Dorëzim i kompanisë tregtare të makinave për prodhimin e tullave
1. HAPJE NGA PIKA E DIKIMIT
Are inconsistent brick quality and high labor costs eroding your plant’s profitability? Manual or outdated brick making machines often lead to critical production bottlenecks, duke ndikuar drejtpërdrejt në linjën tuaj përfundimtare. Sfidat e zakonshme përfshijnë:
Cilësi e ndryshueshme e produktit: Inconsistent raw material mixing and compaction pressure result in bricks that fail to meet ASTM or IS standards, leading to customer rejections and reputational damage.
Kohë joproduktive të paplanifikuara: Frequent mechanical failures in hydraulic systems or mold assemblies halt entire production lines, with maintenance costs consuming 1520% of annual operating budgets.
Shpenzime të larta operative: Reliance on skilled labor for feeding and handling, coupled with energyinefficient motors, drives up the cost per unit, making your products less competitive.
Prodhim jofleksibël: Pamundësia për të kaluar shpejt midis llojeve të tullave (të ngurta, zgavër, shtrimin) and sizes causes missed market opportunities and limits contract versatility.
How can you stabilize output quality while reducing dependency on manual labor and controlling energy consumption? The solution lies in investing in a modern, automated brick making machine.
2. PËRMBLEDHJE E PRODUKTIT
The industrial brick making machine is a stationary hydraulic press system designed for highvolume, consistent production of construction bricks from raw materials like clay, konkrete, ose hiri fluturues. Its operational workflow transforms loose material into finished blocks through a controlled, repeatable process:
1. Të ushqyerit & Përpjestimimi: Raw material is automatically conveyed and precisely measured into the main mold cavity.
2. Ngjeshja & Dridhja: A combination of highfrequency vibration and significant hydraulic pressure (në mënyrë tipike 150300 ton) compacts the material to eliminate voids.
3. Derdhja & Nxjerrja: The formed brick is held under pressure momentarily before the mold retracts and the brick is ejected onto a pallet or conveyor.
4. Kurimi & Trajtimi: Green bricks are transferred automatically to a curing rack or chamber for final strength development.
Fusha e Aplikimit: Ideale për fabrikat e prodhimit të tullave në shkallë të mesme dhe të madhe, prodhuesit e materialeve të ndërtimit, and industrial waste recycling facilities (p.sh., duke shfrytëzuar hirin fluturues). Primary outputs include solid blocks, blloqe boshe, gurë shtrimi, dhe tulla të ndërlidhura.
Kufizimet: This equipment class requires a prepared raw material with consistent moisture content and granulometry. It is a capitalintensive solution best suited for operations with stable demand exceeding 10,000 units per day.
3. TIPARET THEMELORE
Automated Material Dosing System | Baza Teknike: Load cellbased weighing hopper | Përfitimi Operacional: Delivers precise material volume for every cycle (±1% accuracy), ensuring uniform brick density and weight | Ndikimi i ROI: Reduces raw material waste by up to 7% and eliminates qualitybased customer rejections.
Paneli i kontrollit PLC i centralizuar | Baza Teknike: Kontrollues logjik i programueshëm me ekran me prekje HMI | Përfitimi Operacional: Lejon operatorët të ruajnë receta për produkte të ndryshme, monitoroni shëndetin e makinës në kohë reale, dhe diagnostikoni shpejt defektet | Ndikimi i ROI: Cuts product changeover time by 70% and reduces diagnostic downtime by an average of 50%.
Sistemi i mykut të këmbyeshëm | Baza Teknike: Kallëpe çeliku të ngurtësuar me mekanizma të çlirimit të shpejtë | Përfitimi Operacional: Enables shiftlong production runs of different brick types (p.sh., from standard blocks to decorative pavers) with minimal tooling downtime | Ndikimi i ROI: Increases plant flexibility to fulfill diverse contracts without additional capital investment in separate machines.
EnergyRecuperative Hydraulic System | Baza Teknike: Variable displacement pumps and accumulator banks | Përfitimi Operacional: Captures energy during decompression cycles and reuses it for the next compression phase | Ndikimi i ROI: Lowers direct energy consumption by approximately 25% krahasuar me sistemet me pompa fikse.
