1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Lợi nhuận sản xuất gạch của bạn có bị ảnh hưởng bởi chất lượng không nhất quán không?, sự phụ thuộc lao động cao, và thời gian ngừng hoạt động quá mức? 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leading to a 515% breakage rate, inconsistent mixing causing batch rejections, and the financial drain of maintaining outdated, unreliable equipment.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. TỔNG QUAN SẢN PHẨM

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 (chất rắn, đục lỗ, rỗng). The operational workflow is engineered for minimal intervention:
1. Nguồn cấp dữ liệu tự động: Prepared clay is conveyed uniformly into the machine’s feed hopper.
2. Đùn áp suất cao & Cắt: 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 & Chuyển khoản: Green bricks are systematically placed onto setting carts or pallets for transport to the drying chamber.

Phạm vi ứng dụng: Ideal for established brick yards targeting production from 20,000 ĐẾN 100,000+ bricks per day shift. Suitable for a variety of plastic clays.
Hạn chế: Requires a consistent feed of properly prepared clay (adequate crushing, trộn, and tempering). Not designed for onsite mobile construction projects or for nonplastic soils without binder additives.

3. TÍNH NĂNG CỐT LÕI

Vacuum DeAiring System | Cơ sở kỹ thuật: Highefficiency vacuum pump creating >95% vacuum in the extrusion chamber | Lợi ích hoạt động: Removes air pockets from the clay body, significantly reducing laminations and cracks during drying and firing | Tác động 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 & lót | Cơ sở kỹ thuật: Wearresistant chromium alloy components with hardened flight edges | Lợi ích hoạt động: Maintains precise extrusion pressure over extended periods, reducing wearrelated downtime and output consistency drift | Tác động ROI: Extends service life by approximately 40% compared to standard carbon steel, lowering longterm parts replacement costs.

Ổ tần số thay đổi (VFD) Điều khiển | Cơ sở kỹ thuật: Precision motor control via programmable logic controller (PLC) | Lợi ích hoạt động: Allows operators to finetune extrusion speed and torque based on clay plasticity, optimizing output quality and preventing machine jamming | Tác động ROI: Reduces energy consumption by matching power draw to load requirements and minimizes scrap from suboptimal settings.

QuickChange Die & Mouthpiece Assembly | Cơ sở kỹ thuật: Standardized bolting system with alignment pins | Lợi ích hoạt động: Enifies changeover between different brick profiles (ví dụ., from solid to perforated) ở dưới 45 phút | Tác động ROI: Increases plant flexibility and reduces nonproductive time during product changeovers by an average of 60%, allowing responsive fulfillment of diverse orders.

Hệ thống bôi trơn mỡ tập trung | Cơ sở kỹ thuật: Automated pump delivering lubricant to all critical bearing points on a timed cycle | Lợi ích hoạt động: Ensures consistent lubrication under highload conditions, preventing premature bearing failure and unplanned stops | Tác động ROI: Thử nghiệm trong ngành chứng tỏ một 30% reduction in bearingrelated breakdowns, enhancing overall equipment availability.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Máy thông thường) | Premium Affordable Brick Making Machine Solution | Lợi thế (% sự cải tiến) |
| : | : | : | : |
| Brick Output Consistency | ±5% dimensional tolerance; visual surface defects common | ±2% dimensional tolerance; superior surface finish from deairing | 60% improvement in tolerance control |
| Tiêu thụ năng lượng mỗi 1000 Gạch| High fixed consumption; hệ thống truyền động kém hiệu quả| VFDoptimized consumption; efficient gearbox design| Lên đến 18% reduction in kWh usage |
| Thời gian trung bình giữa các lần thất bại (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% chuyển đổi nhanh hơn |
| Labor Requirement for Operation| 34 người vận hành cho ăn & xử lý| 12 người vận hành chủ yếu để giám sát & quản lý pallet| ~50% reduction in direct labor |

5. THÔNG SỐ KỸ THUẬT

Năng lực sản xuất: Các mô hình có thể cấu hình từ 12,000 đến hơn 36,000 gạch tiêu chuẩn mỗi giờ.
Yêu cầu về nguồn điện: Main extruder motor from 90 kW để 160 kW (tùy thuộc vào mô hình); total connected load includes vacuum pump (~15 kW) và hệ thống băng tải.
Thông số vật liệu: Accepts clay with plasticity index (Atterberg Limits) suitable for extrusion; maximum feed particle size ≤8mm.
Kích thước vật lý: Typical footprint ranges from L12m x W4m x H3m (for core unit).
Phạm vi hoạt động môi trường: Designed for ambient temperatures of 10°C to +45°C with appropriate weather protection; requires a stable, level concrete foundation.

6. KỊCH BẢN ỨNG DỤNG

MediumSized Brick Yard Expansion

Thử thách: 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.
Giải pháp: Implementation of a midrange premium affordable brick making machine with automated palletizing and VFD control.
Kết quả: 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

Thử thách: An engineering contractor secured a project requiring specific perforated bricks on a tight timeline but lacked specialized equipment.
Giải pháp: Procurement of a premium affordable brick making machine equipped with quickchange die systems for both solid and perforated profiles.
Kết quả: 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. CÂN NHẮC THƯƠNG MẠI

Bậc giá: 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 & tự động hóa cơ bản.
HighCapacity System (~30k+ bricks/hour): Fullfeatured with advanced PLC automation and telemetry options.
Tính năng tùy chọn: Upgrades include remote monitoring packages, specialized alloy wear parts packages for abrasive clays, or integrated autostacking systems.
Gói dịch vụ: Choose from annual preventive maintenance contracts offering guaranteed response times or payperservice technical support plans tailored based on expected annual operating hours.
Tùy chọn tài chính: 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. Câu hỏi thường gặp

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 Thời gian vận hành cài đặt điển hình là gì?
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 Các điều khoản thanh toán có sẵn là gì?
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