The performance advantages of mullite bricks are highly dependent on the quality of the green body during the forming stage. The raw material particle size distribution is special, the high-purity aggregate has weak fluidity, and the finished product has much higher requirements for internal uniformity than ordinary refractory bricks. Only when the green body has consistent density throughout, no stress concentration, and no pore defects can it maintain a stable crystal phase structure after high-temperature sintering and achieve excellent high-temperature creep resistance and thermal shock resistance. In the industry, high-end mullite bricks (especially sintered mullite bricks and fused mullite bricks) require extremely small volume density fluctuations, no delamination or cracks inside, complete and dense edges and corners, and highly consistent performance within the same batch to meet the harsh working conditions of ultra-high temperature, strong erosion, and frequent temperature changes.

Relying on decades of refractory material forming process accumulation, Zhengzhou Haloong has deeply adapted to the raw material characteristics and forming process requirements of mullite bricks, and specially optimized and upgraded the servo screw press. It has abandoned the traditional transmission shortcomings and adopted a three-in-one core technology of permanent magnet synchronous servo motor direct drive, static pressure transmission, and intelligent numerical control system to create a dedicated mullite brick forming solution, comprehensively ensuring uniform green body density, reaching the required density, and having a complete structure without defects. The equipment performance is benchmarked against international high-end standards and has become the preferred core equipment for mullite brick production enterprises at home and abroad.

The core adopts permanent magnet synchronous servo motor direct drive technology, completely eliminating the traditional clutch and friction disc transmission structure. The transmission chain is shorter, with zero energy loss in energy transmission, and the pressure output is stable and controllable throughout the process. The equipment is equipped with Haloong's independently developed intelligent numerical control pressure control system, which can precisely preset the striking energy, pressurization speed, forming times, and holding pressure duration through the digital panel. The energy repetition control accuracy is ≤±1%, ensuring that the pressure in each forming process is highly consistent and completely eliminating the pressure fluctuations caused by manual operation and mechanical transmission. According to the raw material characteristics of mullite bricks, a flexible stepwise pressurization process can be flexibly set, starting with light pressure for exhaust, then stable pressure for compaction, and finally holding pressure for shaping. This ensures that the density of the green body is completely uniform from the center to the edge and from the surface to the inside, with the volume density fluctuation range controlled within a very small interval. The density variation coefficient is far lower than the industry standard, significantly improving the consistency of the finished product performance.

It adopts a fully enclosed static pressure screw, nut, and dedicated bearing transmission structure. During operation, a stable oil film is formed for protection, achieving flexible and uniform force transmission and pressure application, completely avoiding the impact force and stress concentration problems caused by traditional rigid pressurization. The pressurization process is smooth and gentle, allowing the complete expulsion of residual air inside the green body, ensuring that the mullite aggregate and binder are evenly bonded and densely formed. This eliminates common defects such as delamination, micro-cracks, loose edges and corners, and local material deficiency from the root, ensuring the overall structural integrity of the green body. At the same time, the equipment operates with low vibration and noise, further optimizing the forming stability, significantly reducing the green body rejection rate, and increasing the product qualification rate to over 99%.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a progressive forging forming mode. According to the specifications, dimensions, and shapes of mullite bricks (standard bricks, special-shaped bricks, large lining bricks, thin-walled bricks, etc.), the stroke of the slider, pressurization depth, and pressurization angle can be flexibly adjusted. There is no need to worry about uneven pressurization caused by raw material filling volume deviation or complex shapes. Whether it is conventional general mullite bricks or customized high-end special-shaped lining bricks, it can achieve uniform pressure application throughout the area, ensuring that special parts such as edges and corners and thin walls are also densely formed and meet the standards. Combined with a rapid mold changing system, mold replacement is efficient and convenient, significantly reducing production preparation time and perfectly adapting to the multi-variety, small-batch, and customized production needs of enterprises.

The equipment is equipped with a dedicated mullite brick forming parameter database, integrating the optimal forming process parameters for different purity raw materials and different specifications of products. Operators can call them up with one click, eliminating the need for repeated debugging and exploration, and significantly reducing the interference of human factors on product quality. The forming parameters can be permanently saved and reused in batches, ensuring that the density, size, and compactness of each batch and each piece of green body are highly uniform, meeting the strict requirements of global high-end markets in Europe, America, Southeast Asia, the Middle East, etc. for the batch stability of refractory products, and helping enterprises smoothly enter the international high-end supply chain system.

Compared with traditional friction presses, the Haloong servo screw press adopts an on-demand start-stop and sleep energy-saving mode. The servo motor only operates during the pressing process, with zero energy consumption in standby mode, achieving a comprehensive energy-saving rate of over 55%, significantly reducing production electricity costs. At the same time, the static pressure transmission structure has minimal wear, and when combined with a fully automatic forced lubrication system, the equipment has a low failure rate and a long service life, with maintenance costs reduced by more than 40% compared to traditional equipment. The mold wear is also significantly reduced, comprehensively compressing production, maintenance, and material costs, and enhancing the economic benefits of enterprises.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic feeders, precise distributors, intelligent demolding machines, green body conveyor lines, and temperature control equipment to build a fully automatic mullite brick forming production line, achieving unmanned control throughout the process from distribution, pressing, pressure holding, demolding to green body transfer, reducing labor input and improving production efficiency. At the same time, it supports remote monitoring, parameter adjustment, fault warning, and data traceability functions, facilitating domestic and foreign customers to remotely and in real-time control production progress and product quality, fully aligning with the global refractory industry's trend of intelligent, digital, and green transformation.

As a leading enterprise in the domestic electric servo screw press field, Zhengzhou Haloong Machinery Co., Ltd. has been focusing on the research and development and innovation of refractory forming equipment for 45 years, delving into the pain points of industry processes, and insisting on empowering industrial development through technological upgrades. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T, and are tailor-made for the forming of various high-end refractory materials. For different refractory products such as mullite bricks, high alumina bricks, phosphate-bonded high alumina bricks, and magnesia-carbon bricks, it can provide customized forming solutions. The products not only cover the mainstream refractory production enterprises in China but are also exported to many countries and regions around the world, including Europe, Southeast Asia, Africa, and the Middle East. With stable performance, precise pressure control effects, and comprehensive full-process after-sales service, it has gained consistent recognition and long-term trust from global customers.