The core advantages of cordierite bricks stem from their uniform cordierite crystal phase structure. The integrity and homogeneity of crystal phase development depend entirely on the quality of the green body during the forming stage. The forming process must meet four core requirements: uniform density, intact structure, crack-free, and precise dimensioning.

It is necessary to ensure consistent density across the entire green body, controlling the bulk density of finished products at 1.8–2.2 g/cm³ and apparent porosity ≤ 22%, laying a foundation for the uniform growth of cordierite crystal phases in subsequent high-temperature sintering. Meanwhile, agglomeration of raw material particles, microcracks, or deformation in the green body during pressing must be avoided to prevent defects such as crystal phase segregation, loose structure, and edge chipping after sintering. In addition, pressing speed and holding time must be precisely controlled to adapt to the high viscosity and difficult degassing characteristics of cordierite mixtures, preventing residual pores inside the green body from causing spalling during high-temperature service.

Currently, technical limitations of traditional forming equipment lead to widespread problems in cordierite brick production, including uneven density, green body cracking, large dimensional deviations, poor crystal phase development, and low qualified product rates, severely restricting the industrial development of high-end cordierite bricks. Relying on its third-generation permanent magnet synchronous servo direct-drive core technology, Zhengzhou Haloong has optimized and upgraded the HLDS series CNC servo screw presses to target pain points in cordierite brick forming and develop dedicated forming equipment. With core strengths in precise pressure control, flexible pressure transmission, and intelligent adaptation, it sets a quality benchmark for high-end cordierite bricks.

Compared with ordinary refractory bricks, cordierite bricks pose significantly higher forming difficulty. Their raw materials are mainly fine powders with precise gradation; the mixture features high viscosity, poor fluidity, and difficult degassing, with a drying shrinkage rate as high as 3%–5%. This imposes extremely strict requirements on the accuracy of pressing force, speed, and holding time. Precise pressing is required to densify the green body and provide a uniform structural basis for crystal phase development, while rigid impacts that cause cracking or deformation must be avoided. Air in the mixture must also be efficiently expelled to prevent residual pores from impairing product performance.

Zhengzhou Haloong has conducted in-depth research on the raw material properties, forming process logic, and industry upgrading demands of cordierite bricks. With a trinity core technology of permanent magnet synchronous servo motor direct drive + hydrostatic flexible pressure transmission + intelligent CNC system, the company has carried out customized optimization on the HLDS series servo screw presses, achieving comprehensive upgrades in equipment accuracy, stability, and adaptability. Its advantages precisely match the forming needs of cordierite bricks, making it the preferred equipment for mass production of high-quality cordierite bricks and helping refractory manufacturers develop premium products for high-end high-temperature applications.

Equipped with a permanent magnet synchronous servo motor direct-drive system, the press completely eliminates inefficient transmission components such as traditional friction discs and clutches. Featuring an extremely short transmission chain with zero energy loss, it delivers stable and controllable pressure output throughout operation. The machine is fitted with Haloong’s self-developed CNC pressure control module dedicated to cordierite bricks, enabling digital precise setting of striking energy, pressing speed, stepwise pressing cycles, and holding time. The energy repetition control accuracy is ≤ ±1%, ensuring highly consistent forming pressure for every stroke and completely eliminating quality deviations caused by manual operation and mechanical fluctuations.

In response to the high viscosity, difficult degassing, and easy agglomeration of cordierite mixtures, a customized stepped flexible pressing process is adopted: loose raw materials are first lightly pressed to slowly expel residual air, then compacted layer by layer through stepwise pressure stabilization, and finally shaped via long-term pressure holding. This ensures uniform stress distribution across the entire green body—center, edges, and corners—with density fluctuations controlled within a minimal range, laying a solid foundation for uniform cordierite crystal phase growth during subsequent high-temperature sintering and raising the qualified product rate to over 99%.

The press adopts a fully enclosed hydrostatic screw, nut, and dedicated heavy-duty bearing transmission structure, which forms a stable high-pressure oil film during operation for flexible, even, and gradual pressure application. This completely avoids the severe impact and stress concentration caused by traditional rigid pressing.

