1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Снижается ли рентабельность производства кирпича из-за нестабильного качества?, высокая трудовая зависимость, и чрезмерное время простоя? 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leading to a 515% breakage rate, inconsistent mixing causing batch rejections, and the financial drain of maintaining outdated, unreliable equipment.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. ОБЗОР ПРОДУКТА

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 (твердый, перфорированный, пустой). Рабочий процесс спроектирован с минимальным вмешательством:
1. Автоматизированная подача: Prepared clay is conveyed uniformly into the machine’s feed hopper.
2. HighPressure Extrusion & Резка: 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 & Передача: Green bricks are systematically placed onto setting carts or pallets for transport to the drying chamber.

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

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Vacuum DeAiring System | Техническая основа: Highefficiency vacuum pump creating >95% vacuum in the extrusion chamber | Операционная выгода: Удаляет воздушные карманы из глиняного тела., significantly reducing laminations and cracks during drying and firing | Воздействие на рентабельность инвестиций: Field data shows a reduction in firing losses by up to 8%, directly improving yield per ton of raw material.

Hardened Alloy Steel Auger & Лайнер | Техническая основа: Wearresistant chromium alloy components with hardened flight edges | Операционная выгода: Maintains precise extrusion pressure over extended periods, reducing wearrelated downtime and output consistency drift | Воздействие на рентабельность инвестиций: Extends service life by approximately 40% compared to standard carbon steel, lowering longterm parts replacement costs.

Частотно-регулируемый привод (ЧРП) Контроль | Техническая основа: Precision motor control via programmable logic controller (ПЛК) | Операционная выгода: Allows operators to finetune extrusion speed and torque based on clay plasticity, optimizing output quality and preventing machine jamming | Воздействие на рентабельность инвестиций: Reduces energy consumption by matching power draw to load requirements and minimizes scrap from suboptimal settings.

QuickChange Die & Mouthpiece Assembly | Техническая основа: Standardized bolting system with alignment pins | Операционная выгода: Enifies changeover between different brick profiles (например, from solid to perforated) под 45 минуты | Воздействие на рентабельность инвестиций: Increases plant flexibility and reduces nonproductive time during product changeovers by an average of 60%, allowing responsive fulfillment of diverse orders.

Централизованная система смазки | Техническая основа: Automated pump delivering lubricant to all critical bearing points on a timed cycle | Операционная выгода: Ensures consistent lubrication under highload conditions, preventing premature bearing failure and unplanned stops | Воздействие на рентабельность инвестиций: Отраслевые испытания демонстрируют 30% снижение поломок подшипников, enhancing overall equipment availability.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (Обычные машины) | Premium Affordable Brick Making Machine Solution | Преимущество (% улучшение) |
| : | : | : | : |
| Brick Output Consistency | ±5% dimensional tolerance; visual surface defects common | ±2% dimensional tolerance; superior surface finish from deairing | 60% improvement in tolerance control |
| Потребление энергии на 1000 Кирпичи| High fixed consumption; inefficient drive systems| VFDoptimized consumption; efficient gearbox design| До 18% reduction in kWh usage |
| Среднее время между отказами (среднее время безотказной работы)| ~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% более быстрое переключение |
| Labor Requirement for Operation| 34 операторы по кормлению & умение обращаться| 12 операторы в первую очередь для мониторинга & управление поддонами| ~50% reduction in direct labor |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Производственная мощность: Конфигурируемые модели от 12,000 слишком 36,000 стандартных кирпичей в час.
Требования к питанию: Main extruder motor from 90 кВт до 160 кВт (в зависимости от модели); total connected load includes vacuum pump (~15 kW) и конвейерные системы.
Характеристики материала: Accepts clay with plasticity index (Atterberg Limits) suitable for extrusion; maximum feed particle size ≤8mm.
Физические размеры: Typical footprint ranges from L12m x W4m x H3m (for core unit).
Экологический рабочий диапазон: Designed for ambient temperatures of 10°C to +45°C with appropriate weather protection; requires a stable, level concrete foundation.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

MediumSized Brick Yard Expansion

Испытание: 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.
Решение: Implementation of a midrange premium affordable brick making machine with automated palletizing and VFD control.
Результаты: 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

Испытание: An engineering contractor secured a project requiring specific perforated bricks on a tight timeline but lacked specialized equipment.
Решение: Procurement of a premium affordable brick making machine equipped with quickchange die systems for both solid and perforated profiles.
Результаты: 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. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Ценовые уровни: 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 & базовая автоматизация.
HighCapacity System (~30k+ bricks/hour): Fullfeatured with advanced PLC automation and telemetry options.
Дополнительные функции: Upgrades include remote monitoring packages, specialized alloy wear parts packages for abrasive clays, or integrated autostacking systems.
Пакеты услуг: Choose from annual preventive maintenance contracts offering guaranteed response times or payperservice technical support plans tailored based on expected annual operating hours.
Варианты финансирования: 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. Часто задаваемые вопросы

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 Каковы типовые сроки ввода в эксплуатацию??
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 Какие условия оплаты доступны?
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