Do you want to know how a block-making machine works?
The operation of a block-making machine is based on the vibration and compression of the concrete. They have a hopper in which to receive and store the fresh cement for the production of the blocks. After this, the material is dosed in to fill the mould with the right amounts. To make it easier to fill each mould, the tray and the mould are vibrated, and the shaker is too.
Once this step is done, the piece is compressed to the exact size and the air that appears between the sand grains and the gravel is removed. Finally, it is vibrated again to help its compression (harder than when the mould was filled).
What elements do we need to make the block machines work?
We talk about three types of basic elements in the operation of the block machines:
About Poyatos: Leaders in the block machine market
At Poyatos we have a range of presses consisting mainly of five models. All can work with wooden, plastic or metallic production trays of variable sizes and integrated into a production line equipped with different options (for product transfer, palletising, etc.) to meet each customer’s needs.
Now, we are going to talk about the operation of our block-making machine models. Here we are going to start by distinguishing between automatic, semi-automatic and manual block machines. In the case of the manual machine, it is the machine itself that moves and takes up excessive space in the factory.
In the automatic and semi-automatic models, it is the trays that move. This greatly facilitates the production process and helps to increase production capacity. Our block machines are designed and prepared to manufacture concrete blocks of various characteristics and sizes.
Evolution over the years
These have been evolving exponentially, from the first, which were simple metal moulds in which the mixture was made naturally, to those that we now offer that do all the tasks automatically. They also offer high production values, with minimal maintenance costs and adapt to all the needs of the different customers.
How do the automatic block machines work?
Within the different types of block machines there are different possibilities. Thus, for example, The installation circuit can be configured in a line or in a U with a set of 5-height elevator and descender units that speed up the tray transfer to the dryers by means of a forklift truck. As for palletising, the machine can have a pneumatic or automatic palletiser, etc.
But a block-making machine also has different parts or mechanisms: vibrating table, the mould with different cavities to vary the size and type of concrete blocks that can be prepared, the compacting plates, etc.
There is also the base on which to place the springs, the rails, and a carriage to transport the compactor. We start with the two ranges that offer lower maintenance costs, require fewer installations, but which still offer large productions:
Prima, the cheapest
An inexpensive unit designed for entrepreneurs from developing countries who want to make quality concrete products at an industrial level, or for manufacturers in small markets or who wish to make some type of special product. A model of fixed presses with large production capacity, but also robust and very easy to handle and maintain.
Both the concrete production and the part manufacture are automatic processes. Once the concrete products are manufactured on the production trays, which can be metal or wood and are removed by an operator using a carriage and are transported to the curing area. The products will subsequently be palletised by hand.
Syncro, the block machine with minimum maintenance
The SYNCRO block machine works with a wooden or metal tray with a length ranging from 1200 mm to 1400 mm and a width ranging from 600 mm to 900 mm. The installation circuit can be configured in a line or in a U, with a set of 5-height elevator and descender units that speed up the tray transfer to the dryers by means of a forklift truck.
As for the palletising, the machine can have a pneumatic or automatic electronic palletiser. In all its options, the press can be complemented with equipment to manufacture double layer products.
How do high production block-making machine models work?
Finally, we are going to delve into the three high-production models that we have at our Poyatos block factory.
Universal, block machine of the utmost reliability
The first of the block machines that we are going to talk about is the Universal, a fully automated unit that requires minimal maintenance and few personnel. It requires a single person to control and supervise it as the entire production process is fully automated (it is managed by computer with customised easy-to-use software). It therefore performs an optimised process, with low energy consumption and easy handling. Furthermore, thanks to the synchronised vibration system of the press (extremely reliable and efficient, but at the same time very simple), it requires little maintenance.
Novabloc: reducing manufacturing time
Another fully automatic block-making machine, equipped with the modular vibration system, patented by Poyatos. This vibration consists of two vibrating shafts synchronised one way. In turn, each of these carries two eccentric masses that are added or compensated at full load and at speed, without stopping, vibrating or not, with the motor always running.
Megabloc, the highest production block-making machine
We come to the Megabloc block machines, those of highest production capacity in the market. This press stands out with the highest productivity on the market (more than 4,500 twenty-centimetre blocks per hour, 18 pieces per tray) thanks to its modular vibration system (patented), driven by a single 45 kW motor based on 2 independent vibration tables. This allows compensation of filling through the independent regulation of the vibration parameters of each of the tables. It also has an encoder in its system to electronically and very precisely control the frequency and amplitude of the vibration.