Fully Automatic PLC Controlled Vacuum Extruder for High-Pressure Clay Brick Making with De-airing System

The vacuum brick extruder is the core equipment in clay brick production, primarily used to extrude mixed clay materials under high pressure while applying vacuum treatment to enhance the compactness and strength of the green body. Its performance directly impacts brick quality, production efficiency, and the overall operational stability of the entire plant.

1. Vacuum De-airing System

   Prior to extrusion, a vacuum pump (typically achieving -0.092 to -0.098 MPa) removes air from the clay, reducing body porosity and enhancing density. This prevents cracking, delamination, or explosion during drying and firing.

2. High-Pressure Extrusion System

   Utilizes a spiral auger or two-stage extrusion mechanism to ensure homogeneous clay compaction. Extrusion pressure typically ranges from 2.5 to 4.5 MPa, accommodating clay materials of varying hardness.

3. Adjustable Mold System

   The mold determines brick dimensions and profiles (e.g., solid, hollow, or perforated bricks). High-performance extruders feature quick-change mold systems to minimize downtime and enhance production flexibility.

4. Wear-resistant Materials & Low-maintenance Design

   Critical components (auger, liner, extrusion head) utilize high-chromium alloy steel or tungsten carbide (WC) coatings for extended service life. Premium models incorporate hydraulic clearance adjustment to automatically compensate for wear, maintaining stable extrusion pressure.

5. Automated Control

   Modern vacuum extruders feature PLC-controlled systems monitoring vacuum level, extrusion pressure, and motor load for intelligent adjustment. Advanced models support remote monitoring for predictive maintenance and fault alerts.

1. Material Processing: Mixes and extrudes clay (may include shale or coal gangue).
2. De-airing: Removes air bubbles to enhance strength.
3. Shaping: Forms bricks via dies (solid/hollow blocks, etc.).
4. Cutting: Some models integrate auto-cutting for brick lengths.
5. Conveying: Transfers bricks to drying or stacking systems.

1. Improves Brick Quality, Reduces Waste: Low-end extruders cause cracks, deformation, weak bricks (waste rate >10%). High-end machines ensure dense, precise bricks (waste rate <2%).
2. Boosts Efficiency, Lowers Energy Use: Reliable extruders enable 24/7 production with minimal downtime. Optimized pressure reduces power consumption (e.g., VFD saves 20%+).
3. Extends Lifespan, Cuts Maintenance: Cheap extruders wear fast (auger replacement every 3–6 months). Premium models last 1–3 years, reducing part/labor costs.
4. Adapts to Raw Materials: Handles clay with 14–22% moisture, even mixed with shale/coal gangue. Quick mold changes enable diverse products (solid/perforated bricks).
5. Reduces Issues in the Following Process: Better extrusion minimizes drying cracks, firing deformations.

The vacuum extruder is the "heart" of a brick plant. Choosing a reliable, wear-resistant, automated machine ensures higher quality, lower costs, and long-term competitiveness.