Mullite bricks are mainly made from high-alumina bauxite and synthetic mullite. The raw materials have high hardness and special fluidity. During the forming process, it is necessary to ensure full compaction while avoiding rigid impact that could damage the structure of the green body. Traditional friction presses and ordinary hydraulic presses cannot balance precision, stability, and process adaptability, highlighting the core pain points.

Zhengzhou Halooong has optimized the HLDS series servo screw press specifically for the characteristics of mullite brick raw materials and forming processes. It has abandoned the shortcomings of traditional equipment and adopted three core technologies: permanent magnet synchronous servo direct drive, static pressure flexible pressure transmission, and intelligent numerical control closed-loop. This enables precise pressure control, smooth pressure application, and intelligent management, fully meeting the strict forming requirements of mullite bricks and becoming the preferred equipment for high-end mullite brick production.

The equipment is equipped with a high-performance permanent magnet synchronous servo motor direct drive system, completely eliminating the traditional friction transmission structure. The transmission chain is short, and there is no energy loss during energy transmission. The pressure output is stable and controllable throughout the process. It is equipped with a self-developed numerical control pressure control module that can digitally and precisely set the impact energy, pressurization speed, pressurization times, and holding time. The energy repetition accuracy is ≤±1%, ensuring that the pressure for each forming process is highly consistent. According to the characteristics of mullite raw materials, a customized stepwise flexible pressurization process is adopted. First, light pressure is applied to exhaust air from the green body, then pressure is gradually increased to compact it, and finally, long-term holding pressure is applied to shape it. This ensures uniform force on the center, edges, and corners of the green body, with density fluctuations controlled within a very small range. The density variation coefficient is far better than industry standards, fundamentally improving the density and compressive strength of mullite bricks.

It adopts a fully enclosed static pressure screw, nut, and heavy-duty bearing transmission structure. During operation, a high-pressure oil film buffer is formed to achieve flexible and uniform pressure application, completely avoiding the drawbacks of traditional rigid impact. The pressurization process is smooth and gentle, which can thoroughly eliminate internal pores, delamination, and porosity in the green body, while gently protecting the brittle mullite green body, preventing microcracks, edge and corner defects, and deformation. This increases the product qualification rate to over 99%, significantly reduces raw material waste, and extends the service life of molds, lowering material costs.

It breaks through the structural limitations of traditional equipment with fixed bottom dead centers and adopts a step-by-step forging forming mode. The stroke of the slider, pressurization depth, and force can be flexibly adjusted according to the specifications, dimensions, and shapes of mullite bricks, perfectly adapting to the forming of all types of products, including standard mullite bricks, special-shaped mullite bricks, and special mullite lining bricks. Whether it is conventional-sized brick bodies or complex-shaped parts, uniform compaction can be achieved. Combined with a rapid mold change system, mold changes are convenient and efficient, accommodating both large-scale mass production and small-scale customized production.

The equipment is equipped with a dedicated mullite brick forming parameter database, which includes the optimal forming parameters for different materials and specifications of mullite bricks. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, significantly reducing human operation errors. All parameters can be permanently saved and reused in batches, ensuring that the density, size, and density of each batch and each green body are highly consistent, completely solving the problem of batch quality fluctuations, and easily meeting the strict quality inspection standards of the domestic and international high-end refractory markets.

Compared with traditional friction presses, Halooong servo screw presses adopt on-demand start-stop and sleep energy-saving modes. The servo motor only operates during the pressing process, with zero energy consumption in standby mode. The comprehensive energy-saving rate is over 55%, significantly reducing production electricity costs. The static pressure transmission structure has extremely low wear, combined with a fully automatic forced lubrication system, which greatly reduces equipment failure rates and extends service life far beyond that of traditional equipment. The later maintenance and operation costs are reduced by more than 40%, helping enterprises achieve green, low-carbon, and efficient profitable production. The equipment is equipped with standard industrial communication interfaces, which can be seamlessly integrated with automatic feeding machines, precise material distribution machines, intelligent demolding machines, and conveying inspection equipment to build a fully automatic and intelligent mullite brick forming production line. This enables unmanned operation throughout the entire process, including material distribution, pressing, pressure holding, demolding, and transportation, minimizing human intervention and enhancing production efficiency and forming accuracy. It also supports remote monitoring, parameter adjustment, fault warning, and data traceability functions, facilitating off-site production control for enterprises and aligning with the global trend of intelligent and digital transformation in the refractory materials industry.

Zhengzhou Halooong Machinery Co., Ltd., as a leading enterprise in the domestic servo screw press field, has been dedicated to technological innovation in refractory material forming equipment for 45 years. It has been deeply involved in various refractory material forming processes and adheres to a customer-oriented approach to create high-performance, high-stability, and highly adaptable professional equipment. The Halooong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. Based on the production capacity, specifications, and process requirements of mullite bricks of enterprises, it provides one-to-one customized solutions to fully meet the production needs of enterprises of different scales.