In the cost structure of refractory production, raw materials account for as high as 65%, and energy and labor costs together exceed 30%. Moreover, problems such as inefficiency and waste in the production process further exacerbate the cost pressure on enterprises. Based on the production practices of refractory enterprises at home and abroad, the core pain points are concentrated in three aspects: First, inaccurate pressure control in the forming process leads to uneven green body density, high rejection rates, and severe raw material waste; second, traditional equipment features high energy consumption and rapid wear, resulting in persistently high operation and maintenance costs as well as energy expenditure; third, the production process has a low degree of automation and high reliance on labor, leading to low efficiency and product instability caused by human errors.

Raw material waste is the most direct cost loss in refractory production, and the core cause of high rejection rates lies in uneven green body density and dimensional deviation in the forming process. Zhengzhou Haloong servo screw presses address this problem with precision pressure control technology, and when combined with scientific forming processes, they can increase raw material utilization rate by 10%-15%. Adopting a permanent magnet synchronous servo motor direct drive design, Haloong servo screw presses allow pressing energy to be precisely preset via digital programs with repeat accuracy error close to zero. They can flexibly implement a stepped process of "light pressing for air exhaust first, then heavy pressing for forming", effectively eliminating internal pores of green bodies and ensuring uniform density and precise dimensions of green bodies. Compared with the 8%-12% rejection rate of traditional friction presses, the rejection rate of refractory green bodies can be reduced to below 2% after adopting Haloong equipment, saving hundreds of thousands of yuan in raw material costs per production line annually. For example, Maanshan Iron & Steel Group introduced Haloong's 1250T servo electric screw press for magnesia-carbon brick production, which significantly improved forming precision and reduced rejection rates, increasing raw material utilization rate by 12%. Meanwhile, the equipment's non-fixed bottom dead center design can adapt to the forming of refractory materials of different types and specifications, avoiding raw material loss caused by product switching and further cutting down waste.

Energy consumption is the second largest cost expenditure in refractory production. Especially for presses used in the forming process, traditional friction presses and ordinary hydraulic presses are characterized by high energy consumption and low energy utilization rate, leading to high energy costs in long-term operation. Driven by the "dual carbon" goals, energy-saving equipment has become an inevitable choice for refractory enterprises to reduce costs and improve efficiency, and the energy-saving advantages of Haloong servo screw presses have been widely verified by enterprises at home and abroad. Haloong servo screw presses adopt a "servo direct drive + intelligent hibernation" design; the servo motor only operates during forming operations and automatically enters hibernation during processes such as feeding and demolding, with standby energy consumption almost zero. They save more than 55% energy compared with traditional friction presses and over 30% compared with ordinary hydraulic presses. Calculated based on a production line with an annual output of 100,000 tons of refractories, adopting Haloong servo screw presses can save hundreds of thousands of yuan in electricity bills every year, generating considerable energy-saving benefits in long-term operation. In addition, the slider speed is extremely fast when the equipment approaches the bottom dead center, enabling forming to be completed in an instant before raw materials cool down. This not only reduces energy loss but also further ensures product quality, achieving dual benefits of "energy conservation + quality improvement" and conforming to the green development trend of the refractory industry.

Traditional presses adopt transmission structures such as clutches and gears, which are prone to wear and frequent failures. This not only requires frequent shutdowns for maintenance, affecting production efficiency, but also demands substantial investment in maintenance fees and spare parts costs, resulting in prominent hidden losses. Based on the design concept of "long-term durability", Zhengzhou Haloong optimizes equipment structure, greatly reduces operation and maintenance costs, and helps enterprises cut down hidden expenditures. Haloong servo screw presses adopt fully enclosed static pressure screw, nut and bearing transmission, forming a stable oil film for protection during operation. Combined with a fully automatic forced lubrication system, they avoid wear caused by inadequate manual lubrication, doubling the service life of the equipment compared with ordinary screw presses. At the same time, the equipment has a short transmission chain and simple structure, leading to a significant reduction in failure rate with an annual average failure rate below 3%, cutting maintenance times by 70% compared with traditional equipment. In addition, Haloong has a professional after-sales team at home and abroad, providing rapid maintenance and remote debugging services to minimize downtime and avoid efficiency loss caused by equipment failures. Comprehensive calculations show that adopting Haloong presses can reduce the equipment operation and maintenance costs of refractory enterprises by more than 50%, further compressing overall costs.

Currently, labor costs are on a continuous rise, and the traditional refractory production mode is highly dependent on labor, which not only leads to high labor costs but also easily causes product instability due to human operation errors. With the accelerated digital and intelligent transformation of the refractory industry, automated production has become an important direction for cost reduction and efficiency improvement. Haloong servo screw presses can realize full-process intelligent linkage, significantly reducing labor dependence. Equipped with an intelligent production management system, Haloong servo screw presses can seamlessly link with equipment such as automatic feeding, mold release agent spraying, and product conveying, building a fully automated production line. Stable production can be achieved with only 1-2 staff for monitoring without the need for skilled operators, directly cutting labor costs by over 30%. Meanwhile, the equipment supports one-click control via digital programs, allowing parameters to be precisely preset and adjusted in real time, avoiding human operation errors, ensuring stable product quality, and reducing waste caused by human mistakes. In addition, the equipment enables remote monitoring and parameter debugging, collecting forming data in real time to provide support for production optimization. Conforming to the global trend of intelligent manufacturing, it helps refractory enterprises at home and abroad achieve "staff reduction, efficiency improvement and quality enhancement".

Refractory enterprises have a diverse range of product categories. Equipping multiple types of forming equipment not only requires high investment costs but also leads to equipment idleness and low capacity utilization rate. Zhengzhou Haloong servo screw presses have the advantage of "one machine for multiple uses", being able to adapt to diversified production needs, improve equipment capacity utilization rate, and indirectly reduce unit product costs. Haloong servo screw presses are compatible with the forming of more than 100 types of refractory products such as refractory bricks, refractory balls, and burner composite bricks. They can not only meet the mass production of ordinary shaped refractories but also adapt to the customized processing of special refractories such as high-alumina, magnesia and carbon-based ones. Product switching can be completed only by adjusting parameters without replacing core equipment. At the same time, large-tonnage equipment can also handle the production of small components with stable processing time per stroke, achieving a production effect of "suitable for both large and small products, getting twice the result with half the effort". This greatly improves equipment capacity utilization rate, allowing enterprises to expand their product matrix and increase profit margins with limited equipment investment, so as to respond to changes in market demand.

Cost reduction and efficiency improvement is not a short-term behavior but a core strategy for refractory enterprises to achieve long-term sustainable development. Currently, the refractory material industry is moving towards green, intelligent and high-end transformation. Zhengzhou Haloong has always been guided by industry demands, focusing on press R&D and manufacturing. With 45 years of technical accumulation, strict product quality and a complete domestic and overseas service system, it provides global refractory enterprises with an integrated cost reduction and efficiency improvement solution of "equipment + technology".