The pressing process is smooth and gentle with uniform pressure transmission, which fully removes internal pores, breaks up raw material agglomerates, and eliminates defects such as looseness, delamination, and cracks. It also gently preserves the activity of raw material particles, preventing green body cracking and deformation, significantly reducing waste of high-cost raw materials. Meanwhile, it effectively extends mold service life, lowers consumable costs, and improves enterprise production efficiency.

Breaking through the structural limitation of fixed bottom dead center in traditional equipment, the press adopts a progressive forging forming mode. It can flexibly adjust slider stroke, pressing depth, and force according to cordierite brick material, dimensions, structural complexity (standard bricks, special-shaped bricks, saggers, pushing plates), and density requirements, precisely adapting to the forming needs of various cordierite bricks and covering full-scenario production of high-end refractories.

Uneven pressing caused by deviations in raw material filling, particle fineness differences, or mixture viscosity variations is no longer a concern. Paired with a quick mold change system, mold replacement is convenient and efficient, perfectly suiting flexible multi-variety, mass production and meeting bulk supply demands for high-end applications.

The machine features a built-in dedicated forming parameter database for cordierite bricks, integrating optimal process parameters for cordierite bricks of various specifications, raw material ratios, and density requirements—covering standard bricks, special-shaped bricks, high-strength thermal-shock-resistant cordierite products, and other common items. Operators can retrieve parameters with one click without repeated trial and error, greatly reducing human interference with product quality.

All forming parameters can be permanently stored and reused in batches, ensuring highly consistent density, compactness, and dimensional accuracy for each batch and every product, with uniform crystal phase distribution. This easily meets stringent quality requirements of high-end markets at home and abroad, helping enterprises smoothly access overseas high-end refractory markets.

Compared with traditional friction screw presses, Haloong servo screw presses adopt an intelligent on-demand start-stop and sleep energy-saving mode. The servo motor runs only during the pressing process with zero energy consumption in standby mode, achieving a comprehensive energy saving rate of over 55%. This drastically reduces power consumption for cordierite brick production, aligning with the green and low-carbon development needs of the refractory industry.

Additionally, the hydrostatic transmission structure experiences minimal wear. Coupled with a fully automatic forced lubrication system equipped with an oil shortage alarm, the press realizes maintenance-free operation, features a low failure rate, and a service life far exceeding traditional equipment. Later operation and maintenance costs are reduced by over 40%, comprehensively cutting production, maintenance, and consumable expenses and helping enterprises achieve a green, low-carbon, and highly profitable production model.

Equipped with standardized industrial communication interfaces, the press can seamlessly integrate with automatic precision feeders, closed-loop distributors, intelligent demolding machines, green body non-destructive testing equipment, and constant-temperature conveyors to build a fully automatic intelligent forming production line for cordierite bricks. It enables unmanned control of the entire process from material distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing manual intervention. This not only avoids damage to green bodies from manual handling but also guarantees forming accuracy and production efficiency.

The press also supports remote monitoring, parameter adjustment, fault early warning, and production data traceability, allowing domestic and overseas customers to remotely manage production progress and product quality in real time. It fully aligns with the global trend of intelligent, digital, and green transformation in the refractory industry, helping enterprises build intelligent production bases for high-end cordierite bricks.

As a leading enterprise in the field of electric servo screw presses in China, Zhengzhou Haloong Machinery Co., Ltd. has focused on technological innovation in refractory forming equipment for 45 years. It has deeply addressed forming process pain points of high-end refractory products such as cordierite bricks and persisted in empowering the upgrading of the refractory industry with customized technologies.

Haloong HLDS series CNC servo screw presses cover a full tonnage range from 200T to 1600T. According to customers’ requirements for cordierite brick material, specifications, production capacity, density, and raw material ratio, the company provides one-to-one customized forming solutions, fully meeting the mass production needs of various cordierite bricks and products and supporting refractory supply for different high-end high-temperature fields.