As global industry transitions towards high-end and green development, the performance requirements for refractory products in high-temperature industries such as steel, cement, and non-ferrous metals continue to become more stringent. No layering, high density, and low porosity have become the core standards for refractory products to be qualified for market release. The essence of refractory forming is to achieve a tight bond between raw material particles and expel internal voids through precise pressure application, while ensuring uniform distribution of raw materials (especially materials of different densities such as graphite and corundum) to avoid layer separation due to uneven force application and incomplete gas expulsion. However, traditional forming equipment commonly used in refractory production has significant shortcomings, with layering defects being a key bottleneck restricting the quality improvement and efficiency enhancement of refractory enterprises. The core pain points are concentrated in three aspects.

First, pressure control is coarse, and the risk of layering is prominent. Traditional friction presses and ordinary hydraulic presses cannot achieve digitalized precise pressure control. The pressure intensity and speed cannot be flexibly adjusted according to the raw material ratio and particle gradation, easily leading to pressure deviations such as "heavier top and lighter bottom" and "tighter sides and looser center", resulting in loose bonding of raw material particles and layer separation. Especially for aluminum-carbon refractories, where graphite particles are relatively light, the uneven pressure application of traditional equipment can cause graphite layering and aggregation, significantly reducing the product's resistance to steel water erosion and structural stability. Data shows that the layering defect rate of refractory products produced by traditional equipment is as high as over 8%, seriously affecting product qualification rates and market competitiveness.

Second, uneven force transmission leads to loose layer bonding. The transmission structure of traditional equipment is complex, with energy losses in gears, clutches, and other components. The pressure cannot be uniformly transmitted to all parts of the blank, resulting in significant differences in the density of the surface and inner layers, as well as the center and edges of the blank, and insufficient layer bonding force. This "pseudo-dense" blank is prone to layer separation during subsequent processing or service due to temperature changes and external force impacts, shortening the service life of the refractory and increasing the downtime and replacement costs for end-users.

Third, insufficient process adaptation and incomplete gas expulsion. During the semi-dry forming process of refractory materials, if the internal air of the raw materials cannot be fully expelled, it will form bubbles in the blank, which will burst during drying and create voids, leading to layering. Traditional equipment mostly uses a single pressure application mode, which cannot precisely match "gas expulsion and densification". Either the pressure application is too fast, preventing the air from being expelled, or it is too slow, causing the raw material particles to settle and layer, making it difficult to balance the gas expulsion effect and density, further exacerbating the risk of layering. At the same time, with increasingly strict global environmental protection requirements and rising labor costs, refractory enterprises urgently need efficient, intelligent, and stable forming equipment to solve the layering problem and achieve multiple goals of quality improvement, cost reduction, and efficiency enhancement.

Compared with traditional forming equipment, the servo screw press, with its core advantages of digitalized precise pressure control, flexible process adaptation, and efficient energy transmission, is the best choice to solve the layering problem in refractory materials. It can not only completely address the shortcomings of uneven pressure application and incomplete gas expulsion in traditional equipment but also achieve uniform distribution of raw material particles and tight layer bonding, perfectly meeting the core requirements of refractory layer-free forming and helping refractory enterprises break through quality bottlenecks.

Relying on 45 years of experience in refractory forming equipment research and manufacturing, Zhengzhou Haloong has deeply integrated the third-generation permanent magnet synchronous servo direct drive technology with the semi-dry forming process of refractory materials, and combined the production characteristics of over a hundred refractory products to create a dedicated servo screw press for refractory materials. It benchmarks against global high-end equipment standards, with "uniform force control, thorough gas expulsion, and precise process adaptation" as its core, safeguarding the quality of refractory forming and becoming the preferred equipment for refractory enterprises at home and abroad. It adopts a direct drive design with permanent magnet synchronous servo motors, discarding the traditional clutch and gear transmission structure. The transmission chain is short and energy loss is low. It is equipped with an intelligent pressure control system independently developed by Haloong, which can precisely preset the pressure energy, speed and frequency through digital programs. The energy repetition control accuracy is ≤±1%, far exceeding the industry average, achieving "uniform force pressure throughout the area". According to the forming characteristics of refractory materials, it intelligently matches the three-stage forming process of "light pressure exhaust - medium pressure shaping - heavy pressure densification". In the light pressure stage, it slowly applies pressure to completely expel the air inside the raw materials, avoiding the formation of bubbles and layering. In the medium pressure stage, it applies pressure at a constant speed to promote the uniform distribution of raw material particles, eliminating density differences that cause layering. In the heavy pressure stage, it precisely controls the pressure to achieve a tight bond between particles and enhance the interlayer bonding force, ensuring that the density of the green body is consistent from the surface to the core and from the center to the edge, completely eliminating layering and layer cracking defects, with a product qualification rate stably above 99%.