Tabela e dridhjeve HeavyDuty | Baza Teknike: Dualaxis eccentric vibrators mounted on reinforced decks | Përfitimi Operacional: Ensures thorough material distribution within the mold prior to final compaction, critical for achieving structural integrity in hollow blocks | Ndikimi i ROI: Improves final product compressive strength by an industrytested 15%, allowing premium product pricing.
PalletFree Ejection System (Fakultative) | Baza Teknike: Belt conveyor takeaway system with softdrop mechanism | Përfitimi Operacional: Eliminates the cost, mirëmbajtjen, and logistics associated with wooden or steel pallets for green brick handling | Ndikimi i ROI: Removes ongoing pallet replacement costs (vlerësuar në $0.02$0.05 per brick) from the operational budget.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë (GjysemAutomatik) | Zgjidhja jonë e makinës për prodhimin e tullave | Avantazhi (% Përmirësimi) |
| : | : | : | : |
| Koha e Ciklit | 2225 seconds per block (manual feeding) | 1820 seconds per block (fully automatic) | ~ 20% qarkullim më i shpejtë |
| Kërkesa e Punës| 34 operators per shift for feeding & trajtimin| 1 operator per shift for supervision & pallet loading| Deri në 75% reduktim |
| Reject Rate| Në mënyrë tipike 58% due to inconsistent fill/compaction| Ruhet më poshtë 2% via automated dosing & Kontrolli PLC| Mbi 60% reduktimin e mbetjeve |
| Konsumi i Energjisë| Fixed pump hydraulics at constant draw| Variable pump system with energy recuperation| E dokumentuar 2530% kursimet |
| Koha vjetore e funksionimit| ~ 75%, factoring in mechanical adjustments & mold changes| >90%, supported by robust design & quickchange tooling| +15 pikë përqindjeje |
Based on field data from comparable twoshift operations.
5. SPECIFIKIMET TEKNIKE
Kapaciteti prodhues: I konfigurueshëm nga 2,800 deri në fund 8,000 blloqe standarde të ngurta (200mm x 100mm x 60mm) për ndërrim 8 orësh.
Kërkesat për fuqi: Makina kryesore e mundësuar nga një motor elektrik i rëndë; total connected load ranges from 45 kW në 75 kW në varësi të madhësisë së modelit.
Presioni i Sistemit Hidraulik: Operating pressure up to 25 MPa; system includes oil cooling unit for continuous operation.
Specifikimet e materialit: Compatible with concrete (C30C50), tokë e stabilizuar (clay/cement mix), and industrial byproducts like fly ash (>65%). Optimal moisture content range: 10%.
Dimensionet fizike (Tipike): Machine footprint of approximately L6m x W3m x H3m; weight varies from 18 tons based on capacity.
Gama e funksionimit të mjedisit: Designed for indoor installation; diapazoni i temperaturës së ambientit prej +5°C deri +40°C; requires level concrete foundation (Toleranca ±3 mm).
6. Skenarët e APLIKIMIT
Clay Brick Plant Modernization
Sfida: A regional clay brick manufacturer faced escalating labor costs and an inability to meet new national compressive strength standards using manual presses.
Zgjidhje: Implementation of two fully automatic hydraulic brick making machines equipped with clayspecific conditioning feeders.
Rezultatet:
Labor costs reduced by $85k annually per line.
Compressive strength consistently exceeded minimum standards by over 40%.
Production output increased by 35%, enabling expansion into new municipal supply contracts.
Concrete Block Producer Expanding Product Line
Sfida:A concrete block producer needed greater flexibility to produce both standard construction blocks and premium landscaping pavers without purchasing separate machinery.
Zgjidhje:A single highcapacity universal press was installed featuring our quickchange interchangeable mold system alongside a color dosing feeder attachment.
Rezultatet:
Changeover time between product families reduced from hours down under minutes.
Company captured 25% more market share in the local landscaping sector within one year using existing manpower.
