Refractory irregular bricks, due to the installation requirements of special parts of kilns, need to be designed with irregular shapes, embedded structures or special dimensions based on actual working conditions. Their forming process is more complex than that of ordinary standard refractories, and it poses extremely high requirements for the accuracy, adaptability and stability of forming equipment. Research data shows thatwhen using traditional friction presses or ordinary hydraulic presses to produce refractory irregular bricks, the qualified rate of green bodies is only maintained at 80% or below. It is prone to defects such as cracks, chipped corners, uneven wall thickness and density imbalance, with a raw material waste rate as high as 20% to 35%. Moreover, the daily output of a single machine is less than 600 pieces, which is difficult to meet the customized and large-scale production needs of irregular bricks.

 Specifically, the core pain points of the forming of refractory irregular bricks are concentrated in four aspects: First, insufficient forming accuracy. Traditional equipment has rough pressure control and uneven force transmission, making it difficult to precisely match the compaction requirements of the complex structures of irregular bricks. This leads to large dimensional deviations in green bodies and insufficient density in key parts, causing deformation and cracking after sintering, and failing to meet the precise requirements of kiln assembly. Second, poor adaptability. Traditional equipment has a fixed structure and is difficult to flexibly adjust parameters to adapt to different specifications and shapes of irregular bricks. Mold replacement is cumbersome and debugging takes a long time, and problems such as stuck machines and mold jams often occur, seriously affecting production continuity. Third, unstable green body quality. Traditional equipment relies on manual parameter control, and human operation errors lead to significant differences in density and strength within the same batch of irregular bricks, making it difficult to meet the strict requirements of high-end kilns for the consistency of refractory performance. Fourth, low production efficiency. Traditional equipment has slow pressurization speed and high energy consumption, and requires multiple operators to assist with loading, demolding and inspection, resulting in high labor costs. At the same time, the high rate of rework for unqualified green bodies further compresses the profit space of enterprises.

 Zhengzhou Haloong's HLDS series servo screw press, as a national patent product, adopts the third-generation permanent magnet synchronous servo motor direct drive technology, benchmarking the global high-end refractory forming equipment level. It targets the core demands of refractory irregular bricks - "complex shapes, high precision requirements, and strong adaptability" - to create a full-process precision forming and intelligent control system. It can perfectly adapt to the batch forming and customized production of various complex-structured refractories such as irregular bricks, special-shaped bricks, honeycomb lattice bricks, and large prefabricated blocks. Its six core advantages comprehensively solve the pain points of irregular brick forming, helping refractory enterprises achieve the production goals of "precision improvement, efficiency doubling, loss reduction, and quality stability", and meeting the upgrade needs of intelligent manufacturing production lines of domestic and foreign refractory enterprises. It empowers the high-end upgrade of the refractory irregular brick industry through equipment innovation.

With a direct drive design using permanent magnet synchronous servo motors, it discards the traditional clutch and gear transmission structure, achieving digitalized and precise control of pressurization speed, pressure and stroke. The energy repetition control accuracy is ≤±2.5%, approaching the level of international top servo forming equipment. It can precisely match the special forming requirements of "light pressure exhaust, heavy pressure forming, and gradient compaction" for the complex structures of irregular bricks, precisely applying pressure to the corners, grooves, and embedded structures of irregular bricks, ensuring uniform density from the center to the edge and from the surface to the interior of the green body, with dimensional deviations controlled within ±0.5mm. This effectively avoids defects such as cracks, chipped corners, and uneven wall thickness. The precise pressure control stably increases the qualified rate of green bodies of irregular bricks to over 99%, significantly reducing the waste of raw materials caused by unqualified green bodies, and increasing the raw material utilization rate to over 99%. It conforms to the technical trend of efficient utilization of waste materials in the refractory industry, and at the same time lays a solid foundation for the subsequent sintering process, ensuring that the finished irregular bricks meet the strength, temperature resistance, and erosion resistance requirements of high-end markets. It breaks through the structural bottom dead center limit of traditional equipment, eliminating concerns about overloading and mold jamming caused by the complex shapes and size deviations of special-shaped bricks. It can flexibly adjust the molding parameters and quickly adapt to the molding requirements of different specifications and shapes of special-shaped bricks without complex debugging. The mold changing time is reduced by more than 50%, and it can achieve precise molding for both small special-shaped bricks, large prefabricated blocks, and irregular special-shaped bricks, significantly enhancing production flexibility. At the same time, when the equipment approaches the bottom dead center, the slider speed is extremely fast, allowing the molding to be completed instantly before the refractory raw materials and binders cool down, avoiding molding defects caused by material solidification. The daily output of a single device is increased to over 1,000 pieces, with an efficiency improvement of more than 30% compared to traditional equipment, easily meeting the production needs of customized, multi-batch, and large-scale special-shaped bricks.

