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Malaysia Clay Brick Factory Project - Brictec Turnkey Solution for Decorative & Facing Bricks1
Assembly Line Production Line, Building Materials Production Line, Turnkey Brick Solution, Brick Production Line
Xi'an Brictec Engineering Co., Ltd.
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Product Description Project overview:Malaysia CBT decorative bricks production line project is Brictec's flagship model project in Southeast Asia, designed to produce a daily output of 70,000 decorative bricks (215x100x67mm). Due to the molding shift of 6 days per week, the actual daily output is about 85,000 pieces.The main project process for decorative bricks production line:The project adopts wet plastic extrusion process, its drying adopts single layer tunnel dryer with support bar recycling, and firing uses external firing tunnel kiln with flat ceiling of lightweight mullite. The operating equipment can be automatically controlled, and the drying chamber and tunnel kiln are centrally controlled. Xi'an Brictec always adheres to the concept of high standard and strict control, and carries out standardized and real-time comprehensive management over project material, equipment supervision, construction process, delivery process and construction progress.The Importance of Process Design in the Early Stage of Clay Brick Project Planning1. Process Design PerspectiveProcess design serves as the project's "blueprint," determining the overall layout and equipment selection. Key considerations include:Raw material properties (plasticity index, mineral composition)Product specifications (solid bricks, perforated bricks, etc.)Capacity coordination (avoiding over/under-capacity issues)Energy efficiency (integrated thermal system design)2. Raw Material ProcessingRaw material processing directly affects brick quality and equipment longevity:Crushing size control: Double toothed roll crusher output ≤3mm (oversize reduces plasticity, fines increase energy use)Aging & homogenization: ≥72 hours aging ensures moisture uniformity and forming stabilityImpurity removal: Magnetic separators + screening for iron and stones3. Aging & FormingAging process: Enclosed aging shed with >80% humidity promotes clay ion exchangeExtrusion forming: Vacuum extruder (vacuum ≥-0.092MPa) improves green body densityDie design: L/D ratio ≥4:1 minimizes spiral marks, chrome-plated lips reduce friction4. Drying TechnologyDrying is the most critical pre-sintering stage:Multi-stage drying:Preheating (40-60°C, 70% RH) to prevent crackingFast drying (80-120°C) for bound water removalAirflow design: Vertical airflow to keep temperature difference <5°C in stacksWaste heat recovery: Reuse tunnel kiln cooling zone heat for drying5. Tunnel Kiln Firing CurveThe firing curve determines brick strength and fuel efficiency:Preheating zone (200-600°C): Heating rate ≤50°C/hour to prevent explosionsFiring zone (900-1050°C): Hold for 2-4 hours under oxidizing atmosphereCooling zone: Slow cooling to <80°C (rapid cooling causes glass-phase cracking)Failure Cases vs. Good Design:Issue Poor Design Good DesignBrick Cracking Single-stage drying Multi-stage gradient dryingHigh Fuel Consumption No kiln waste heat recovery Integrated drying-firing heat recovery systemLow Production Capacity Mismatched crusher and extruder capacity Holistic equipment capacity coordinationSpiral Mark Defects Insufficient extruder compression ratio Optimized die L/D ratio (≥4:1)Material Waste No homogenization causing material inconsistency Enclosed aging shed + automated batching systemAdditional Notes:Consequences of Poor Design:Increased rework costsReduced equipment lifespanLower product qualification rateBenefits of Good Design:20-30% energy savings≥15% production increase40% lower maintenance costsThe Critical Role of Kiln Cars:Load-Bearing Core:Kiln cars must continuously carry tons of green bricks under combined mechanical and thermal stress. Poor-quality cars cause:Frame deformation triggering "kiln jams" (>$10,000/day downtime)Refractory spalling contaminating bricks (↑15% defect rate)Sealing Vitality:Ineffective sand sealing between cars and kiln walls leads to:Heat loss (8-12% higher energy consumption)Flue gas crossflow disrupting firing curvesMobility Foundation:Wheel systems must feature:High-temp bearings (>400oC)Self-adjusting rail alignment (derailment prevention)Brictec's Commitment"We refuse to compromise kiln car quality for cost savings. Every refractory brick laid is a pledge to our client's productivity for the next decade."- Brictec Process DirectorData Backing: Projects using Brictec kiln cars report <0.5% annual failure rate vs. industry average 3%.Brictec's Philosophy in Tunnel Kiln ManufacturingAt Brictec, we consider tunnel kilns the "heart" of clay brick production. Every kiln we build embodies our clients' demands for product quality and energy efficiency. We insist on:Stringent Refractory Standards: Kiln walls use high-load-bearing bricks (>60% Al2O3, refractoriness>1750oC), while roofs adopt lightweight insulation composites for maximum thermal efficiency.Millimeter Precision: Kiln straightness tolerance <3mm/10m, eliminating temperature deviation or product color variation caused by deformation.Dynamic Validation: CFD simulation + physical kiln testing to optimize firing curve stability.The Critical Role of Tunnel Kilns:Quality Determinant:Kiln temperature control directly affects bricks:±5oC variation causes>10MPa strength differencePreheating-firing-cooling balance sets water absorption (optimal 6-10%)Energy Center:Consumes>70% of total energy. Brictec solutions achieve:>65% waste heat recovery (industry avg. 40%)<90m3 gas/10k standard bricksProduction Hub:Kiln width and car speed coordination ensures:Uninterrupted production (>95% capacity utilization)<15min/car cycle time deviation"Every refractory brick in our kilns carries a traceable 'ID', documenting material batches and firing parameters, making your high-temperature investment transparent and controllable."- Brictec Kiln DivisionIndustry Comparison: Brictec kiln bricks last 8-10 years (industry avg. 5-7) with 40% lower annual maintenance costs.
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