Unikiln.MaCF

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Welcome to the right place wherever you could find a secure but investment friendly solution with mordern technology for a successful bricks plant,no matter any clay,fuel, we have a customized machinery and thermal engineering package only for you!

In the extrusion of clay bricks and blocks, the vacuum degree of the extruder significantly affects the quality of the g...
20/06/2025

In the extrusion of clay bricks and blocks, the vacuum degree of the extruder significantly affects the quality of the green body as detailed below:

Improved Green Body Density:
High vacuum effectively removes air and moisture from the clay raw material, resulting in a denser internal structure of the green body. Reduced porosity increases the density, thereby enhancing the strength and forming precision of the green body. This helps minimize cracking and deformation during subsequent firing.

Enhanced Green Body Plasticity:
During vacuum extrusion, clay particles align more closely under low-pressure conditions, and moisture in the raw material is distributed more uniformly. This improves the plasticity and forming performance of the green body, making it easier to shape during extrusion, with smoother surfaces and more stable dimensions.

Reduced Internal Defects:
Low vacuum or non-vacuum extrusion may lead to residual air bubbles or microcracks in the green body. These defects can expand during drying and firing, causing cracking or reduced strength in the fired bricks. High vacuum significantly reduces such internal defects, improving the quality of the finished bricks.

Impact on Drying and Firing Performance:
Green bodies with high vacuum have fewer internal pores and more uniform moisture distribution, leading to more even shrinkage during drying and a lower risk of drying cracks. Additionally, denser green bodies exhibit more uniform heat conduction during firing, resulting in higher strength and durability of the fired bricks.

Production Efficiency and Cost:
Appropriate vacuum levels can improve extrusion efficiency and reduce defect rates in green bodies, thereby lowering scrap rates and production costs. However, excessively high vacuum may increase equipment energy consumption and maintenance costs, necessitating a balance between quality and cost.

Practical Considerations:
The vacuum degree is typically controlled within the range of -0.085 to -0.1 MPa, depending on the properties of the clay (e.g., plasticity, moisture content) and the type of brick.
The particle size, moisture content, and impurity levels of the clay raw material affect the vacuum extrusion outcome, requiring optimization of the raw material formulation to match the vacuum degree.
Equipment sealing and vacuum pump performance directly influence vacuum stability, requiring regular maintenance.
In summary, higher vacuum levels generally lead to better green body quality; however, the vacuum level should be optimized based on specific raw materials and process conditions to balance quality, efficiency, and cost.

In the clay brick production process, the importance and complexity of drying cannot be overemphasized; It determines th...
16/06/2025

In the clay brick production process, the importance and complexity of drying cannot be overemphasized; It determines the efficiency, cost, and most importantly, the quality of the bricks.

If only the thermal factors are considered, we can think of the drying process to be a complete convective heat transfer process, and there are three determining factors:
(1) The temperature of the drying medium;
(2) the contact area between the drying medium and the clay brick;
(3) the flow rate of the drying medium;

When we introduce the above three factors into the design of brick dryers, we must consider the influence of industrial production on the drying process:
(1) How to make the temperature field of the whole drying furnace evenly distributed and eliminate the temperature difference to heat every piece of product evenly?
(2) How to make each brick have the largest area in contact with hot air, which involves how to stack wet billets and the way to send hot air.
(3) How to control the hot air flow rate inside the drying furnace and control the dehydration rate of the green body; It is required to increase the drying speed and ensure the safety of the product at the same time.

Balancing drying efficiency and drying quality in the drying process is extremely challenging, which requires overall planning of products, raw materials, drying kiln design, and control of the drying system. Only by making customized drying solutions can we contribute to customers.

Our years of experience in intermittent chamber dryers, continuous dryers, fast roller dryers, hot air circulation systems, diversified hot air supply management systems, and controllable moisture exhaust management systems can contribute to your success.
www.unikiln-macf.com

Fuzzy-PID on Tunnel Kiln Temperature ControlUnikiln Technical Department,June. 2025Fuzzy-PID control is an advanced cont...
11/06/2025

Fuzzy-PID on Tunnel Kiln Temperature Control
Unikiln Technical Department,June. 2025

Fuzzy-PID control is an advanced control strategy that combines fuzzy logic with traditional PID control, particularly suitable for handling nonlinear, time-varying, or uncertain industrial systems like tunnel kiln, roller kiln for ceramics or clay bricks industries;

Traditional PID control calculates the control output to reduce system error (the difference between the actual value and the setpoint) using three parameters: Proportional (P), Integral (I), and Derivative (D). Specifically:
● Proportional (P): Responds immediately to the current error, making large adjustments for large errors and small adjustments for small errors.
● Integral (I): Accounts for the accumulation of past errors to ensure the system stabilizes at the setpoint, but may cause overshoot.
● Derivative (D): Predicts future error based on the rate of change, helping the system approach the target smoothly, but may amplify noise.

However, traditional PID control may perform poorly in nonlinear systems (such as kiln temperature control) or time-varying systems because its parameters are fixed and cannot adapt to complex conditions.

