Fully Automatic Brick Packing Machine and Brick Making Machine: A Golden Combination of High Efficiency

Fully Automatic Brick Packing Machine and Brick Making Machine: A Golden Combination of High Efficiency

In modern brick factory production processes, the compatibility between fully automatic brick packing machines and brick making machines has become a key factor determining production efficiency, cost control, and product quality. Through technological integration and process optimization, these two types of equipment have formed a complete closed loop from raw material forming to finished product bundling, providing core support for brick factories to achieve intelligent and large-scale production.

I. Core Value of Compatibility: From "Breakpoint Production" to "Closed-Loop Efficiency"

In the traditional brick production model, bricks formed by brick making machines need to be manually transferred, stacked, and packaged. This is not only time-consuming and labor-intensive but also suffers from problems such as irregular stacking, unstable packaging quality, and high labor costs, becoming a "breakpoint" restricting the improvement of production line efficiency. The core value of the effective compatibility between fully automatic brick packing machines and brick making machines lies in opening up the entire "forming-packing" process, realizing automated closed-loop operation from brick blank forming to finished product packaging.

On the one hand, well-matched packaging equipment can precisely match the output speed of the brick machine with the brick specifications, avoiding production line stagnation caused by poor equipment integration and maximizing production capacity. For example, a fully automatic brick machine with an annual output of 10 million standard bricks, when paired with a suitable brick-threading and packaging machine, can increase the efficiency of the packaging process to match the output efficiency of the brick machine, increasing the overall production line capacity by more than 30% compared to manual packaging. On the other hand, automation can significantly reduce human intervention, decreasing the brick breakage rate caused by human error, while ensuring the neatness and sturdiness of the packaging, improving the safety of finished product transportation, and reducing loss costs. Furthermore, suitable automated equipment can reduce production space occupation, optimize workshop layout, and lay the foundation for lean manufacturing.

II. Key Dimensions of Adaptation: Precise Matching for Efficient Collaboration
Adapting a fully automatic brick-making and packaging machine to a brick-making machine is not a simple matter of equipment splicing. It requires precise matching across multiple dimensions, including brick-making machine characteristics, brick parameters, and production needs. The core adaptation dimensions mainly include the following:

(I) Capacity and Speed ​​Adaptation: Building a Solid Foundation for Collaboration
Capacity adaptation is a prerequisite for collaborative operation. Different models of brick-making machines have significantly different output speeds, ranging from hundreds to thousands of bricks per hour. The processing speed of the fully automatic brick-making and packaging machine must be precisely matched with the brick-making machine's capacity—neither insufficient packaging speed leading to brick accumulation nor excessive packaging speed causing equipment idleness and waste. When selecting a machine, companies must first clarify the rated capacity and actual production efficiency of the brick-making machine (considering factors such as equipment wear and tear and raw material replacement), and then choose a packaging machine with the corresponding processing capacity. For example, a hydraulic brick machine with a capacity of 1500 bricks per hour should be paired with a fully automatic brick-threading and packaging machine with a processing speed of no less than 1500 bricks per hour, while reserving a 10%-20% capacity redundancy to cope with the needs of full-load production or short-term capacity fluctuations.

(II) Brick Specifications and Shape Adaptation: Ensuring Packaging Accuracy
The specifications and shapes of brick products directly determine the clamp design, stacking method, and brick-threading strategy of the packaging machine, which is the core challenge of adaptation. Currently, there are various types of brick products on the market, including standard bricks (240mm×115mm×53mm), hollow bricks, permeable bricks, and irregularly shaped bricks. Different bricks have significant differences in size, weight, strength, and pore distribution. For example, because hollow bricks have pores, the clamps must avoid squeezing and damaging the weak parts of the brick; permeable bricks often have rough textures on the surface, and anti-slip stability must be ensured during stacking. The fully automatic brick-threading and packaging machine must be flexible in its adjustment capabilities: Firstly, the clamps should be adjustable, allowing for quick switching based on brick size to accommodate different specifications. Secondly, the palletizing system should have multiple preset palletizing modes, selecting appropriate stacking layers and arrangements based on brick shape (e.g., standard bricks often use a grid pattern, while hollow bricks often use a triangular pattern). Simultaneously, the brick-threading mechanism must precisely align with the gaps between stacked bricks to ensure that strapping tape, threading rods, and other consumables can pass through smoothly, guaranteeing secure packaging. For special-specification products such as irregularly shaped bricks, customized clamps and packaging processes are required to avoid loose packaging and brick breakage.

