Traditional forming equipment has obvious shortcomings in the production of special-shaped refractory bricks: Firstly, the pressure control accuracy is insufficient, making it difficult to meet the force requirements of different parts of the special-shaped bricks, which often leads to defects such as edge material shortage, central porosity, and corner breakage, resulting in a low product qualification rate. Secondly, the force transmission is uneven, and the irregular shape of the special-shaped bricks can easily cause local overloading or underloading, resulting in significant density differences in the green body, which can lead to cracking and spalling during high-temperature service due to stress concentration, seriously affecting the safety of equipment operation. Thirdly, the customization adaptability is poor, with cumbersome mold replacement and time-consuming parameter adjustment, making it difficult to quickly respond to the customization needs of different specifications and materials of special-shaped bricks, leading to low production efficiency. Fourthly, the energy consumption is high and maintenance is difficult. The complex transmission structure of traditional equipment leads to high energy loss, and the core components wear out quickly, making remote control difficult, which cannot meet the requirements of global production layout. At the same time, the implementation of international rules such as the EU's carbon border adjustment mechanism, as well as the rising labor costs, further force refractory material enterprises to upgrade the forming equipment for special-shaped bricks and seek efficient, precise, and energy-saving forming solutions.

Compared with traditional isostatic pressing and extrusion forming processes, the servo screw press, with its advantages of digital precision pressure control and flexible adaptability, has become the best choice for the forming of special-shaped refractory bricks - it can not only solve the problems of high equipment and mold costs and short mold life in isostatic pressing, but also make up for the shortcomings of high plasticity requirements for the material and insufficient density of the products in extrusion forming, perfectly meeting the core requirements of "precise forming, uniform density, and efficient customization" for special-shaped refractory bricks.

Relying on 45 years of experience in the research and development and manufacturing of refractory forming equipment, Zhengzhou Haloong has deeply integrated the third-generation permanent magnet synchronous servo direct drive technology with the forming process of special-shaped refractory bricks, creating a dedicated servo screw press that meets the global high-end equipment standards. It targets the forming needs of different materials such as brown corundum, white corundum, magnesia-carbon bricks, and chrome corundum, achieving the core goals of "precise pressure control, flexible adaptation, high efficiency and energy saving, and stable reliability", becoming a "core weapon" for domestic and foreign refractory material enterprises in the production of special-shaped refractory bricks, comprehensively solving the industry's forming pain points.

It adopts a direct drive design with permanent magnet synchronous servo motors, eliminating the traditional clutch and gear transmission structure, with a short transmission chain and low energy loss. It is equipped with an intelligent pressure control system that can precisely preset the pressing energy, speed, and frequency through digital programs, with a repeatable control accuracy of pressure ≤ ±1%, far exceeding the industry average. In response to the core requirements of "exhausting - shaping - densification" for special-shaped refractory bricks, it intelligently matches the three-stage forming process of "light pressure exhaust - medium pressure shaping - heavy pressure densification", thoroughly eliminating the internal pores of the raw materials. At the same time, it precisely allocates pressure according to the force requirements of different parts of the special-shaped bricks, ensuring uniform density from the center to the edge and from complex sections to irregular corners of the green body, with a density variation coefficient controlled below 1.5% and a porosity reduced to below 15%, significantly improving the high-temperature stability, erosion resistance, and wear resistance of the special-shaped bricks, effectively eliminating forming defects such as cracking, corner breakage, and porosity, and maintaining a product qualification rate of over 99%, fully meeting international and domestic industry standards.

It breaks through the structural bottom dead center limit of traditional equipment and adopts a step-by-step forging mode, allowing flexible adjustment of the slider stroke and pressing angle according to the irregular shape and complex cross-section of the special-shaped refractory bricks, without worrying about overloading and jamming caused by material size deviations or complex shapes. Whether it is conventional shaped bricks such as arc-shaped, wedge-shaped, and grooved bricks, or complex products like large special-shaped bricks, burner combination bricks, and large-sized prefabricated blocks, precise molding can be achieved, ensuring uniform pressure on every part of the brick body and perfect replication of the mold shape. This eliminates problems such as edge material deficiency and dimensional deviation, meeting the customized production needs of various shaped refractory bricks without the need for frequent equipment structure adjustments, significantly enhancing the molding adaptability.

