Fully Automatic Fly Ash Brick Press Machine

1. Introduction

A Fully Automatic Fly Ash Brick Press Machine is a state-of-the-art hydraulic pressing system that manufactures bricks using fly ash, a by-product of coal combustion. These machines are engineered to perform high-capacity, labor-free production of bricks with consistency and durability.

Designed to suit commercial and industrial-scale brick manufacturing operations, these machines integrate raw material batching, mixing, pressing, and stacking operations into one seamless system. Due to increasing demand for sustainable and cost-efficient construction materials, these machines are becoming essential in the infrastructure and real estate industries.

2. Manufacturer Overview

2.1 What Do Manufacturers Offer?

Leading manufacturers of fully automatic fly ash brick press machines offer:

Customizable machine capacities
Precision hydraulic and vibration technology
PLC-based automation
Energy-efficient operations
Complete setup including raw material feeding, mixing, pressing, and curing

2.2 Key Manufacturing Locations (India)

India is one of the leading producers of these machines, with manufacturing hubs in:

Ahmedabad, Gujarat
Coimbatore, Tamil Nadu
Morbi, Gujarat
Kolkata, West Bengal
Hyderabad, Telangana

2.3 Trusted Manufacturers in India

Reva Engineering Enterprises
Laxmi Engineering Works
B & B Machines
Vortex Hydra
Himat Machine Tools
Neptune Industries Ltd.

Most top-tier manufacturers also provide turnkey project solutions, including layout planning, installation, and staff training.

3. Usage of Fully Automatic Fly Ash Brick Press Machines

3.1 Industrial Applications

Mass production of fly ash bricks for commercial and residential construction
Infrastructure projects (flyovers, highways, airports)
Government housing schemes (PMAY, EWS housing)
Institutional projects (schools, hospitals, hostels)

3.2 Process Flow

Raw Material Loading � Fly ash, sand, cement/lime, gypsum are fed into hoppers.
Weighing and Batching � Accurate batching system measures required proportions.
Mixing � Planetary or pan mixers blend the materials into a homogenous mix.
Brick Pressing � The mixture is conveyed into molds and pressed using hydraulic/vibratory force.
Curing � Bricks are transferred to pallets for steam or water curing.
Stacking and Storage � Cured bricks are automatically stacked and transported.

3.3 Products Made

Solid Fly Ash Bricks
Hollow Fly Ash Bricks
Interlocking Bricks
Paver Blocks
Curbstones (in some machines with mold options)

4. Benefits of Fully Automatic Fly Ash Brick Press Machines

4.1 High Production Efficiency

Produces 10,000 to 30,000 bricks per shift, based on configuration
Ideal for meeting high-demand timelines for real estate and government projects

4.2 Labour-Free Operation

Fully automatic with PLC/SCADA integration
Requires only 4�6 operators per shift
Significant savings on labor costs

4.3 Uniform Quality

Hydraulic pressure (up to 200 tons) ensures:
- High compressive strength
- Uniform density
- Accurate dimensions
- Low water absorption

4.4 Customization and Flexibility

Interchangeable molds allow production of multiple brick/block types
Adjustable pressure and vibration settings for different materials

4.5 Eco-Friendly Manufacturing

Fly ash utilization reduces environmental waste
Low carbon footprint compared to red bricks
Less water usage for manufacturing and curing

4.6 Cost Effective

Reduces long-term manufacturing costs through automation
Low maintenance due to robust mechanical design
Energy-efficient hydraulic and motor systems

4.7 Compliance & Certifications

Machines adhere to BIS and ISO quality standards
Compliant with government policies for green construction

5. Technical Specifications (Typical)

Parameter	Specification Range
Production Capacity	1,000 � 3,000 bricks/hour
Power Consumption	25 HP � 80 HP
Hydraulic Pressure	Up to 200 tons
Brick Size	230x110x75 mm (customizable)
Cycle Time	10�20 seconds per cycle
Mold Changing Time	20�30 minutes
Machine Lifespan	8�15 years (with regular maintenance)
Operation Mode	PLC-Controlled Fully Automatic

6. Frequently Asked Questions (FAQs)

Q1. How is a fully automatic machine different from a semi-automatic machine?

A: Fully automatic machines automate the entire process�from raw material feeding and mixing to pressing, curing, and stacking. Semi-automatic machines require manual intervention for feeding and stacking.

Q2. What raw materials are used in these machines?

A: The typical raw materials include:

Fly ash
Cement or lime
Stone dust/sand
Gypsum
Water (for mixing and curing)

Q3. How many workers are required to operate a fully automatic press machine?

A: Typically, 4 to 6 operators are sufficient per shift for loading materials, overseeing machine function, and managing final product stacking.

Q4. What is the average cost of a fully automatic fly ash brick press machine?

A: The cost depends on capacity and automation level. Price range:

Entry-Level: ?20�30 lakhs
Mid-Level: ?30�50 lakhs
High-End Custom Models: ?50 lakhs � ?1.5 crores

Q5. What are the advantages of using fly ash bricks made by these machines?

A: Fly ash bricks have:

Higher strength
Uniform shape and finish
Lower water absorption
Better thermal insulation
Greater earthquake and fire resistance

Q6. How long does it take to set up a fully automatic plant?

A: On average, it takes 45�90 days to set up a fully automatic fly ash brick plant, including civil work, machinery installation, and training.

Q7. Is government subsidy available for such machinery?

A: Yes, many state governments and MSME schemes provide:

15�35% capital subsidy
Interest subsidies
Power tariff reductions
GST and tax incentives for eco-friendly units

Q8. How long do the bricks need to be cured?

A: Generally, bricks require 7�14 days of curing. With steam curing, the process can be reduced to 2�3 days.

Q9. Can this machine produce paver blocks and other shapes?

A: Yes. By changing the mold, the same machine can produce:

Paver blocks
Hollow bricks
Curbstones
Interlocking blocks

Q10. What certifications should the machine have?

A: Look for:

ISO 9001 Certification
BIS certification
CE marking (for export models)

7. Final Thoughts

Investing in a fully automatic fly ash brick press machine is a strategic step for construction businesses aiming for scalability, consistency, and sustainability. As India and other developing nations push for cleaner construction methods, these machines are set to play a pivotal role in shaping the future of infrastructure.

By partnering with a reliable manufacturer and choosing the right configuration, businesses can ensure high ROI, operational ease, and a significant contribution to green building practices.