Compared with ordinary refractory bricks, silica bricks face numerous industry pain points in the pressing process due to their special raw material characteristics (poor fluidity of SiO₂ particles, unique bonding strength of binders) and strict forming requirements, which severely restrict industrial upgrading. Traditional friction presses rely on mechanical transmission with unstable energy release, and cannot precisely control pressing force and speed. This easily leads to uneven density and excessive vertical density difference in silica brick green bodies. After subsequent sintering, defects such as cracks, delamination and spalling tend to occur, making the products unable to withstand long-term erosion in high-temperature working conditions. Ordinary hydraulic presses feature slow response and insufficient transmission rigidity, failing to meet the special process requirements of silica bricks: “light pressing for exhaust, heavy pressing for forming”. In addition, uneven force transmission easily causes edge chipping and excessive dimensional deviation. For complex-structured silica bricks with inclined holes in the middle, the qualified forming rate is extremely low. Some silica brick pressing equipment has a low degree of automation and relies on manual parameter adjustment and auxiliary demolding. This not only keeps labor costs high, but also leads to obvious quality differences in the same batch due to human operation errors, failing to meet the standardization requirements of high-end markets at home and abroad. Furthermore, traditional equipment has poor adaptability. After replacing molds for different specifications of silica bricks, parameter debugging is cumbersome and time-consuming, unable to quickly respond to customized production of multi-specification, small-batch silica bricks, and incompatible with the flexible production transformation of silica brick enterprises. At the same time, high energy consumption and rapid wear further increase the overall production cost of enterprises.

At present, the domestic silica brick industry still suffers from low added value of products, with most enterprises mainly producing low-value-added bulk silica bricks. In high-end overseas markets such as Europe, North America and Southeast Asia, stricter standards have been imposed on the density uniformity, dimensional accuracy and service stability of silica bricks. The core of silica brick pressing lies in “precise pressure control” and “full-area compaction”: it is necessary to fully exhaust air inside the green body through precise pressure regulation to ensure uniform density, while taking into account the characteristics of silica brick raw materials to avoid overpressure chipping and underpressure loosening. This requires pressing equipment to have high-precision pressure control capability, flexible process adaptability and stable operation performance. Against this backdrop, relying on 45 years of experience in equipment R&D and manufacturing, combined with the raw material characteristics and pressing process features of silica bricks, Zhengzhou Haloong has carried out targeted optimization and upgrading of servo screw presses, launching exclusive equipment suitable for pressing various silica bricks (ordinary silica bricks, high-density silica bricks, complex-structured silica bricks, special-shaped silica bricks). With core advantages of precise pressure control, intelligent adaptation, stability and high efficiency, it has become the core support for silica brick enterprises to break through production bottlenecks and seize high-end markets. It demonstrates the technical strength of “Haloong” as the leading brand of electric screw presses, helping enterprises expand their high-end silica brick product portfolio and enhance global market competitiveness.

As a national patented product, Zhengzhou Haloong HLDS Series Servo Screw Press adopts the third-generation permanent magnet synchronous servo direct drive technology, benchmarked against world-class high-end refractory forming equipment. Specially optimized for the difficulties in silica brick pressing, it is perfectly suitable for mass pressing and customized production of silica bricks of different materials and specifications. It can meet both large-scale production of conventional silica bricks and precision pressing of high-density silica bricks and complex-structured silica bricks with inclined holes in the middle. The press comprehensively solves the pain points of silica brick pressing, consolidates the product quality foundation, adapts to the upgrading needs of silica brick intelligent manufacturing production lines, and helps refractory enterprises achieve high-end breakthroughs in silica brick products.

Adopting a permanent magnet synchronous servo direct drive design and eliminating traditional clutch and gear transmission structures, the equipment realizes digital precise control of pressing speed, pressure and stroke, with energy repeat control accuracy ≤ ±2.5%, approaching the level of the world’s top servo forming equipment. It can accurately match the special pressing requirements of silica bricks: “light pressing for exhaust, heavy pressing for forming, gradient compaction”. Aiming at the characteristics of poor fluidity and difficult exhaust of silica brick raw materials, the equipment can preset multi-stage pressing programs, precisely controlling the striking force, speed and stroke of each stage. It first quickly exhausts air inside the green body at low pressure, then completes dense forming at high pressure, effectively avoiding insufficient compactness caused by material agglomeration. This ensures uniform density across the entire silica brick green body, with density coefficient of variation controlled below 1.0%, effectively preventing defects such as cracks, delamination and spalling after sintering. Meanwhile, the servo motor features strong overload capacity, allowing a load of twice the nominal pressure, adapting to the compaction demand of high-hardness silica brick raw materials while maintaining the bonding stability of binders. It precisely controls the pressing force at corners and complex parts, avoiding overpressure chipping and underpressure insufficient filling, greatly improving the qualified forming rate of silica bricks. Especially for complex silica bricks with inclined holes in the middle, it can effectively reduce damage to forming shafts and corner defects, significantly improving forming quality.

Breaking through the structural bottom dead center limitation of traditional presses, the equipment adopts a non-fixed bottom dead center design, eliminating the risk of equipment overload and jamming caused by raw material ratio deviation, particle size difference or uneven mixing. Its adaptability far exceeds that of traditional forming equipment. Through digital programs, the equipment can flexibly adjust forming parameters and quickly adapt to the pressing requirements of ordinary silica bricks, high-density silica bricks, special-shaped silica bricks and complex-structured silica bricks with inclined holes in the middle without complex debugging. It is especially suitable for layered compaction forming of thick-walled and thin-walled silica bricks, ensuring consistent compactness at all positions of the green body, with dimensional accuracy error controlled within ±0.5 mm. This meets the requirements of dimensional standardization and precise assembly for high-end high-temperature equipment at home and abroad. At the same time, the equipment can realize free switching between high and low speeds in a single stroke. According to the needs of different pressing stages of silica bricks, it flexibly adjusts the pressing speed to avoid material displacement caused by high-speed pressing, further improving forming quality and reducing green body defects. It adapts to customized production of multi-specification, small-batch silica bricks, helping silica brick enterprises realize flexible production.