Relying on 45 years of refractory molding experience, the servo screw press can intelligently customize the molding program and pressure application mechanism based on the raw material characteristics and particle size distribution of different types of shaped refractory bricks. For different specifications and shapes of shaped bricks, a rapid mold changing system is equipped, making mold replacement convenient and efficient. Combined with an in-built database of shaped brick molding parameters, the system can automatically adjust the pressure application parameters according to product requirements, eliminating the need for frequent manual adjustments and significantly reducing production preparation time. Whether it is small-batch customized production or large-scale mass production, it can achieve efficient adaptation, helping enterprises expand their shaped brick product matrix and quickly respond to the diverse demands of the global market. The products are exported to Europe, Southeast Asia, Africa, and other regions, and have been highly recognized by global customers.

Equipped with the intelligent production management system independently developed by Zhengzhou Haloong, it is provided with standardized industrial communication interfaces, which can be seamlessly integrated with upstream and downstream equipment such as automatic feeding systems, raw material proportioning systems, green body inspection equipment, and intelligent warehousing systems, building an intelligent production line for the entire process of shaped refractory brick molding, achieving unmanned control from "raw material entry - proportioning - pressing - inspection - warehousing". The system supports remote monitoring and parameter adjustment, facilitating domestic and foreign customers to manage production remotely, and real-time collection of molding data provides data support for process optimization, reducing errors caused by manual intervention. The operation is simple and easy to learn, and even non-professionals can quickly get started, significantly reducing labor costs and increasing production efficiency by more than 30%.

Adopting the "on-demand start, sleep energy-saving" intelligent mode, the servo motor only operates during the molding process, and stops and enters sleep mode during feeding, demolding, and mold changing processes, eliminating unnecessary power consumption. Compared with traditional friction presses, it saves more than 55% of energy, with motor efficiency ≥ 95%. It can save a large amount of energy costs for enterprises every year. At the same time, the equipment intelligently optimizes the molding process, shortens the molding cycle, intelligently matches the mold adaptation parameters, reduces the loss of green bodies due to rework, and increases the raw material utilization rate to over 99%. This not only reduces raw material waste but also reduces carbon emissions, meeting the global carbon reduction requirements and the green transformation needs of the refractory industry, helping enterprises achieve multiple goals of "energy conservation, cost reduction, and efficiency improvement", and enhancing their competitiveness in the international market.

Equipped with an intelligent diagnosis and early warning system, it can monitor the equipment operation status in real time, collect and analyze the wear, temperature, and operation parameters of core components such as screws, bearings, and motors, and provide early warnings of potential faults in advance, avoiding production losses caused by sudden equipment shutdowns and reducing equipment failure rates by more than 70%. It is equipped with a fully automatic forced lubrication system, intelligently matching the lubrication cycle and dosage, reducing the friction loss of transmission components, and extending the equipment service life by more than twice. Moreover, it has a short transmission chain, simple structure, easy maintenance and repair, and extremely low later operation and maintenance costs, meeting the operation and maintenance needs of large-scale production of refractory enterprises at home and abroad, providing a solid guarantee for the continuous and stable production of shaped refractory bricks.

As a core supporting material for high-temperature industries, the quality of shaped refractory bricks directly affects the safe and stable operation and service life of high-temperature equipment, and is also a key for refractory enterprises to capture the high-end market and enhance their core competitiveness. Currently, the global refractory industry is accelerating its transformation towards high-end, refined, intelligent, and green, and the demand for customized shaped refractory bricks is continuously increasing. Professional molding equipment has become the core support for refractory enterprises to achieve transformation and breakthrough. Zhengzhou Haloong has been deeply engaged in the field of refractory forming equipment for 45 years. It has always adhered 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 perfect management system, it continuously promotes technological innovation in servo screw presses, focuses on the core pain points of the forming of special-shaped refractory bricks, and creates exclusive intelligent solutions. It helps global refractory enterprises break through the bottleneck of transformation and achieve an all-round improvement in the quality, production efficiency and cost control of special-shaped refractory bricks. From the intelligent production line upgrades of domestic large refractory enterprises to the batch applications of customers in high-temperature industrial powerhouses overseas, Haloong's servo screw presses, with their stable intelligent performance, precise pressure control capabilities and flexible customization and adaptation advantages, have become the preferred equipment for global refractory enterprises to produce special-shaped refractory bricks, promoting the leap of China's refractory equipment from "Made in China" to "Intelligently Made in China".