It breaks through the structural bottom dead center limit of traditional equipment and adopts a step-by-step forging mode. According to the requirements of different materials and specifications of refractory materials, it can flexibly adjust the slider stroke and pressure angle, without worrying about the problem of uneven pressure caused by raw material size deviation or property changes. Whether it is high alumina, magnesia, carbon, and other different material refractory materials, or complex products such as special-shaped bricks, honeycomb lattice bricks, and large lining bricks, it can achieve precise uniform force pressure, ensuring the uniform distribution of raw material particles and tight interlayer bonding, and eliminating layering caused by local overpressure or underpressure. At the same time, the equipment can flexibly adapt to green bodies with different compression ratios, without the need for frequent adjustments to the equipment structure, significantly improving the forming adaptability and helping enterprises expand the refractory product matrix.

It adopts a fully enclosed static pressure screw, nut and bearing transmission, forming a stable oil film for protection during operation, and is equipped with a fully automatic forced lubrication system, effectively reducing the wear of transmission components, ensuring the continuous and stable transmission of pressure, without energy loss or pressure attenuation. Compared with the rigid transmission of traditional equipment, the static pressure transmission of Haloong's servo screw press can achieve flexible pressure transmission, avoiding interlayer separation caused by local stress concentration. At the same time, the transmission stability is strong, and the equipment operation vibration is small, further ensuring the uniformity of green body forming and eliminating the risk of layering from the process level. In addition, the transmission chain is short, the structure is simple, it is easy to maintain and repair, and the later operation and maintenance cost is extremely low, meeting the large-scale production needs of refractory enterprises.

Relying on Haloong's 45 years of refractory forming process experience, the servo screw press is equipped with a database of multiple refractory forming parameters. According to the characteristics of raw materials from different origins and different ratios, it can intelligently customize forming programs and pressure parameters, eliminating the need for frequent manual adjustments and reducing the impact of human factors on forming accuracy. For the ratio differences of raw materials with different densities such as graphite and corundum, it can precisely adjust the pressure speed and force to avoid layering and aggregation caused by density differences. It is equipped with a rapid mold changing system, making mold replacement convenient and efficient, significantly reducing production preparation time. It can meet both small-batch customized production and large-scale mass production needs, ensuring that each batch of products can achieve no layering and high-quality forming.

It is equipped with an intelligent production management system independently developed by Zhengzhou Haloong, with standardized industrial communication interfaces, which can be seamlessly linked with automatic feeding systems, raw material ratio systems, and green body detection equipment to build an intelligent production line for the entire refractory forming process, achieving unmanned control from "raw material entry - ratio - pressing - detection - storage". The system collects real-time data such as forming pressure and speed, and can dynamically adjust the pressure process to correct pressure deviations in a timely manner, ensuring uniform force pressure. At the same time, it supports remote monitoring and parameter adjustment, facilitating domestic and foreign customers to control production remotely, and real-time detection of forming hazards, further ensuring the quality of no layering. In addition, the equipment adopts a "start on demand, sleep for energy conservation" mode, which saves more than 55% of energy compared to traditional friction presses, helping enterprises achieve multiple goals of "energy conservation, cost reduction, no delamination, and high quality".

No delamination in refractory material forming is the core bottom line of refractory material quality and also the key for refractory material enterprises to capture market share and enhance core competitiveness. Zhengzhou Haloong has been deeply engaged in the field of refractory material forming 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 sound management system, it continuously promotes technological innovation in servo screw presses, focuses on the core pain point of no delamination in refractory material forming, and creates exclusive intelligent solutions.