Brick factory equipment. Production of bricks at the factory and machine. Manufacturing Technology Brick Factory Production Equipment Line
Entrepreneurs, both new and experienced, are wise to pay attention to the construction market. Every year it develops more and more, so any product intended for this market will be in demand. Today in this article we will talk about how to establish your own brick production.
In any season, there is a stable demand for brick, so it is quite profitable to produce it. And although there are a lot of competitors in the market for the production of building bricks, the increase in the pace of construction makes it possible for potential entrepreneurs to work for the future. By the way, experts predict for the next few years that the growth rate of the brick market will be approximately 4-5% annually.
Start
From the very beginning, you need to find a room that will be suitable for the production of bricks. Looking for a shop minimum size which is at least 500 square meters in order to completely and without any problems place a brick production line. It is clear that this room can be rented, and not redeemed as a property. Abandoned workshops, factories, plants, out-of-town warehouses, etc. are ideal for this. The rent for such premises will not be very high.
Note that the production of bricks, unlike other industries, does not require a mandatory connection to the sewerage system, which will save a lot of money, time and effort.
The room for the production of bricks should ideally consist of three zones (a warehouse for raw materials, a workshop for production, a warehouse for finished products) with a ceiling height of at least five meters. It is better, of course, to choose a building so that the ceiling height is even higher.
Range
Brick can be divided according to the following criteria:
- According to its composition and technology - for ceramic, silicate, acid-resistant, clinker, brick - expanded clay;
- By size - for single, one and a half, double and non-standard;
- By appointment - for facing, construction and special;
- In terms of strength - for full-bodied (voids not more than 45% of the volume), hollow (voids not more than 13% of the total volume);
- By type of surface - smooth, embossed, and with a chipped surface;
- For frost resistance, there are grades F15, F25, F30, F50, F100;
- By water absorption - the designation of this indicator should be in the range from 6 to 16%. The largest indicator is determined for clinker bricks.
Brick Making Equipment
After finding the premises and preparing it for use, you need to start buying the necessary equipment for production:
- Mixer. Used for mixing clay mass.
- Sludge strip cutting machine. The resulting mixture is cut into strips.
- Raw brick cutting machine. The resulting strips are cut into raw bricks.
- Bake. It is usually built, not sold. But it's on sale ready-made options though they are small. An oven is not required when using the hypercompression method in production (see below).
- Dryers. They are tunnel and chamber. Dryers are not required with the traditional method of production by firing only.
- Trolleys, carts etc.
This list can, of course, be supplemented with various automatic developments, but the most basic thing is presented above.
Manufacturing methods
As you know, brick is produced in several ways and sometimes with different equipment.
Manufacturing Methods:
- plastic forming method. The finished mixture is cut into raw bricks and they are allowed to dry. After drying, they are fired. This method is considered the most costly. It is economically justified to use it in the annual production of more than 30 million pieces of bricks.
- Hyperpress method. This method of brick production is considered relatively new, giving high quality products. It is economically justified to use it in the annual production of more than 20 million pieces of bricks. It requires a stationary vibpropress. Such an automatic press costs from 1 million rubles. More about hyper-pressed brick.
- Traditional firing method. This method of production is considered the oldest of all the above methods and, accordingly, the cheapest. It is economically justified to use it in the annual production of more than 400 thousand pieces of bricks.
Now hyper-pressed brick is in high consumer demand, it is distinguished by its chemical composition and production process.
The method of brick production depends only on how much financial resources you are willing to invest in production. To start the first type of brick production, you need about 100 million rubles. To start the second type - 10 million rubles. To start the third type - 2 million rubles.
After determining the type of equipment that will be used in the business, you need to find its supplier. Today it will not be difficult, because. equipment of this type is sold in almost every region. You just need to remember that by purchasing it from reliable and trusted suppliers who are close to you, you make your life easier. Firstly, it will make commissioning easier. And, secondly, it will greatly simplify the maintenance of your plant in the future.