(III) Production Line Layout and Connection Adaptation: Optimizing Space Utilization The layout and connection between the fully automatic brick-threading and packaging machine and the brick-making machine directly affect the smoothness of the production process and the utilization rate of the space. The suitable layout needs to be comprehensively planned based on factors such as workshop space size, brick-making machine discharge direction, and subsequent transportation routes. Common connection methods include straight-line connection and corner connection. Straight-line connections are suitable for workshops with ample space. After the brick machine outputs material, the bricks are directly conveyed to the baling machine via a conveyor belt, resulting in a simple process and high transmission efficiency. Corner connections are suitable for workshops with limited space. A corner conveyor adjusts the direction of brick transmission, achieving a staggered layout between the brick machine and the baling machine, saving space.

Furthermore, during the connection process, attention must be paid to matching the height and speed of the conveyor belt with the height and speed of the baling machine's feed inlet to prevent bricks from falling or colliding during transmission. Simultaneously, a buffer zone should be set at the connection point to cope with short-term fluctuations in brick machine output and ensure stable feeding to the baling machine.

(IV) Control System and Signal Adaptation: Achieving Intelligent Collaboration The efficient operation of an automated production line relies on the collaboration of the control system. Seamless integration of control signals and data transmission between the fully automatic brick-making and baling machine and the brick machine is essential to achieve the intelligent collaborative effect of "linked start/stop and fault feedback." The compatible equipment should adopt a unified communication protocol (such as the Modbus protocol commonly used in PLC control systems) to ensure that the brick machine's production signals (such as material discharge start, shutdown, and capacity adjustment) can be transmitted to the baling machine in real time. The baling machine can then automatically adjust its working status based on the signals. Simultaneously, the baling machine's operating status (such as fault alarms, insufficient consumables, and baling completion) can also be fed back to the brick machine control system. When the baling machine malfunctions, the brick machine can automatically reduce its capacity or stop to prevent brick accumulation. For example, when the baling machine runs out of strapping, the signal feedback can temporarily slow down the brick machine's output, restoring normal capacity after the consumables are replaced, achieving intelligent linkage throughout the entire process.

III. Efficiency Improvement: Dual-Machine Linkage Creates Multiplied Value

1. Precise Matching of Production Cycle Time
In large-scale tunnel kiln production lines, the brick machine and baling machine achieve material flow through conveyor belts. Based on a daily production capacity of 500,000 bricks: the brick-making machine produces 400 bricks per minute, with 408 bricks per stack, completing one stack every 1.02 minutes; the baling machine takes 45 seconds to complete the binding simultaneously, leaving a 17-second buffer time for stack transfer, ensuring zero production downtime.

This cycle time matching increases single-line capacity by 30% and reduces labor costs by 65%.

2. Fault Redundancy Design Ensures Continuous Production To address the high-load operation of brick factories, the equipment supplier adopts a "main and backup dual-machine" configuration: the main baling machine is equipped with an automatic belt feeding and unloading system, supporting 24-hour continuous operation; the backup machine is a handheld pneumatic baling machine, allowing manual binding during main equipment maintenance, avoiding complete line shutdown.

IV. Cost Optimization: Lifecycle Value Management

1. Refined Control of Consumable Costs
The fully automatic sling-and-brick packaging machine reduces packaging costs through three key technologies:

 Improved tape utilization: Utilizing friction-locking technology reduces tape consumption by 15% compared to traditional iron-locking methods;

 Optimized energy management: Standby power is only 50W, saving 40% more energy than similar equipment;

Extended maintenance cycle: Oil-free guide rollers and wear-resistant blades reduce the frequency of replacing vulnerable parts by 70%.

Based on an annual production of 150 million bricks, this translates to annual savings of approximately 800,000 RMB in packaging costs.

2. Structural Reduction in Labor Costs
Equipment automation upgrades drive a transformation in the brick factory's workforce structure:

 Packaging process: Reduction from 6 operators per line to 1 inspector, resulting in an 83% decrease in labor costs;

Management process: Real-time equipment status monitoring via a PLC system reduces the need for dedicated maintenance personnel;

 Skills upgrade: Operators are transformed into equipment maintenance engineers, increasing per capita output by 3 times.

V Conclusion

With automated production becoming a trend in the brick manufacturing industry, the compatibility between fully automatic brick-making and packaging machines and brick-making machines is no longer an "additional requirement," but a "key indicator" determining the core competitiveness of the production line. Enterprises need to abandon the traditional mindset of "emphasizing brick-making machines while neglecting supporting equipment," and precisely control the compatibility aspects from multiple dimensions such as capacity, specifications, layout, and control. Through scientific selection, meticulous debugging, dynamic optimization, and standardized operation and maintenance, efficient synergy between the two can be achieved.

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