The core advantage of refractory hollow sphere bricks lies in their special structure of "hollow spheres + matrix". The integrity and uniform distribution of hollow spheres are the keys to achieving lightweight and energy-saving, while the forming process directly determines the stability of this structure. High-quality refractory hollow sphere bricks require a volume density controlled within 1.2-1.8g/cm³, a compressive strength at room temperature of ≥30MPa, a reasonable and uniform porosity, and at the same time, it is necessary to ensure that the green body has no micro-cracks, no delamination, and no broken hollow spheres. Otherwise, it will lead to a significant decrease in insulation performance, insufficient mechanical strength, and easy collapse and damage of the brick body in high-temperature environments, which not only affects the normal operation of equipment but also increases energy consumption and replacement costs. With the acceleration of the global industrial green and energy-saving transformation, the demand for "energy-saving, lightweight, and long-lasting" refractory materials in high-temperature industries continues to upgrade. Lightweight, high-strength, and stable insulation refractory hollow sphere bricks have become the mainstream in the industry, which also puts forward higher requirements for the accuracy, flexibility, and stability of forming equipment.

Compared with traditional forming equipment, the servo screw press, with its core advantages of digital precision pressure control, flexible pressure transmission, and batch stability, has become the best choice to solve the forming problems of refractory hollow sphere bricks. It can not only precisely control the pressure to protect the integrity of the hollow spheres but also achieve uniform density throughout the green body without cracks, while ensuring the consistency of batch production. It perfectly meets the core forming requirements of refractory hollow sphere bricks for "lightweight, high strength, and energy-saving", helping enterprises break through quality bottlenecks, expand the high-end market, and promote the upgrade of refractory material industry equipment from traditional mechanical transmission to digital and intelligent.

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 hollow sphere bricks. Combining the core demands of refractory hollow sphere bricks for "vulnerability of hollow spheres, difficulty in controlling density, easy cracking, and need for uniform distribution", it has developed a dedicated servo screw press for refractory hollow sphere bricks. This press is benchmarked against global high-end equipment standards, with "flexible pressure control, precise pressure transmission, and intelligent stable production" as its core. It addresses issues such as uneven density and stress cracks, providing a guarantee for the forming quality of refractory hollow sphere bricks. It has become the preferred equipment for refractory hollow sphere brick enterprises at home and abroad, and its core performance can rival that of international high-end similar equipment.

It adopts a permanent magnet synchronous servo motor direct drive design, eliminating traditional clutches and gear transmission structures. The transmission chain is short and energy loss is low. It is equipped with Haloong's independently developed intelligent flexible pressure control system, 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 "flexible and uniform force pressure", precisely matching the fragile and easily broken characteristics of refractory hollow spheres. According to the forming characteristics of refractory hollow sphere bricks, it intelligently matches a three-stage forming process of "light pressure slow discharge - medium pressure uniform distribution - gentle pressure densification": in the light pressure stage, it slowly applies pressure to completely expel the internal air and excess moisture of the raw materials, avoiding the formation of residual bubbles and cracks; in the medium pressure stage, it applies pressure at a uniform speed to promote the uniform distribution of hollow spheres, ensuring the close adhesion of the matrix and hollow spheres, and preventing local aggregation or absence of hollow spheres; in the gentle pressure stage, it precisely controls the pressure, flexibly adjusting the pressure size based on the particle size of the hollow spheres and the raw material ratio. While ensuring the density of the green body, it effectively protects the integrity of the hollow spheres (with a hollow sphere breakage rate controlled below 3%), achieving precise control of the green body density, with the volume density fluctuation range controlled within ±0.05g/cm³. It completely eliminates defects such as excessive density and insufficient mechanical strength, and the product qualification rate is stably above 99.5%. The insulation and energy-saving effect of the products is 18% higher than that of products produced by traditional equipment. It breaks through the structural bottom dead center limitation of traditional equipment and adopts a successive forging mode. According to the different specifications, shapes (straight bricks, arc-shaped bricks, and special-shaped hollow sphere bricks), and different hollow sphere particle size ratios of refractory hollow sphere bricks, it can flexibly adjust the slider stroke, pressing angle, and pressure size. There is no need to worry about the problem of uneven pressing caused by hollow sphere particle size deviation or complex brick shapes. Whether it is ordinary specification hollow sphere standard bricks, large special-shaped hollow sphere bricks, or hollow sphere bricks with holes, it can achieve flexible and uniform force pressing, ensuring that the entire part of the blank, the density of the edge and corner details is consistent, and the hollow sphere distribution is uniform, eliminating the problem of local over-pressing causing hollow sphere breakage or under-pressing causing blank porosity. At the same time, the equipment can flexibly adapt to hollow sphere blank materials with different compression ratios without frequent adjustment of the equipment structure. Combined with a rapid mold changing system, the mold replacement is convenient and efficient, significantly reducing the production preparation time. It can not only meet the small-batch customized production needs but also adapt to large-scale mass production requirements, helping enterprises expand the product matrix of refractory hollow sphere bricks and meet diversified market demands.