If we consider the line for the production of bricks, then it consists of a screen, a crusher, a receiving hopper, a concrete mixer, a molding unit, a two-arm chute, an elevator, a compressor, an output hopper.
You need four workers to operate the line, even though brick production is semi-automated. Believe me, there is enough work for everyone.
Based on practice, a brick factory pays off from one to three years. It all depends on the type of production. As you can see, this business has serious prospects due to its profitability.
Production at home
This type of activity can be organized at home. Making bricks at home will require very little effort from you. In order to verify this, we suggest you watch a video on this topic:
Such a brick is perfect for buildings on your site, and the equipment will cost you quite inexpensively for it.
For thousands of years, brick has been considered the most popular material suitable for the construction of various buildings and buildings. Until relatively recently, bricks were produced by hand, using special hand presses and kilns. These simple devices formed the basis of modern automated equipment, which made it possible to minimize labor costs in the field of brick production.
Brick production methods in a brick factory
Depending on the production technology, there are two main methods of brick production. The firing method involves placing the clay mass, pre-treated with belt presses, into special kilns for subsequent firing and obtaining the finished building material. The non-firing method does not require an oven - the material dries naturally. To begin with, the raw material is crushed to a particle size of no more than 3-5 mm, after which it is combined with water and cement, and then pressed. For the pressing procedure, vibropress machines, hyperpresses or tribopresses are required.
A brick factory is a complex production that requires the owner to know the specifics of this business and a number of subtleties. Of course, the production of bricks is a very profitable occupation, which leads to the constant emergence of new players in the market. industrial production. You can start with a mini-factory, gradually developing and turning the existing production into a large enterprise. To a greater extent, the efficiency of work depends on the available equipment.
The main equipment of the brick factory
Let us give an example of the equipment necessary for the operation of a brick mini-factory, which allows to produce from 3 million bricks per year.
- 1) Equipment for the preparation of the main raw material (clay) is the first stage of production. To obtain a homogeneous clay mass and separate stones from it, rollers are used.
- 2) For pressing clay. At this stage, the clay mass is placed in special machines for pressing. The belt press used in the production of bricks using firing technology is connected by a wire to a cutting machine, which allows the product to be molded. Brick made using non-fired technology involves the use of hyper-pressing or tribo-pressing methods, which are "cold welding". Finely ground mineral materials with the addition of a small amount of water and cement are pressed under high pressure
- 3) For moving bricks (special). For transportation of bricks to the drying chamber, wooden frames (drying slats or drying trays) are used. They are located below the material conveyor and move at a speed slightly faster than the clay belt.
- 4) For drying bricks (drying chambers). The molded bricks are transported to dryers, which are of three types, depending on the type of heating. Natural drying is used in cases where the volume of produced bricks is relatively small. Such drying takes a long time and requires free space to accommodate the material. During artificial drying, steam is used, which remains after firing bricks, or gases of combustion products. The drying process of the bricks takes place due to hot air (its temperature is 350-400 ° C), which is fed directly from the furnace into the drying chamber, for which an exhauster is used. Fans installed in the chamber allow even distribution of hot air and prevent premature drying of the surface. Flue gases for drying bricks are used much less frequently, since underground pipes or channels must be laid to get them into the drying chamber.
- 5) Equipment for roasting - special kilns are one of the most important components of production. As a rule, modern plants are equipped with tunnel-type furnaces, although there are ring-type furnaces. Inner part furnaces are laid out with fireclay refractory bricks. There are three main zones of the furnace: the preparatory zone, the firing zone, the zone for cooling the material. Bricks are fired by burners installed on the sides of the kiln or at the top. The firing procedure takes place at a very high air temperature - from 900 to 1000 ° C, which affects excellent properties this building material. Finished brick has a different color, depending on the composition of the feedstock and the degree of firing. In any case, the material must be matte, free of cracks, chips and internal voids, and produce a ringing sound upon impact.
- 6) For packaging - brick packaging lines. After firing, the material is transferred to product pallets for subsequent wrapping. Automated equipment for capturing bricks from kiln trolleys allows you to work without interruptions and disturbances. Bricks are packed mainly with stretch film or metal / polyurethane tape.