Fly Ash Recycling Facility
Sfida:A thermal power plant's recycling arm struggledto find reliable equipment capableof processing highvolume fly ash into durable building materials due its abrasive natureand low cohesion properties when dry
Zgjidhje:The deploymentof specially hardened wear partsand enhanced vibration protocols withinour heavyduty press model optimizedfor cementstabilizedflyash mixtures
Rezultatet:
Achieved target density (>1800 kg/m³)and durability ratingsfor nonload bearing applications
Turneda costly waste streaminto revenue generatingproduct line meetinggreen building certifications
KONSIDERATA TREGTARE
Equipment pricing tiers are structured around production capacityand automation level:
1.Basic SemiAutomatic Model:Idealfor established producers seeking reliability upgrade.Entrylevel investment covers core presswith manual feedconveyor.Pricing typically starts inthe low sixfigure USD range dependingon configuration
2.Fully Automatic Standard Model:The most common selectionfor new plantsincludes complete automated batchingfeeding systemsand PLC control.This tier represents themidrange investmentwith clear operational payback periods
3.Turnkey Customized Solution:Pricedas projectspecific quotationincludes full plant designancillary equipmentlike mixerstacker/curing systemsand commissioning services
Karakteristikat opsionale& Përmirësimet:
Palletfree ejection systems(highly recommendedfor new facilities)
Automated robotic pallet stackers
Advanced color/surface texture attachments
Remote monitoring IoT packages
Paketat e Shërbimit:
12month comprehensive warrantyon all partsand laboris standard.Extended service agreements(ESA)covering scheduled maintenancepredictive part replacementare availablein year incrementsfinancially protectingyour operationagainst unexpected repair costs
Opsionet e financimit:
We workwith several international trade finance institutionsto offercompetitive leasing arrangementsor equipment loanstailoredto cash flow requirementsof growing businesses.Structured payment planscan often alignwith projected revenue increasesfrom improved production
FAQ
P:Whatrawmaterial preparationis requiredbefore usingthisbrickmakingmachine?
A:The machine requirespremixedmaterialwith consistent moisturecontent(typicallybetween%%).For concreteblocksa panmixeris prerequisite.For clayan extruderor pugmillmay be neededto achieveproper consistencyprior feedinginto presshopper
P:Canyour machines produceinterlocking bricksmeetinginternationalstandardslike ASTM C?
A YesOur interchangeablemold systemincludes designs certifiedto produceinterlocking concretepaving units(ICPUs)that complywith major internationalstandardsincludingASTM Cprovidingnecessarydimensional tolerancesstructural performancecharacteristicsrequiredby specifiersarchitects
Q Howlongdoes installationcommissioningtaketypically?
A Forstandardautomaticmodelinstallation foundation preparationby your teamfollowedby our technicians' mechanical electrical setuprequiresapproximately weeksCommissioningincluding trialrunsoperator trainingadds another weekassumingrawmaterialsare ready onsiteTurnkey projectsvarysignificantlybasedon scopecomplexityof ancillaryequipmentinvolvedbut detailedtimelineprovidedduringproject planningphasewillbe adheredto strictlyas partof contracttermsconditions agreedupon beforehand ensuringminimal disruptiontoyouroperations schedule commitments made clients customers alike during transition period new machinery implementation process completion handover procedures finalized satisfactorily both parties involved agreement reached mutually beneficial outcomes achieved successfully meetingall predefined objectives setout initially commencement works undertaken jointly collaborative manner throughout duration project lifecycle management approach adopted ensures smooth seamless integration into existing workflows where applicable otherwise establishment entirelynewproductionline capabilities according plan specifications outlined clearly documentation provided advance commencement activities onsite location designated facility premises owned operatedby customer entity purchasing goods services described hereinabove context thisdocument purpose clarification only not intended constitute legal bindingoffer sale unless otherwise stated separate formal agreement executed duly authorized representatives respective organizations party thereto subject governing law jurisdiction specified therein accordance terms conditions contained such document superseding any prior understandings communications whether oral written relating subject matter hereof except as expressly set forth said agreement amendment modification thereof made writing signed bothparties hereto effective date thereof indicated therein supersedes replaces all previous discussions negotiations understandings agreements proposals whether oral written relating thereto same extent they conflict inconsistent therewith notwithstanding anything else contained hereinabove below elsewhere thiscommunication correspondence exchanged between us you regarding potential transaction(s).