It adopts a fully enclosed static pressure screw, nut, and bearing transmission. During operation, a stable oil film is formed for protection, and it is combined with a fully automatic forced lubrication system to effectively reduce the wear of transmission components, ensuring the continuous and stable transmission of pressure without energy loss or pressure attenuation. It perfectly meets the forming requirements of refractory hollow sphere bricks, which are "uneven in texture and prone to cracking". Compared with the rigid transmission of traditional equipment, the static pressure transmission of the Haloong servo screw press can achieve flexible pressure transmission, avoiding stress concentration in the internal and edge parts of the blank, effectively eliminating the hidden dangers of micro-cracks, delamination, and corner dropping in the blank. At the same time, the transmission stability is strong, and the equipment operation vibration is small, further ensuring the uniformity, consistency, and dimensional accuracy of the refractory hollow sphere brick blank forming, eliminating forming hazards 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 reduced by more than 40% compared with traditional equipment, meeting the needs of large-scale and low-cost production of refractory hollow sphere brick enterprises and significantly improving the production efficiency of enterprises.

Relying on Haloong's 45 years of refractory forming process experience, the servo screw press is equipped with a dedicated forming parameter database for refractory hollow sphere bricks, covering the forming parameters of hollow sphere bricks with different particle sizes, different ratios, different specifications, and different shapes. According to customer needs and the characteristics of raw materials from different origins, it can intelligently customize the forming program and pressing parameters without frequent manual adjustments, reducing the influence of human factors on forming accuracy. For the batch production needs of refractory hollow sphere bricks, the equipment can achieve one-click calling and batch copying of forming parameters, ensuring that the density, size, hollow sphere distribution, and mechanical strength of each batch and each product are consistent, with a density variation coefficient controlled below 1.0%, perfectly meeting the batch procurement needs of high-end metallurgical and petrochemical enterprises. At the same time, it is equipped with an intelligent detection and early warning function, which can monitor the forming parameters in real time and correct the pressure deviation in time, further ensuring the stability of batch production and solving the industry pain point of large quality fluctuations in batch production of traditional equipment.

Equipped with the intelligent production management system independently developed by Zhengzhou Haloong, it is equipped with standardized industrial communication interfaces and can be seamlessly linked with the automatic feeding system, raw material ratio system, and blank detection equipment for refractory hollow sphere bricks, building an intelligent production line for the entire process of hollow sphere brick forming, achieving unmanned control from "raw material entry - ratio - pressing - detection - storage", significantly reducing labor input and meeting the industry's demand for rising labor costs. It can help enterprises reduce two-thirds of the operators and significantly improve production efficiency. The system can collect data on forming pressure, speed, and size in real time and dynamically adjust the pressing process to correct pressure deviations in time, ensuring flexible and uniform force pressing and guaranteeing the density, dimensional accuracy, and uniformity of hollow sphere distribution of the refractory hollow sphere brick blank. It supports remote monitoring and parameter debugging simultaneously, facilitating domestic and foreign customers to manage production remotely and in real-time, and promptly identify potential problems during molding, further ensuring product quality. Additionally, the equipment adopts a "start on demand, sleep for energy saving" mode, which saves more than 55% energy compared to traditional friction presses, helping refractory hollow sphere brick enterprises achieve multiple goals of "energy conservation, cost reduction, high quality, and high efficiency", aligning with the global trend of green production and injecting impetus into the sustainable development of enterprises.

Refractory hollow sphere bricks, as high-end lightweight and energy-saving refractory materials, are the core support for high-temperature industries to achieve energy conservation and emission reduction and green transformation. The molding equipment is the core guarantee of quality. With the global industrial transformation towards high-end, green, and efficient, the quality requirements for refractory hollow sphere bricks continue to rise. Lightweight, high-strength, heat-insulating, and stable hollow sphere bricks with consistent batch quality have become the mainstream demand in the industry, and also put forward higher requirements for the accuracy, intelligence, and flexibility of molding equipment. Zhengzhou Haloong has been deeply engaged in the field of refractory material 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 detection means, and a perfect management system, it continuously promotes technological innovation of servo screw presses, focuses on the core pain points of refractory hollow sphere brick molding, and creates exclusive intelligent solutions.