So, high-quality equipment is the key to the efficient operation of a brick factory. The relevance of this material for builders and architects determines the constant demand for bricks, which accordingly affects the income level of brick production owners and allows you to quickly recoup the funds invested in the business. Production, equipped with high-quality machines and devices, will not only speed up the workflow and facilitate the work of employees, but also help to expand the range of products.
For many centuries of the history of building materials, brick has established itself as a reliable universal material. The latest developments in the construction industry are not able to completely force bricks out of the market, and this situation will continue for a long time to come. Brick is excellent for the construction of capital buildings and structures due to its properties. The production of bricks from clay has not undergone significant technological changes over the past few centuries, but other methods for making blocks for brickwork have appeared. Among them, the most popular technologies are the production of sand-lime bricks, as well as the use of high pressure as an alternative or addition to firing.
Types of bricks and their characteristics
It is customary to call bricks solid blocks for laying structures of certain sizes. With a large deviation from the standards of length, width and height, products are already referred to simply as building blocks. Single, simple brick Russian production they are made 250 mm long, 120 mm wide and 65 mm high, there are also one and a half and double versions with a height of 88 and 138 mm, respectively. Europe has adopted its own standards for brick sizes, which is associated with the historical development of the measurement system. The material for making bricks can be a large number of loose and crushed substances, but the most popular are clay and sand with lime. This is reflected in the name of the blocks, red ceramic bricks are made almost entirely of clay, while the production of sand-lime bricks is based on a mixture of sand and lime. The characteristics of such a material are somewhat lower than those of ceramic, which is offset by a relatively low price. The third type of hyper-pressed blocks can consist of a wide variety of materials, depending on the characteristics planned by the manufacturer. All three main types are divided into a large number of subtypes with different properties and applications.
Technology
Methods for the production of bricks vary, depending on the raw materials used. The technology for the production of clay bricks using high-temperature firing has remained unchanged for several thousand years, while the manufacture of silicate bricks began only at the end of the 19th century. Sand-lime brick does not require firing, like ceramic, instead, the mixture is exposed to water vapor under great pressure. Hyperpresses for the manufacture of brick blocks generally arose relatively recently, this method does not use high temperatures to form a solid material. Nevertheless, hyper-pressed bricks are not inferior in their properties, and often surpass their "ancient counterparts". Experts compare such material with high-quality clinker bricks.
Production of ceramic bricks
Equipment for the production of bricks from clay by plastic or semi-dry methods should include the following mandatory units and premises:
fireclay brick
In the construction of furnaces and other refractory surfaces, the use of ordinary bricks is unacceptable. Silicate brick is not able to withstand even the temperature of an ordinary fire of burning wood, and a simple ceramic block loses its strength properties at temperatures above 800 ° C. Yes, and constant temperature fluctuations adversely affect the properties of ordinary bricks. A material is required that can withstand periodic high heat and subsequent cooling over a long service life. One of the most popular refractory materials is fireclay bricks, which are based on the production of bricks from special clay - fireclay. Equipment for the production of bricks from it is similar to that described above, but distinctive features From the production technology of conventional ceramic blocks are two stages:
When preparing raw materials, refractory clay undergoes preliminary high-temperature treatment; mineral additives, in particular aluminum oxide, are used to improve the refractory properties of the finished product.
Raw firing does not occur at 1000 ° C, and at 1500 and above, the firing time is at least 5 hours.At such temperatures, sintering of the material occurs and the transformation chemical composition generally.
The porosity of fireclay bricks determines its strength and thermal insulation properties.