Fuzzy-PID control introduces fuzzy logic to dynamically adjust PID parameters, making the controller more flexible. Fuzzy logic is a reasoning method that handles uncertainty and vague information, allowing control rules to be described in natural language rather than relying on precise mathematical models. For example:
● If the error is large and changing rapidly, increase the proportional gain for a quick response.
● If the error is small and stable, reduce the integral gain to avoid overshoot.

This approach is particularly suitable for complex industrial scenarios, such as temperature control and pressure regulation.

The core of Fuzzy-PID control is a Fuzzy Logic Controller (FLC), with the following workflow:
● Input: The FLC receives two primary inputs—error (E, the difference between the actual value and the setpoint) and the rate of change of error (ΔE, the rate of error change).
● Fuzzification: Maps E and ΔE to fuzzy sets using membership functions (e.g., triangular or trapezoidal functions) to represent concepts like “large error” or “fast change.”
● Fuzzy Inference: Performs reasoning based on predefined fuzzy rules. For example:

● Rule 1: If the error is large and changing rapidly, set a high proportional gain.
● Rule 2: If the error is small and stable, set a low integral gain.
● These rules are typically designed based on expert experience or system characteristics.

System Configuration for Fuzzy-PID Kiln Temperature Control
The following describes the system configuration for a Fuzzy-PID kiln temperature control system with 1 line containing 6 burner units, each with 12 burners:

Hardware:
● An industrial computer equipped with an Intel Core i7 processor, 32GB RAM, 512GB SSD, and Windows operating system.
● A Siemens S7-315 PLC or another PLC of equivalent grade.

Software:
● MATLAB for FLC programming.
● Siemens TIA Portal for programming or another PLC programming platform;

05/06/2025

Automatic Green Clay Bricks Loading to Dryer

For the double setting process, Unikiln's Mode 1018 System gives a simple, full automatic, well-protected green bricks surface manner, enabling the fast, flexible, and reliable loading of the Dryer Trolley:

(1) Dryer Trolley Capacity: 1200 pcs per car by 10 layers;
(2) Only bearing bars, not the cumbersome steel frameworks, instead.
(3) Only about 10 minutes to complete one trolley, which means 100,000 pieces loaded a day easily;
(4) The green brick's exposed surfaces are not touching the bars, which gives the best surface quality in favor of the late drying and firing;
(5)Full automatic with PLC, Position Sensor, Servo Motors under a simple HMI;
(6) Investment Friendly;

below to find more details
https://www.unikiln-macf.com/col.jsp?id=197

30/05/2025

The Charm of Clay Texture Variations

Clay bricks can present diversified colors despite the usual red or blue, when we dig more clay sources in multiple types and techniques when playing with it;

See this clay paver brick with a wooden texture, which looks so natural, like a tribute to the natural wood, and the appearance is irregular, enabling a sense of comfort.

The method to realize it? 3 types of clay in varied colors, coming out of the extruder to build up the unpredictable flow texture, can be?

Talk to us to explore the behind........

Single or Double Settings? Between the forming and firing for making clay products like clay bricks perforated or not, c...
26/05/2025

Single or Double Settings?

Between the forming and firing for making clay products like clay bricks perforated or not, clay hollow blocks, an important decision has to be made to apply for green bricks handling automatically, Moni or Double Setting the green bricks?

If you go with the dry clay and stiff exteuder for making solid or 30% void below perforated bricks, the hard extruded green bricks are strong enough to be set directly on the tunnel kiln car without worrying the deformation, and the after the drying, the same kiln cars with loads will be pushed directly to the tunnel kiln, which means the once-done setting green bricks can come to the end of tunnel kiln exit, as a streamlined and simplified route to go-Mono Setting.

but the corns of mono setting is prominent, low efficiency drying because of the stacking and more cracks may happen and marks of stacking left could reduce the value of bricks.

in order to avoid those negatives, the double setting technology is emerged, that means the green bricks are set onto the customized dryer trolley where every brick is separated from each other without surface touching, thus the ventilation in drying is more superior and good surface quality could be achieved too, and the deformation of the bricks is less logically. After the drying, the dried bricks are unloaded off the dryer trolley and to be rearranged onto the tunnel kiln car, this process as we suggest as Double Settings. Obviously it is better for those high valued products: Facing bricks, Hollow Blocks, despite of its technological complex.

We'd like to lisen on what is your thinking of this critical decision.

23/05/2025

One of Best Sold our Extruder

Since the first vacuum extruder in China was successfully developed by our company in 1988, we are pleased to have handed over 2000 extruders serving customers in China and around the world;Here is one of the best-selling models of extruder in our catagory: MJYK-50/45 vacuum double-stage combined extruder;

This model is fitting various clays with different plasticity, fineness, and moisture owning to its wide range of adaptability, thanks to its rich expereinced design of:
❏ extrusion screw auger
❏ extrusion main shaft speed adjustment ratio range,
❏ optimized rear gearbox reducer that provides a maximum torque of 200,000 NM,
❏ achieving perfect balance in feeding and extruding;

This model can cater to different types of quality clay and products for customers, equipped with various extruder pressure heads maintained at 3.5 MPa continuously and stably ;

