to 40°C; влажность без конденсации.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Large Clay Brick Manufacturer Scaling Premium Products

Испытание: Needed to produce highstrength engineering bricks alongside standard facing bricks but lacked extrusion pressure consistency; high reject rate was impacting margins.
Решение: Implementation of a hightonnage Завод по переработке машин для производства кирпича featuring a 20bar vacuum deairing extruder with programmable pressure controls.
Результаты: Achieved consistent compressive strength exceeding 35 Н/мм²; reject rate fell from 7% 2%; enabled entry into lucrative civil engineering contracts.

Fly Ash Brick Producer Expanding Capacity

Испытание: Manual batching led to inconsistent mix quality; existing equipment could not meet new contract volume demands without excessive labor costs.
Решение: Installation of an automated processing plant with twinshaft compulsory mixer PLCcontrolled water injection automated conveyor feed.
Results Increased output by 140%; reduced labor requirement per thousand bricks by 50%; achieved uniform color finish due precise mix control enhancing brand reputation.

Regional Block Plant Adding Product Diversity

Challenge Market demand growing for both standard hollow blocks decorative pavers but changeovers were prohibitively timeconsuming
Solution Procured modular brick making machines processing plant featuring quickchange die cutter system multiple preprogrammed recipes
Results Now profitably produce six different product types on single line changeover completed minutes capturing multiple local market segments previously served competitors

7 КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Pricing tiers are based on throughput capacity automation level:

1 Basic Tier Semiautomated processing plants focusing core extrusion cutting start at approximately $185000 suitable established facilities upgrading single process stage
2 Standard Tier Fully integrated automated plants including automated material handling PLC control priced $350000 $650000 representing most common turnkey solution
3 Premium Tier Highcapacity customengineered plants with advanced robotics energy recovery diagnostic telemetry exceed $800000 designed maximum uptime largescale producers

Optional Features include robotic palletizing systems advanced moisture probes remote monitoring software packages extended wear part kits

Service Packages offered are:
Bronze Package includes standard warranty onsite commissioning training
Silver Package adds scheduled preventive maintenance visits priority spare parts dispatch
Gold Package provides full annual service contract guaranteed response times dedicated technical support line

Financing Options available through partner institutions include capital lease operating lease equipment loans subject credit approval typical terms range months months

8 Часто задаваемые вопросы

Q What level foundation required installing this processing plant?
A A reinforced concrete foundation minimum compressive strength MPa is essential specifications include detailed foundation drawing ensure stability dampen vibrations

Q How does system handle variations moisture content incoming raw material?
A Advanced plants incorporate realtime moisture sensors feedback loop automatically adjusts water addition mixer maintaining plasticity within tight tolerance regardless feedstock condition

Q Can existing dryer kiln be integrated new processing line?
A Yes integration possible often requires interface conveyor modifications our engineering team can conduct site audit provide integration specifications ensure compatibility

Q Каково типичное время выполнения заказа с момента ввода заказа в эксплуатацию??
A For standard configurations lead time ranges months months depending complexity Customengineered solutions may require longer detailed project schedule provided upon quotation

Q Какое обучение операторов проводилось??
A Comprehensive training included covers daily operation routine maintenance basic troubleshooting safety procedures conducted onsite during commissioning typically spans working days