A Complete Breakdown of the Exmork Brick Making Machine Production Process Every Key Step from Raw Material Mixing to Curing and Forming

A Complete Breakdown of the Exmork Brick Making Machine Production Process Every Key Step from Raw Material Mixing to Curing and Forming

A efficiently operating Exmork brick making machine is like a sophisticated modern industrial workshop. It transforms scattered raw materials into uniform, solid bricks. Each step is closely linked, and each profoundly impacts the quality of the final product. This article takes you inside the production line, providing a panoramic breakdown of every key step, from raw material mixing to curing and forming.

Step 1: Precision Begins—Raw Material Mixing and Mixing

This is the "genetic coding" stage that determines brick quality, and its accuracy is the foundation of all subsequent processes.

Raw Material Preparation: Prepare the appropriate raw materials based on the target product. Common combinations include:

Cementitious materials: Cement is the "glue" that gives bricks their strength.

Aggregates: Sand, stone powder, crushed stone chips, etc., form the "skeleton" of the brick.

Admixtures: Industrial waste materials such as fly ash and slag reduce costs and improve performance.

Water: The "key" that triggers the cement hydration reaction. Additives: Inorganic pigments are required for colored bricks.

Precise Mixing: All raw materials must be mixed according to strict weight or volume ratios. This is a scientifically calculated process. Excessive water content can cause deformation of the bricks, while insufficient cement can result in insufficient strength. The accuracy of the mix directly determines the strength, density, and durability of the bricks.

Uniform Mixing: The mixed raw materials are fed into a forced mixer for thorough and uniform mixing. The goal is to ensure that every aggregate particle is perfectly coated with the cement paste, resulting in a mix with excellent workability and optimal moisture content. The mixture should be "soft when held in the hand, but disintegrates when dropped to the ground."

Second Step: Efficient Conveying and Distribution - Precise Preparation Before Molding

The mixed materials are transported to the molding station via a conveyor system.

Conveying: Belt conveyors or elevators are used to smoothly transport the materials to the hopper above the brickmaking machine.

Uniform Distribution: This is a crucial yet often overlooked step. A distribution cart below the hopper moves the material back and forth over the mold box, ensuring that the mixture is evenly and smoothly filled into every cavity of the mold. Uneven distribution can lead to serious defects in the subsequently formed bricks, such as chipped corners and uneven density.

Step 3: Core Shaping—High-Pressure Vibration Molding

This is the "soul" of the entire production process and the crucial moment in which the material undergoes qualitative transformation. It is here that the loose material is given shape and initial strength.

Mold Positioning: The precision mold that will shape the brick is ready.

Combined Vibration and Compressive Pressing:

High-Frequency Vibration: A vibrating table below the mold begins vibrating at high speed, liquefying the material within the mold. This overcomes friction between particles, allowing the material to flow and form a denser arrangement, and maximizing the removal of air from the mold.

High-Pressure Compaction: Simultaneously, the upper ram descends rapidly, exerting tens or even hundreds of tons of vertical pressure on the material in the mold. This synergistic effect of "vibration + pressure" compresses the loose mixture into high-density, regularly shaped bricks within just a dozen seconds. Demolding: The ram lifts, and the mold box rises simultaneously. The formed bricks are steadily ejected and rest on the pallet (pallet) at the bottom.

Step 4: Brick Extrusion and Palletizing—A Fragile Transition

At this point, the bricks have a complete shape, but their strength is extremely low and they break easily, requiring careful handling.

Exporting the Forming Area: The pallets carrying the bricks are smoothly transported out of the main machine by a conveyor belt.

Automated Palletizing: A robot or automatic palletizer carefully stacks the pallets containing the bricks, preparing them for the curing phase. The palletizing process must be smooth, avoiding any shock or vibration.

Step 5: Infusing the Bricks—Curing and Curing

This is the "magic" stage that gives the bricks their final strength. The ideal temperature and humidity conditions are created to stimulate the cement's gelling potential.

Stationary Rest: The stacked bricks are first allowed to rest at room temperature for several hours to achieve a preliminary hardening strength sufficient to withstand subsequent handling. Curing: There are two main methods:

Natural curing: The bricks are stacked in an open-air area, covered with film to maintain humidity, and allowed to harden naturally. This method is low-cost but extremely time-consuming (typically requiring 28 days to reach standard strength) and is highly susceptible to weather conditions.

Steam curing: The bricks are placed in a dedicated curing kiln (steam curing room) and purged with saturated steam at 60-80°C for 8-12 hours. The high temperature and humidity significantly accelerate the hydration reaction of the cement, quickly increasing the bricks' required strength (approximately 70%-80% or higher). This is the mainstream and most efficient method in modern industrial production.

Sixth stage: Final product—packaging and shipment

After curing, the bricks have become as hard as stone. They are transported from the curing kiln, inspected, and packaged before being shipped to the construction site as finished products for use.

Summary

The production process of a brick making machine is a continuous process that seamlessly integrates materials science and precision machinery manufacturing. From the scientific formulation of precise proportions, to the physical energizing of vibration and pressure, to the chemical activation of steam curing, every step is essential, ensuring the final product becomes a reliable foundation for our modern world. Understanding this complete process is key to optimizing production, improving quality, and creating greater value.