VFD control based on the SCADA system provides efficient, energy-saving, and intelligent operational management;

For high-quality clay products with a daily output of 120 to 200 tons, such as clear water bricks, roofing tiles, and insulation blocks, the MJYK-50/45 is always a mature,reliable, and proven choice;

Importantly, it is also very cost friendly those high value added products investor;

Know more for this machine, please refer to: https://www.unikiln-macf.com/en/col.jsp?id=223

19/05/2025

Roller Kiln on Firing Clay Products

Unikiln has devoted to introduce the Roller Hearth Kiln (RHK) into the clay products, as some meant as flat extrusion bricks and tiles, like roof tiles, thin bricks, perforated bricks for years, and successfully commissioned projects domestically and internationally;

This short video shows a RHK we installed for roof tiles firing coming out the line;

Traditionally, RHK is used for ceramics and porcelain products thanks to its fast firing cycle, energy saving, and excellent temperature uniformity; Those advantages apply to the clay products too, surely, however, some important differences tailored for the clay characteristics must be carefully taken care of.

Just think of the exciting data below compared to Zigzag, Hoffman, or tunnel kiln:
❏ Firing cycle down to 3~8 hours;
❏ 15-20% energy saving;
❏ A coal-firing system could be integrated.
❏ Quick installation without foundation;
❏ Reduced Investment;

know more details for RHK, please refer to: https://www.unikiln-macf.com/col.jsp?id=185

15/05/2025

A Shuttle Kiln Delivered

We are very pleased with the just delivery of a complete set of shuttle kiln for our honored custermer based in South Asia for firing high temperatuer porcelain tablewares;

The Shuttle kiln features its notable flexibility on the productions, and within this shipped one, it follows the below technical data:
● Highest classification temperature: 1400℃;
● Effective volume: 20 cu.m within a kiln car;
● Atomsphere: Oxidation & Reduction;
● 24 Venturi burners are equipped for minimum electrical loads;
● DSC Controlling Platform;
● It will be used for Hard Porcelain Glost Firing;

Knowing us more about our kilns for porcelain:
https://www.unikiln-macf.com/col.jsp?id=250

12/05/2025

Behind the Fast Drying

In the production process of ceramic products such as clay bricks, roof tiles, porcelain, drying is a key link to improve product quality, increase efficiency, and reduce energy consumption;

Unikiln drying technology addresses the current situation, following these four principles:
1. A controllable and adjustable drying curve; maintaining necessary environmental humidity during the initial drying phase, gradually increasing the temperature while decreasing humidity, finding the optimal balance between the drying cycle and preventing deformation and cracking;
2. An efficient heat supply and moisture removal system; using residual heat from kilns or biomass fuels as the heat source, and evenly delivering hot air to the surface of the products, while adjusting the moisture removal speed based on the characteristics of the green body to control environment humidity;
3. A reliable and automated green body conveying system; employing a hydraulic continuous pushing system or a gap-type pushing system, the process can be fully automated;
4. A heat recycling system; by using an internal hot air circulation system, only minimal heat is used to achieve the drying effect, thereby reducing energy consumption;

The positive results achieved are:
● Drying cycles of 4 to 36 hours;
● Heat consumption level of

Understanding of Roof TilesTerracotta Roof Tiles feature notably their beauty and outstanding performance, keeping the i...
09/05/2025

Understanding of Roof Tiles

Terracotta Roof Tiles feature notably their beauty and outstanding performance, keeping the indoor climate within comfort, thanks to the proper water absorption, but also draining the water even during heavy rain.

To achieve those exceptional advantages, the clay selection, tiles forming design, and firing system should be addressed and handled carefully; To be true, the roof tiles are better reflecting the terracotta quality than the porcelain and giving the benefits which are important but might be easily neglected for the end users

Given the internal quality of the roof tiles, the manufacturers going to the porcelain roof tiles or low water absorption might lead to the opposite effects that the roof tiles are supposed to grant;

Dry or Wet technology of shaping?
Roller Kiln or Tunnel Kiln?
Ceramic or Porcelain?

know more about us on
https://www.unikiln-macf.com/col.jsp?id=246

07/05/2025

The Final Testing of SCADA before Delivery

Unikiln.MaCF is currently testing a SCADA system for automatic controlling of a thermal engineering project which includes of a Roller Hearth Kiln and a continual tunnel dryer as a whole;

Based on the PID for temperature control, VFD for the transistion, and VFD for the pressure regulation, Logicl Circuit for safety devices, all those elements are integrated into the HMI via a PLC programing, securing the overall control and feedback system to monitor, regulate, adjust the thermal production as per the most optimized firing system to the final products like clay bricks, roof tiles, hollow blocks, porcelian insulator, porcelain dinnerware, sanitary ware and so on;

Unikiln is always working with the best reliable and world class components to build up the SCADA, like Siemenz,Mitsubishi, Omron, Innovance to secure the core function to manage the stable states of running;

Talk to us for more details or refer to the link:
https://www.unikiln-macf.com/col.jsp?id=201

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Rm1708/1709, Zhongfu Center
Foshan
528000

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