The equipment adopts a fully enclosed static pressure screw, nut and bearing transmission structure, forming a stable oil film protection during operation. Coupled with a fully automatic forced lubrication system, it effectively reduces equipment wear, doubling the service life compared with ordinary screw presses. It can stably support large-scale, high-intensity pressing of silica bricks for a long time — especially suitable for continuous production of intelligent manufacturing projects with an annual output of 50,000 tons and above. Featuring a short transmission chain and simple structure, with no vulnerable parts such as friction discs and gearboxes, it enables convenient later maintenance and extremely low maintenance costs. The equipment failure rate is reduced by more than 60%, ensuring continuous and stable production, minimizing downtime losses and avoiding raw material waste in silica brick production. In addition, the equipment runs smoothly with no vibration at low speed, preventing density deviation and uneven material distribution caused by vibration, further guaranteeing forming accuracy and dimensional consistency of silica bricks. Even under long-term continuous operation, it maintains stable and precise pressure control, ensuring uniform quality of the same batch and meeting the standardization requirements of high-end markets at home and abroad.

Equipped with Zhengzhou Haloong’s independently developed intelligent production management system and standardized industrial communication interfaces, the press can seamlessly link with upstream and downstream equipment including automatic feeding systems, raw material proportioning systems, mold release agent spraying equipment, automatic picking robots and green body inspection equipment. It realizes full-process automatic and digital control for silica brick pressing, adapting to the upgrading needs of silica brick intelligent manufacturing production lines and benchmarking the intelligent level of the world’s first automatic production line of servo direct-drive CNC screw presses for refractory forming. The equipment can receive real-time data such as upstream raw material ratio and feeding speed, automatically adjusting forming parameters to avoid deviations caused by manual intervention, adapting to production requirements of silica bricks of different materials and specifications. Targeting the difficulty of demolding silica bricks, the system can precisely control demolding speed and force. Cooperating with automatic picking robots, it achieves seamless connection between demolding and picking, reducing the damage rate of silica brick green bodies to below 0.5% and avoiding corner damage caused by manual demolding. Meanwhile, a built-in high-precision data acquisition module with a sampling frequency up to 100 times per second collects key data during pressing in real time, uploading to the central control system to form a full-process quality traceability system. This ensures each batch of silica bricks is traceable and controllable, greatly increasing product qualification rate to over 99%. Furthermore, the system supports remote monitoring and parameter debugging, facilitating off-site production management for domestic and overseas customers. It is simple and easy to operate, with one-button control requiring no skilled operators, helping enterprises achieve “staff reduction and efficiency improvement”.

Relying on the core advantages of servo direct drive technology, the equipment realizes an “on-demand start, hibernation energy saving” mode: the motor runs only during pressing operations and enters hibernation during feeding, demolding, mold cleaning and other processes, with no invalid power consumption. It saves more than 60% energy compared with traditional friction presses, with motor efficiency ≥ 95%, greatly reducing energy costs for silica brick enterprises — especially suitable for energy-saving demands in large-scale production, in line with the global trend of green industry and low-carbon production. At the same time, the slider speed is extremely fast when approaching the bottom dead center, completing forming instantly before silica brick raw materials and binders cool down. Short contact time with the mold reduces mold wear, extending mold service life by more than 30% and further compressing overall production costs. For the high cost and easy damage of silica brick molds, the precise pressure control of the equipment reduces mold loss and indirectly lowers mold investment. In addition, the equipment operates without transmission noise, greatly improving the workshop working environment, complying with domestic and foreign trends of green production and low-carbon development, and meeting the Emission Standard of Air Pollutants for Refractory Industry (GB 41618-2022) and overseas environmental standards. It helps silica brick enterprises transform to green production, enhance global market competitiveness, and promote the green development of the refractory industry.

As an important branch of the refractory industry, silica bricks are the core guarantee for the safe and stable operation of high-temperature industrial equipment. Their quality directly concerns the safe production, green transformation and efficiency improvement of the global high-temperature industry. The upgrading and iteration of forming equipment is the core driving force promoting the silica brick industry toward high-end, standardized and intelligent development, as well as a key starting point for the refractory industry to achieve structural optimization and added value improvement. At present, the refractory industry is transforming toward “high efficiency, long service life, low carbon and intelligence”. As a core category of acidic refractories, the precise and high-end production of silica bricks has become an important breakthrough for enterprises to enhance core competitiveness, and the performance of pressing equipment is the decisive factor for silica brick quality. With 45 years of deep cultivation in the field of refractory forming equipment, Zhengzhou Haloong has always adhered to the philosophy of “Starting with Design, Excelling in Technology, Focusing on Processing, Succeeding in Assembly”. Relying on scientific and technological progress, rigorous process procedures, complete testing methods and a sound management system, Haloong continuously promotes technological innovation of servo screw presses. It creates exclusive solutions for silica brick pressing process requirements, helping silica brick enterprises break through technical bottlenecks, promoting the refractory industry to transform from “scale expansion” to “quality improvement”, freeing refractory enterprises from the constraints of traditional forming processes, realizing independent and large-scale production of high-end silica bricks, and driving China’s refractory industry toward high-end and high-value-added development.