برڪ ٺاهڻ جي مشين پروسيسنگ پلانٽ بروشر
1. PAINPOINT driven اوپننگ
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?
اهي عملياتي چئلينج سڌو سنئون توهان جي هيٺئين لائن تي اثر انداز ڪن ٿا. 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.
پلانٽ مينيجرز لاءِ مرڪزي سوال هي آهي: توهان ڪيئن حاصل ڪري سگهو ٿا اعلي, more consistent output with lower operational expenditure and greater flexibility? The answer lies in the engineering precision of a modern سرن ٺاهڻ جي مشين پروسيسنگ پلانٽ.
2. پيداوار جو جائزو
اي سرن ٺاهڻ جي مشين پروسيسنگ پلانٽ is an integrated industrial system designed to automate the transformation of raw materials (مٽي, شيل, اڏامڻ, وغيره) into finished, highdensity bricks or blocks. It moves beyond a single machine to a coordinated production line.
The core operational workflow typically involves:
1. خام مال جي تياري: پرائمري ڪرشنگ, اسڪريننگ, and controlled feeding into the mixing system.
2. Precision Mixing & Conditioning: Homogenizing raw materials with water/additives to achieve exact moisture content and plasticity for optimal extrusion.
3. HighPressure Extrusion & ٺهڻ: Compacting the conditioned material through a deairing extruder and die to form a continuous column of precise shape and density.
4. Automatic Cutting & سنڀالڻ: Cutting the extruded column to precise brick lengths and transferring them to downstream dryers or kilns via automated systems.
5. Centralized Control & نگراني: 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. بنيادي خاصيتون
Intelligent Feed System | ٽيڪنيڪل بنياد: Gravimetric or volumetric feeding with loadcell feedback | آپريشنل فائدا: Eliminates guesswork, ensures perfect raw material ratios batch after batch | ROI اثر: تائين مادي فضول کي گھٽائي ٿو 8% and guarantees uniform product quality
Vacuum DeAiring Extrusion Chamber | ٽيڪنيڪل بنياد: Highcapacity vacuum pump removing air from the pugmill | آپريشنل فائدا: Dramatically increases brick density and mechanical strength while reducing cracking during drying/firing | ROI اثر: Enables production of premiumgrade bricks with higher market value and lower firing losses
HardFaced Alloy Wear Parts | ٽيڪنيڪل بنياد: Tungsten carbide or specialized steel liners in mixer shafts, extrusion auger, and die mouth | آپريشنل فائدا: Withstands highly abrasive materials, extending service life by multiples compared to standard parts | ROI اثر: Cuts replacement part costs by over 60% and reduces downtime for maintenance
ماڊلر مرڻ & Cutter System | ٽيڪنيڪل بنياد: Quickchange mechanisms for profile dies and cutting heads | آپريشنل فائدا: Allows shift change between different brick types or sizes in under 30 منٽ | ROI اثر: Maximizes line utilization, enabling smallbatch custom orders without sacrificing overall plant throughput
PLC with HMI Touchscreen Control | ٽيڪنيڪل بنياد: Programmable Logic Controller with HumanMachine Interface storing recipes for all products | آپريشنل فائدا: Operators manage the entire سرن ٺاهڻ جي مشين پروسيسنگ پلانٽ from one station; parameters are locked in for repeatability | ROI اثر: Lowers skill barrier for operation, reduces human error, and provides diagnostic data to preempt failures
Integrated Energy Recovery | ٽيڪنيڪل بنياد: Heat exchange systems capturing thermal energy from motors/hydraulics | آپريشنل فائدا: Redirects waste heat to prewarm process water or facility spaces | ROI اثر: Lowers total energy consumption of the plant by an estimated 1015%
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Average Plant) | اسان جي Brick Making Machines Processing Plant حل | فائدو (% سڌارو) |
| : | : | : | : |
| پيداوار جي مطابقت (Density Variation) | ±5% tolerance common due to manual feed control maintained within ±1.5% via automated gravimetric systems improves quality control by ~70% |
| ناڪامين جي وچ ۾ وچولي وقت (لباس جا حصا) requires replacement every 400600 operating hours engineered wear parts last 1,500+ hours extends service life by ~150% |
| Changeover Time (Brick Profile) can take half a shift (4 ڪلاڪ) modular system completes changeover in <45 minutes reduces downtime by over 80% |
| Overall Equipment Effectiveness (اي اي) typically ranges from 6575% field data supports OEE consistently above 85% boosts productive capacity by ~15% |
5. ٽيڪنيڪل وضاحتون
ظرفيت جي درجه بندي: کان ترتيب ڏئي سگهجي ٿو 12,000 ختم ڪرڻ 40,000 standard brick equivalents per 8hour shift.
بجلي جي گهرج: Total connected load between 180 ڪلواٽ 450 kW ترتيب تي منحصر ڪري ٿو; requires stable 3phase supply.
مواد جي وضاحت: Processes natural clay, شيل, صنعتي ضمني مصنوعات (اڏامڻ), and mixed aggregates with particle size up to 8mm.
جسماني طول و عرض: Typical footprint for a complete line ranges from 30m (ايل) x 8m (ڊبليو) x 5m (ايڇ) to 50m (ايل) x 10m (ڊبليو) x 6m (ايڇ).
ماحولياتي آپريٽنگ رينج: Designed for indoor installation; ambient temperature range 5°C to 40°C; humidity noncondensing.
6. درخواست جا منظر
Large Clay Brick Manufacturer Scaling Premium Products
چيلنج: Needed to produce highstrength engineering bricks alongside standard facing bricks but lacked extrusion pressure consistency; high reject rate was impacting margins.
حل: Implementation of a hightonnage سرن ٺاهڻ جي مشين پروسيسنگ پلانٽ featuring a 20bar vacuum deairing extruder with programmable pressure controls.
نتيجا: Achieved consistent compressive strength exceeding 35 N/mm²; reject rate fell from 7% 2%; enabled entry into lucrative civil engineering contracts.
Fly Ash Brick Producer Expanding Capacity
چيلنج: Manual batching led to inconsistent mix quality; existing equipment could not meet new contract volume demands without excessive labor costs.
حل: 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 تجارتي خيالات
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 FAQ
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 What is typical lead time from order commissioning?
A For standard configurations lead time ranges months months depending complexity Customengineered solutions may require longer detailed project schedule provided upon quotation
Q What operator training provided?
A Comprehensive training included covers daily operation routine maintenance basic troubleshooting safety procedures conducted onsite during commissioning typically spans working days
