Key Control Points in Standardized Brick Production Process

Key Control Points in Standardized Brick Production Process

Achieving standardization in brick production hinges on strict control and standardized management of several crucial stages throughout the entire production process. Mastering these key points ensures stable product quality, improves efficiency, and reduces costs.

I. Raw Material Processing and Batching: The Cornerstone of Quality

This is the first step determining the intrinsic quality of the brick blanks and must be addressed from the source.

Standardized Raw Material Acceptance: Establish simple raw material entry standards. Visually inspect and conduct simple tests on each batch of main materials such as sand, gravel, and fly ash to ensure their cleanliness and relatively stable particle size, removing large impurities and excessive soil.

Precise Batching Measurement: This is the core of standardization. Accurate measuring tools (such as weighbridges and batching scales) must be used. Weighing and batching must strictly adhere to the optimal proportions verified through testing, especially for cementitious materials such as cement; estimations based on experience are strictly prohibited. Centralized batching is recommended to reduce human error.

Controlling the Uniformity of Mixing: Ensure sufficient mixing time to ensure thorough mixing of water and various raw materials, resulting in uniform moisture content. Uneven mixing leads to inconsistent internal strength in the brick blank, making it prone to cracking later.

II. Molding Stage: Imparting Shape and Initial Density

This is the core process determining the appearance, dimensions, and initial strength of the brick blank.

Stable Control of Molding Pressure: The molding pressure of the brick-making machine must be stable within the set range. Insufficient pressure results in loose brick blanks with low strength; pressure fluctuations lead to inconsistent batch quality. The pressure system needs to be checked, recorded, and calibrated regularly.

Standardized Management of Molds: The mold is the "model" for the brick, and its condition directly determines the product's shape. Establish mold files, regularly check their wear and dimensional accuracy, and replace or repair them promptly. Ensure molds are properly installed and clean.

Uniformity of Material Distribution: The raw material must be filled into the mold evenly and sufficiently to avoid localized material shortages that could lead to incomplete brick blanks or uneven density.

III. Curing Stage: The Key to Strength Development

After the brick blank is formed, curing is a crucial chemical process that determines its final strength.

Standardized Curing: Newly formed wet brick blanks must be left to stand for a sufficient time (e.g., 12-24 hours) in a stable environment away from direct sunlight and wind to allow for even distribution of internal moisture and initial hardening. This is a crucial step in preventing cracking.

Systematized Watering Curing: Develop clear watering curing procedures (such as start time, frequency, and water volume) based on climate and season. Ensure the brick blanks maintain appropriate humidity during the critical period of strength development (usually 3-7 days after forming). Inadequate curing is the most common cause of insufficient strength.

Cure Environment Management: Plan a dedicated curing area with a level surface and adequate shade and rain protection. Brick blanks from different batches and production dates should be clearly separated and stacked for easy management.

IV. Inspection and Traceability: Closed-Loop Control Standardization relies on inspection and data feedback to form a closed-loop management system.

Establish Process Inspection Points: Establish inspection points after material preparation, after forming, and during the curing process. For example, randomly check the appearance, dimensions, and integrity of wet blanks, and quickly test the humidity of the curing area.

Regular Finished Product Testing: In accordance with national standards, finished brick samples are regularly sent to professional institutions for testing of key indicators such as compressive strength and water absorption rate, using authoritative data to verify whether the production process meets standards.

Establish Traceable Records: A simple file is created for each batch of products, recording the batch of raw materials used, production date, key process parameters (such as pressure values), curing records, and final inspection results. In case of quality problems, the problematic环节 can be quickly traced back to achieve precise improvement.

Summary: Replacing Experience with Procedures, Driving Decisions with Data

The essence of standardized processes is to transform production relying on experienced craftsmen's "experience" into a controllable process driven by clear procedures, stable parameters, and objective data. The focus of management is to ensure, through training, supervision, and record-keeping, that the standards of the above four key links are strictly implemented every day and in every batch of products. When these links are under control, the stable production of qualified bricks is a natural result.