You’ve purchased a brick extruder at considerable expense, yet you often feel it wears out too quickly or doesn’t perform at its best. So how can you prevent this from happening?
Raw Material Selection
If the raw materials are too hard or the particles are too large, this will naturally increase machine wear and tear.Hard raw materials not only reduce production efficiency but also increase the machine’s energy consumption.Raw materials with excessively large particles are prone to clogging the die, forcing operators to frequently stop the machine to clear debris.
Therefore, proper preparation of raw materials is crucial. Improving raw material quality ensures a smoother production process, higher efficiency, and lower costs.
Proper Operation
Operating the Vacuum Pump
Before starting the machine, turn on the vacuum pump first. Wait until the vacuum pump has extracted enough air from the mud cylinder before adding raw materials to make bricks. This ensures the bricks meet the required vacuum standards.
When shutting down the machine, turn off the vacuum pump last to prevent the slurry from being sucked back into the pump, which could damage it.
To summarize: turn on the vacuum pump first and turn it off last.
Starting and Shutting Down the Machine
When starting the machine, do not rush to add raw materials. Allow the machine to start up and run stably before adding them. Otherwise, the machine will have to operate with raw materials immediately upon startup, which not only consumes more electricity but also causes significant wear and tear on the machine.
There is also a proper procedure for shutting down the machine: stop feeding raw material first and allow the machine to run slowly until all the material stored inside has been completely discharged before turning off the main power switch. If a large amount of material remains inside, the next startup will—just like the initial startup mentioned above—consume more electricity and damage the machine.
Scientifically Increasing the Extruder’s Rotational Speed
Some people believe that increasing the extruder’s rotational speed will result in higher output and improved efficiency; however, this is not conducive to long-term production.
In reality, the optimal rotational speed varies by extruder model and must be determined based on actual conditions.
Two Common Methods for Speed Adjustment
Changing Pulley Sizes
Machines typically come equipped with several sets of pulleys of different sizes from the factory. To increase speed, use a smaller pulley; to decrease speed, use a larger one. Brick factories often use this method to adapt to the requirements of different raw materials or brick types. While this method is low-cost, it is time-consuming and results in a relative decrease in efficiency.
Using a Variable Frequency Drive (VFD)
Nowadays, many manufacturers equip extruders with VFDs right out of the box. According to reports, some extruder models have already adopted “program-controlled VFD speed regulation,” which allows for continuous speed adjustment and features a digital display—so you can see the current speed at a glance. This is much more convenient—you can adjust the speed simply by turning a knob without having to shut down the machine.
Pay Attention to Component Wear
The operational efficiency of an extruder depends on the seamless coordination of its components, some of which are prone to wear, such as the screw, barrel liner, and die.
Take the auger screw, for example:
Regularly inspect the screw for wear
Conduct a minor inspection of core components approximately every six months, and perform a thorough disassembly and cleaning about once a year.
Buy a high-quality auger
When purchasing screw assemblies, opt for slightly higher-quality ones; their increased durability reduces the need for frequent replacements, naturally lowering costs.
Keep several spare Auger Screws on hand in case an inspection reveals issues requiring replacement
For split-type Auger Screws, replace parts one at a time, starting with the most worn ones. If all parts are replaced at once, the clearance between components will suddenly decrease, increasing resistance to material flow and potentially causing temporary issues such as “material feeding failure” or “reduced output.”
FAQ
Q: How low does the vacuum pump need to go before I can start feeding material?
A: Generally, the vacuum level should reach -0.06 MPa or higher (approximately 25 inches of mercury) before starting the machine and feeding material.
Q: How do I know when I should replace the Auger Screws?
A: When the corners of the extruded slurry are not as firm as before, when the extruded slurry strands are abnormal and curved, the machine makes noise, vibrates abnormally, or consumes more electricity than before, you should consider replacing the Auger Screw.
Q: How can I tell the condition of my machine?
A: The most straightforward way is to check the ammeter directly. During normal operation, the current remains relatively stable; a sudden spike or fluctuating readings indicate the machine is working harder than usual, suggesting possible part wear or raw material issues. The same applies if the machine makes noise or vibrates.
Q: Will choosing a motor with too high a power rating consume more electricity?
A: Not necessarily. It’s best to select a motor that matches your machine’s power requirements, which depends on both your raw materials and production output. A motor with too low a power rating is prone to burning out, while one with too high a power rating operatingunder a low load for extended periods is not conducive to improving efficiency or reducing costs.
Post time: Jul-13-2026