Brick Machine Production Efficiency Enhancement in Practice: From Cycle Time Optimization to Rapid Mold Changeover
Brick Machine Production Efficiency Enhancement in Practice: From Cycle Time Optimization to Rapid Mold Changeover
1 Abstract With the deepening of global climate change action, the building materials industry faces increasingly stringent carbon constraints. As the core equipment in block production, brick making machines urgently require systematic research and solutions to their carbon emissions. This paper takes the entire brick making process as the research object, constructing a carbon emission analysis framework covering raw material processing, molding, curing, and solidification, systematically identifying major emission sources and their generation mechanisms. Based on this, a multi-level, phased emission reduction pathway system is proposed, covering process optimization, equipment modification, energy substitution, and management improvement, providing theoretical basis and practical guidance for the low-carbon transformation of brick making machine production.
2 Decomposition Framework for Carbon Emissions from Brick Machine Production
2.1 Emission Source Identification and Classification
Carbon emissions from brick machine production mainly originate from three levels:
Direct energy consumption emissions: including indirect emissions from fossil fuel combustion or electricity use, such as electric drive and heat supply.
Raw material conversion process emissions: involving greenhouse gases released during the physical and chemical changes of raw materials, such as crushing, mixing, and molding.
Auxiliary system operation emissions: covering energy consumption emissions from auxiliary equipment such as cooling, dust removal, and transmission.
2.2 Emission Structure Analysis Method
A decomposition model is established based on the intersection of three dimensions: "process-energy-raw materials":
By production process: emission characteristics of pretreatment, molding, curing, and post-treatment stages.
By energy type: emission contributions from different energy carriers such as electricity, steam, and fuel.
By raw material category: carbon footprint differences of raw materials such as natural aggregates, industrial solid waste, and binders.
2.3 Emission Hotspot Identification Logic
Through qualitative comparison and theoretical derivation, the following emission hotspots are identified:
Energy conversion efficiency bottlenecks in high-energy-consuming processes
Inherent emissions from raw material chemical reactions
Redundant energy consumption due to poor system matching
3. Multi-Dimensional Emission Reduction Path System
3.1 Process Optimization Path
Raw material compatibility optimization: Reducing process temperature and time requirements by adjusting aggregate gradation and binder selection.
Process reengineering design: Reorganizing the production sequence to reduce energy conversion cycles and heat loss.
Precise parameter control: Establishing a dynamic adjustment mechanism for key process parameters.
3.2 Equipment Upgrade Path
Power system transformation: Improving the energy conversion efficiency and load adaptability of drive units.
Thermal system optimization: Improving the heat transfer efficiency and temperature uniformity of heating devices.
Waste energy recovery and utilization: Constructing a recycling system for low-grade energy such as waste heat and waste pressure.
3.3 Energy Structure Path
Clean energy substitution: Gradually increasing the proportion of renewable energy in the energy structure.
Multi-energy complementary configuration: Establishing a diversified energy supply system adapted to production fluctuations.
Energy storage technology application: Utilizing energy storage devices to smooth out peak energy demand.
3.4 Management Improvement Path
Carbon Emission Monitoring System: Establish a carbon emission tracking and reporting mechanism covering the entire process
Continuous Improvement System: Form a production optimization cycle based on carbon performance
Supply Chain Collaboration: Promote carbon management collaboration among upstream and downstream enterprises
4. Implementation Framework and Guarantee Mechanism
4.1 Phased Implementation Strategy
Short-term Focus: Primarily low-cost and quick-resulting technological transformation
Mid-term Planning: Promote process innovation and systematic equipment upgrades
Long-term Layout: Achieve energy structure transformation and production model restructuring
4.2 Key Technological Support
Adaptive improvement of carbon footprint accounting methodology
Innovative research and development of low-emission process technologies
Development and application of intelligent carbon management systems
4.3 Institutional Guarantee System
Construction of internal carbon management organizational structure for enterprises
Design of carbon emission reduction performance evaluation system
Improvement of industry standards and norms system
5. Conclusion and Outlook
This study, by constructing a framework for decomposing carbon emissions from brick machine production, systematically reveals the formation mechanism and interrelationships of multi-dimensional emission sources. The proposed emission reduction path system breaks through the limitations of traditional reliance on specific data, forming a theoretical framework with universal guiding significance. Future research should deepen in the following directions: First, explore the path adaptation adjustment mechanism under different regional and climatic conditions; second, study the impact mechanism of policy tools such as carbon trading markets on emission reduction path selection; and third, construct a comprehensive evaluation system covering economic and technological feasibility. Through continuous theoretical innovation and practical exploration, carbon emission reduction in brick machine production will provide important support for the green transformation of the building materials industry and contribute to the achievement of global carbon neutrality goals.
Innovation Points:
6. Implementation Key Points and Management Recommendations
6.1 Phased Implementation Strategy
It is recommended that enterprises implement the strategy in three phases based on their own conditions: The first phase focuses on optimizing cycle time, achieving rapid results through parameter adjustments and minor equipment modifications; the second phase implements standardized mold modifications to establish the foundation for quick changeover; the third phase improves the management system to form a continuous improvement mechanism.
6.2 Key Success Factors
Senior Management Support and Investment: Improving production efficiency requires equipment investment and system upgrades, necessitating management support.
Cross-Departmental Collaboration:Involving multiple departments such as equipment, process, production, and maintenance, an effective collaboration mechanism is essential.
Employee Training and Participation: Skill enhancement for operators and maintenance personnel is crucial for successful implementation.
Continuous Improvement Culture: Establishing a regular evaluation and optimization mechanism to continuously explore improvement potential.
6.3 Risk Control Measures
Develop detailed implementation plans and timelines to control the impact of the upgrade process on production; conduct thorough testing and verification before major upgrades; establish contingency plans to ensure rapid production recovery in case of problems during the upgrade process.
7. Conclusion and Outlook
This paper systematically studies practical methods for improving brick machine production efficiency, focusing on solving two key issues: cycle time optimization and rapid mold changeover. Through comprehensive measures including equipment upgrades, process optimization, and management improvement, a complete efficiency improvement solution was formed. Practice has proven that this solution can significantly improve equipment utilization, reduce production costs, and improve product quality, demonstrating high promotional value.
Future research directions include: the development of intelligent production efficiency monitoring systems to achieve real-time optimization of the production process; the application of mold life prediction technology to establish a scientific mold replacement decision-making mechanism; and the introduction of digital twin technology to verify the effectiveness of optimization schemes in advance through virtual simulation. With technological advancements and management innovation, brick machine production efficiency will continue to improve, injecting new momentum into the industry's development.
