FAM-1800 With Batching Plant

What Is FAM-1800 With Batching Plant?

The FAM-1800 with Batching Plant is a semi-automatic or fully automatic fly ash brick manufacturing system equipped with a batching plant that ensures precise, automatic weighing and proportioning of raw materials like fly ash, cement, stone dust, and water.

This integrated setup offers high production capacity, reduced material wastage, and improved consistency in the quality of bricks or blocks.

How It’s Made – Components & Construction

Major Components:

Component	Function
FAM-1800 Press Machine	Hydraulic/vibro press for brick molding
Batching Plant Unit	Auto batching of raw materials
Double Pan Mixers	Mixes materials into a uniform consistency
Conveyor Belts	Transfers materials to mixers and press
Hydraulic Power Pack	Powers the press system
Control Panel (PLC/Manual)	Synchronizes batching, mixing, and pressing
Feeder & Hopper System	Transfers batch mix to pressing unit
Storage Bins	Store fly ash, cement, aggregates
Water Dosing Unit	Precise water addition to the mix

Manufacturing Process

Design Engineering
- CAD-based layout for batching and pressing line.
Steel Fabrication
- Heavy-duty frames for the press and batching structure.
Mechanical Assembly
- Mixers, bins, conveyors, vibrators installed.
Hydraulic System Integration
- High-pressure pumps, valves, and tanks mounted.
Automation Wiring
- Sensors, motors, PLC programming for automated operations.
Calibration & Testing
- Dry test runs for batching accuracy and press cycles.

How It Works – Operational Flow

Material Loading
- Fly ash, sand, cement loaded into dedicated bins.
Automatic Batching
- Weighed in programmed ratios using load cells.
Mixing
- Raw materials fed into twin mixers for 2–3 min mixing cycle.
Conveyor Transfer
- Mixed material transferred to pre-feeder.
Brick Pressing
- Hydraulic or vibro-press compresses material into bricks.
Curing
- Green bricks are stacked for natural or steam curing.

Technical Specifications (Typical)

Parameter	Value
Production Capacity	18,000 – 22,000 bricks/day
Power Requirement	35–50 HP
Operation	Semi or Fully Automatic
Hydraulic Pressure	Up to 150 bar
Brick Types	Fly Ash, Paver, Hollow
Water Dosing	Auto with timer
Cycle Time	12–15 seconds
Raw Material Storage	3–4 bins, 1–2 tons each

Uses

Industry	Application
Housing Projects	Brick supply for walls and partitions
Brick Plants	Mid- to high-volume production
Infrastructure	Roads, footpaths, culverts
Factories	Boundaries, sheds, interiors
Smart Cities	Sustainable brick solutions

Importance & Significance

1. Automation-Driven Accuracy

Automatic batching ensures exact weight-based material proportioning – key for high-strength bricks.

2. Improved Production Efficiency

Reduces manual labor, avoids errors in mix quality, and saves time.

3. Uniform Brick Quality

Maintains homogeneous mixture consistency, leading to crack-free, strong bricks.

4. Cost Savings Over Time

Reduces cement overuse, material wastage, and human error – resulting in cost savings.

Advantages

Advantage	Description
Smart Batching	Load cells ensure exact recipe adherence
Continuous Mixing	No production halt due to dual mixer system
Better Brick Quality	Uniform strength, size, and finish
Operational Savings	Less manual labor needed
Time Efficient	Reduces cycle time and increases daily output
Modular Setup	Easy integration and scalability
Low Maintenance	Robust mechanical design and fewer moving parts

Where It Is Used

Government Housing Projects (PMAY, NREGA)
Urban Development Infrastructure
Private Brick Manufacturing Plants
Export-Oriented Brick Units
Construction Equipment Parks

FAQs

Q1: What makes this system better than manual batching?

A: Manual batching often results in inconsistent brick quality due to improper raw material ratios. Automatic batching ensures precision and repeatability.