It adopts a fully enclosed static pressure screw, nut, and bearing transmission structure, forming a stable oil film for protection during operation, and is equipped with a fully automatic forced lubrication system, effectively reducing equipment wear. Compared to ordinary screw presses, its service life is increased by more than double. The transmission chain is short and the structure is simple, without friction discs, gearboxes, and other easily worn and consumed parts, making later maintenance convenient and reducing maintenance costs by more than 60%, and reducing equipment failure rates by more than 60%, ensuring continuous and stable operation of special-shaped brick production and reducing downtime losses caused by equipment failures. At the same time, the equipment operates smoothly, with no vibration at low speeds, avoiding uneven material distribution and size deviations in the special-shaped brick blanks caused by vibration, further enhancing the stability of blank quality, providing reliable support for the large-scale production of special-shaped bricks.

It is equipped with the intelligent production management system independently developed by Zhengzhou Haloong, with standardized industrial communication interfaces, which can be seamlessly linked with upstream and downstream equipment such as automatic feeding systems, raw material proportioning systems, spray release agent equipment, automatic blank picking robots, and blank inspection equipment, achieving full automation and digital control of the entire refractory special-shaped brick molding process, reaching the intelligent level of the world's first refractory molding servo direct drive CNC screw press automation production line. Full automation operation can significantly reduce the reliance on manual labor, with only 2-3 operators required per production line, reducing the workforce by more than 60% compared to traditional production lines, significantly lowering labor costs. At the same time, the equipment can receive real-time data from upstream raw material proportioning and feeding speed, automatically adjusting the molding parameters to avoid parameter deviations caused by manual intervention, ensuring consistent quality of the same batch of special-shaped bricks and reducing rework losses, further improving production efficiency. In addition, the system supports remote monitoring and parameter adjustment, facilitating remote production control for domestic and foreign customers. The operation is simple and easy to learn, with one-button operation that does not require skilled operators, helping enterprises achieve the dual goals of "reducing staff and increasing efficiency".

Refractory special-shaped bricks, as core supporting components of high-temperature industrial kilns, their quality and production efficiency are directly related to the energy conservation, safety production, and sustainable development of the global high-temperature industry. They are also an important breakthrough point for the refractory industry's transformation towards high-end and high value-added. Currently, the global refractory industry is transforming towards "high efficiency, long life, low carbon, and intelligent". The demand for high-end special-shaped bricks is continuously expanding. The implementation of international rules such as the EU carbon border adjustment mechanism further urges refractory enterprises to accelerate equipment upgrading and technological innovation. High-precision, green, and large-scale special-shaped brick production has become an inevitable choice for the survival and development of enterprises. Zhengzhou Haloong has been deeply engaged in the field of refractory molding equipment for 45 years, always adhering to the concept of "starting from design, excelling in process, emphasizing processing, and achieving in assembly". Relying on technological progress, with strict process regulations, complete testing methods, and a complete management system, it continuously promotes technological innovation in servo screw presses, targeting the core pain points of refractory special-shaped brick molding, creating exclusive solutions, and assisting global refractory enterprises in breaking through development bottlenecks and achieving the transformation of "high precision, high efficiency, low loss, and high quality" in special-shaped brick production.