Clinker blocks
Wall cladding and other structural elements are not only beautiful appearance material, but also its resistance to weathering and mechanical damage. Manufacturers of bricks since the 18th century have produced a particularly durable material, comparable in wear resistance to natural stone. The name comes from German for the sonorous response of a brick when tapped, which is not surprising, because clinker blocks are one of the densest materials in their class. Clinker production of bricks imposes increased requirements on the quality of raw materials, it is required to control the content of iron, calcium and magnesium oxides, as well as a sufficient content of aluminum oxide. The firing temperature of the facing material according to this technology is 1000-1400 ° C, otherwise production technology repeats the method of obtaining ordinary ceramic bricks. One of the main disadvantages of clinker ceramic blocks is their good thermal conductivity, therefore, when facing the outer walls of a building, additional heat and sound insulation may be required. Bricks using this technology are produced in a variety of designs,including those with voids on the rear b side and glaze on the front.
Silicate brick production technology
The process of forming solid blocks from a mixture of lime and sand is based on the heat treatment of the finished solution and arose relatively recently, while the use of the mixture in construction dates back a couple of millennia. In the production of silicate bricks, 3 main stages can be distinguished: preparation of raw materials, lime slaking and the actual production of blocks. Preparation includes the following steps and devices:
Seeder for sand. The fraction of sandy raw materials should be no more than 2.5 mm, in addition, the sifting process allows you to clean the sand from organic inclusions.
Plants for grinding quicklime.
It is possible to install a silo for preliminary slaking of lime
Apparatus that doses the supply of raw materials into the mixture. The mixture is 90-92% sand, the rest is slaked lime, color pigments and modifiers.
Lime slaking plants are divided into 2 types:
Drum installations using water vapor allow you to quickly complete the process of quenching in the mixture, but they are energy-intensive.
Multi-section silos allow for a continuous flow of finished mix, even though the reaction can take up to 10 hours.
At the last stage, blocks are formed in pressing machines and the raw material is sent to the autoclave, where, under pressure and under the influence of water vapor, high temperature calcium hydrosilicate compounds are formed in the brick, which provides hardness to the building block. Autoclave processing lasts 10-20 hours, so the installation of several autoclaves will be required for in-line production.
vibropress
This machine for the production of bricks and other blocks based on building mixtures is quite versatile, because the replacement of molds can be done without significant modifications to the entire plant. On sale there are models equipped with dispensers, mixers and even transporters of products to the place of drying or additional processing.
Hyper pressed brick blocks
This manufacturing option does not use heat treatment at all, as it is based on the astringent property of cement. The production line is reduced to a minimum, which allows it to be placed in a small area. The equipment, in addition to the hyperpress itself, may include the following installations:
Filtering and crushing equipment for grinding raw materials and removing organic debris.
Dispenser for automatic control over the supply of components.
The mixer can be built into the design of the hyperpress.
Installation of transportation of bricks to the storage place.
Ready-made options for mini-factories
Despite the abundance of manufacturers, the building materials market is not oversaturated, according to experts, they also note a stable annual growth in demand and construction volumes. Therefore, your own mini-brick factory can become a profitable family business. The payback of such a business can be from one to two years, depending on the established production and qualifications of workers, as well as marketing routes. finished material. The minimum investment for technological equipment and commissioning can be from 3 million rubles. up to 1 billion. To this should be added the rental of suitable premises and the purchase of raw materials. It is especially worth paying attention to the production of hyper-pressed bricks, which require the least amount of space to accommodate installations.
production in the garage
To open the production of bricks in the local area, it will be enough to spend money on a hyperpress, then all other operations will have to be done manually. The cost of such a brick will be the lowest, but labor costs are much higher.
Conclusion
The profitability of the brick business is confirmed by many examples. However, production will require not only serious financial investments, but also efforts to maintain the workflow, to control quality and to find distribution channels. In a year or two, the efforts will definitely pay off with a stable profit.
Experienced entrepreneurs and start-ups have always directed their interests towards the construction industry sector. From year to year, the construction market is expanding, creating an opportunity for businesses to compete adequately and develop dynamically.
Brick is one of the most used materials in this area, the need for which is not reduced for any season. Business analysts inform about the annual growth in consumer demand for bricks up to 5%. This becomes a motivating factor for entrepreneurs whose areas of interest cover the construction market segment.
In any business design, perspective is important, hence the expediency of investing in this particular type of activity. The production of bricks is classified as successful, which is due to the quick (annual) payback of the project. The choice of premises, method, equipment will be the key to successful business, make it profitable.
Brick production as a business idea
Where to begin
Initially, you need to decide on the room where the main brick-making equipment will be located. An area of more than 500 m² is ideal for a full-fledged brick production line. The height of the ceilings for the production workshop should start from 5 m. The premises of the future plant can be searched among the empty factories, warehouses, hangars. If these areas are rented, then the price will be suitable. It is possible to purchase the premises for personal use. The form of ownership will directly depend on the available financial capabilities.
For brick production, it is not at all necessary to connect to sewer system. Such an advantage can save money, time to choose a room, and your strength. It will be better if the building is divided into three sectors (raw materials warehouse, production workshop, storage room).
Types of produced bricks
Products are usually divided according to the following parameters:
1. Composition - manufacturing technology is determined:
- acid resistant
- Expanded clay containing
- Ceramic
- Clinker
- Silicate.
2. Brick dimensions:
- Single;
- Double;
- non-standard;
- One and a half.
3. Industrial Application:
- Special appointment;
- Building cladding;
- For classical construction, erection of walls, partitions.
4. The structure of the brick body.
- full bodied
- Hollow
5. Surface.
- chipped surface;
- Embossed surface;
- Smooth structure.
6. Resistance to low temperatures (5 types of frost resistance grades).
7. Indicators of water absorption. A high rate is noted for clinker bricks, in other cases the limit of 6-16% is considered the norm.
Basic equipment for making bricks in a factory
The main thing is to place the main equipment for production, additional equipment can be purchased later.
The brick production line necessarily includes:
1. Mixer. Designed for kneading clay mortar.
2. Mechanism for automatic cutting of clay mass into strips.
3. A mechanism for automatic cutting of a raw product from the obtained clay strips.
4. Kiln for roasting. Basically, this equipment is built independently, but you can buy ready-made small sizes. For hyperpressing no oven required.
5. Drying of finished products. They look like a chamber or a tunnel. Special drying is not required if the production is reduced to the manufacture of products only by firing.
6. Trolleys for transportation, trolleys.
1. Method of plastic formation. The kneaded clay mixture is cut into raw products, and then they wait until they dry. After drying, put in a kiln for firing. This manufacturing method is too costly, and the expediency of its production is justified if the output of finished products reaches 30 million units per year.
For starters, it will be enough to invest 100 million rubles.
2. Hyperpressing. Distinguished by its novelty, high quality. The basis for its application should be the production of finished products of at least 20 million units annually. Method hyperpressing will require the purchase of a stationary automatic vibropress, the price of which may exceed 1 million rubles. At the moment hyperpressed products are the most demanded in the construction market because of their chemical properties, quality indicators, production method.
Such a method of production would require a capital of 10 million rubles.
3. Traditional firing. Known since ancient times. It is distinguished by low cost, the ability to use more than 400 thousand units per year in the production of finished products.
To start producing products in this way, it will be enough to invest 2 million rubles.
Having decided on the method and type of equipment used, it is necessary to enlist the support of the supplier. Now it is not as difficult as before, because any equipment is easy to find in any Russian region. It is better to work with trusted suppliers whose office is located within easy reach of. This will allow regular maintenance of the brick shop in technical terms, simplifying the commissioning as well.
The production line for the manufacture of finished products consists of a screen, a crushing mechanism, a receiving hopper, a concrete mixer, a molding plant, a two-hose chute, lifting equipment, a compressor, an output hopper.
A semi-automated brick production line will require four workers to operate. A sufficient amount of work will be distributed to all specialists. Recruitment for work has the advantage: no special skills or diplomas are required.
homemade lego bricks
Even this type of private activity can be organized at home. The cost of equipment, effort for this kind of production will be much less than for industrial production. At the exit, such a product will be a good option for display suburban buildings, tracks.
Buying a machine for the production of homemade Lego bricks will result in an amount of 15 thousand rubles. But its productivity will be low: enough to ensure its own construction, but not enough to sell such volumes (only 1 brick is molded at a time).
Although after watching the video, I want to buy myself this:
Notes.
The above business project can be applied to the prospective, practical organization of a small business, however, each entrepreneur determines his needs and opportunities on his own.
The constantly developing construction segment of the economy gives businessmen the opportunity to develop almost any area of the construction market. The payback of a business project for the manufacture of bricks ranges from 1 to 3 years, which is due to the method chosen by the type of production.
Mold movement speed, m/min | 1,5 |
Overall dimensions, mm: | 2250x1690x1610 |
Weight, kg: | 1765 |
Supercharger swing frequency, swing/min | 50 |
Supercharger stroke vertically, mm | 40 |
Supercharger stroke horizontally, mm | 160 |
Supercharger drive power, kW | 4 |
Form displacement drive power, kW | 2,2 |
Number of forming cells in the form, pcs | 4 |
Overall dimensions of blocks, mm: | 390x190x90 |
Productivity max, blocks/hour: | 150 |
Mains voltage, V | 380 (220, 200) |
Current frequency, Hz | 50, 60 |
Control | push-button |
PK250 - a complex for the manufacture of building blocks
The equipment is used in production at a construction site or in a workshop. It can work with soil-sand, soil-cement compositions, as well as various low-moisture and loose masses. The company conducts patented activities. It is documented by patents:
No. 2340446 for the production of devices for working with bulk and plastic materials;
No. 2416516 for the method of forming products by the method of batch compaction.
The rich nomenclature includes complete systems for the production of building materials. Products are available at manufacturer's prices. Delivery across the country is possible. Sales managers will answer all questions by phone and indicate the cost.
Description and characteristics
Model PK250 is designed to create building materials by batch compaction. It uses a low-moisture free-flowing composition in the process, in particular with mixtures of soil, sand and cement. The main advantage is the application directly on the construction site.
The unit is designed to meet all standards and meets current requirements. The model has a number of advantages:
Profitability due to low energy costs;
Minimum consumption of the mixture;
High productivity in the processing of fine-grained, soil-sandy and low-moisture raw materials;
Ease of operation and maintenance;
The quality of finished products;
Low cost;
Same density.
The machine operates with an impeccable batch compaction technique that outperforms all other molding methods. The main advantages of the technique are the low price and the efficiency of the production process. The design of the complex is based on several modules. This simplifies the installation process and Maintenance. It is possible to use 4 types of forms at once. PK250 eliminates the cost of creating an expensive foundation.
Design features
The equipment is based on several separate parts that work together and form single system to create products High Quality. Components of PK250:
Chopper - performs the function of preparing the composition before serving. Prevents solid parts from entering the system and prevents machine breakdowns.
Molding machine - evenly distributes the components when creating products;
Conveyor belt - guarantees the feed at the right speed;
Mixer - is responsible for maintaining proportions when combining a mixture of different consistency.
The technique has unique technical characteristics. PK250 has a capacity of 150 blocks per hour. Push button controls make it easy to use. Model characteristics: dimensions 2250x1690x1610 mm and total weight 1.765 tons. The supercharger swings at a frequency of 50 times per minute. It moves horizontally and vertically by 160 and 40 mm. Each form is equipped with four cells for finished blocks with parameters 390x190x90. Requirements from the network -380 (220, 200) V. The blower drive has a power of 5 kW. Specifications ensure convenient and efficient use.
Cooperation and company advantages
Sales managers are ready to answer in detail all questions regarding the configuration and modes. You can find technical details and prices, as well as get help choosing the right configuration. The company's specialists will help with installation and configuration, as well as tell you about the intricacies of connecting to the engineering network. It is possible to train personnel and perform commissioning manipulations.
The manufacturer gives a guarantee for complexes for the production of building material. Maintenance and repair is carried out within the agreed time frame and taking into account the interests of the client. Advantages of the Kuvandyk plant "Valley".