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100T Fly Ash Bricks Press press view 1
Standard Density Fly Ash Bricks · Hydraulic Press Machine

100T Four Column Hydraulic Press for Standard Density Fly Ash Bricks

100T Rated Capacity
100 mm/s Slider Down Speed
7–15 mm/s Slider Pressing Speed
90 mm/s Slider Return Speed
100T Fly Ash Bricks Press press view 1
100T Fly Ash Bricks Press press view 2
100T Fly Ash Bricks Press press view 3
100T Fly Ash Bricks Press press view 4

01 — Press System

100T Four Column Hydraulic Press Machine

The 100-ton four-column hydraulic press machine for making wall construction fly ash bricks is a heavy-duty compaction manufacturing system engineered by Sinter Hydraulics India. Its rigid four-column guide structure and high-precision hydraulic control deliver consistent pressing force, producing dense, dimensionally accurate bricks for structural building applications.

Use Case

Production of 12,000 Bricks/8 hour operations. This press compacts homogenous raw material mixtures under heavy hydraulic force, producing durable, high-strength fly ash bricks with precise sharp edges for fast-track masonry and wall construction.

Core Applications

  • Manufacturing high-strength, dimensionally uniform fly ash bricks for load-bearing and non-load-bearing masonry wall construction work
  • High-volume eco-friendly building material production for residential, commercial, and industrial infrastructure projects

Material

  • Fly Ash, Sand, Lime/Cement, Water, Gypsum/Admixture binder thoroughly mixed into a homogenous semi-dry slurry matrix
  • Industrial thermal power plant fly ash combined with sand or stone dust aggregate and hydraulic setting binders

Typical Products Processed: Standard 228 x 104 x 75 mm Brick Size, standard modular wall bricks, solid building blocks, and custom paving units

Key Functions

  • Application of a uniform 100-ton hydraulic pressing force to compress raw powder mix and eliminate internal void spaces
  • Dual-stage hydraulic compression cycle featuring top and bottom pressing for consistent density throughout the brick body
  • Automated mold feeding, fast hydraulic press stroke cycle, and smooth multi-cavity brick ejection system

Why 100 Ton Hydraulic Press?

  • Delivers the exact tonnage required to achieve compressive strength ratings exceeding 6 to 8 MPa for standard brick sizes
  • Four-column guide architecture maintains absolute platen parallelism, ensuring uniform brick thickness, sharp edges, and zero cracking

02 — Technical Specifications

SM 100 HP – HYDRAULIC PRESS MACHINE COMPLETE TECHNICAL DATA

The SM 100 HP heavy-duty hydraulic press delivers high-precision compaction force and rigid four-column guidance engineered specifically for fly ash brick production. Its pre-stressed frame, high-flow hydraulic system, and multi-stage pressure control eliminate density variations, ensuring high compressive strength and sharp brick geometry.

Capacity

  • Maximum continuous vertical compaction force capacity of 1000 kN
  • Dedicated hydraulic mold ejection mechanism force capacity of 200 kN

Structural Design

  • Heavy stress relieved four column pillar structure engineered for high volume abrasive slurry compaction
  • FEA stress relieved heavy steel plate welded bolster and upper moving press platen assembly

Frame Type

  • Precision aligned solid induction hardened column frame guide structure
  • Heavy duty stress relieved welded steel plate base bolster and guided compression slide plate

Hydraulic System

  • High flow variable displacement axial piston pump fluid power assembly
  • Multi stage high capacity offline oil filtration loop with integrated oil coolers

Main Ram Stroke

  • Maximum vertical slide compaction travel distance capability of 350 mm
  • Adjustable mechanical and electronic stroke limitation positioning system

Working Hydraulic Pressure

  • Maximum continuous operating main hydraulic system fluid pressure of 200 bar
  • Peak shock safety valve pressure relief calibration threshold limit of 230 bar

Daylight Gap

  • Maximum open vertical daylight window working clearance of 600 mm
  • Minimum closed compaction mold height space of 250 mm

Approach Speed

  • Accelerated downward advance slide rapid travel speed of 200 mm/Sec
  • Controlled mold contact deceleration compaction velocity of 20 mm/Sec

Pressing / Drawing Speed

  • Precision high pressure fly ash brick compaction speed of 8 to 20 mm/Sec
  • Maximum resistance continuous pressing velocity of 25 mm/Sec

Return Speed

  • Smooth upward ram retraction extraction travel speed of 180 mm/Sec
  • Fast automated hydraulic decompression pre return system cycle timing

Bed / Platen Size Platen

  • Total clear mold installation bed width left to right of 800 mm
  • Total clear mold installation bed depth front to back of 600 mm

Columns

  • High tensile forged alloy steel column diameter of 110 mm
  • Heavy duty wear resistant bronze guide bushings with automatic grease lubrication

Working Envelope

  • Total internal mold mounting area of 800 by 600 mm
  • Maximum allowable top platen compaction load resistance capacity of 100 tons

Control System

  • Industrial programmable logic controller linked with a graphical touchscreen station
  • Dual redundant non contact linear transducer position tracking systems accurate within 0.010 mm

Main Motor Power

  • High efficiency primary hydraulic pump electric drive motor power of 15 kW
  • Dedicated auxiliary cooling and continuous oil filtration motor power of 2 kW

Valves & Hydraulics

  • High dynamic response proportional pressure and flow control cartridge valve manifold block
  • Fast acting overhead gravity pre fill oil valve unit assembly

Automation

  • Digital interface connection ports for synchronized raw material feeder and automated stacker systems
  • Integrated multi cavity hydraulic brick ejectors and automatic feeder box movement

Safety Features

  • Dual channel infrared light curtain barriers guarding operator workspace zones
  • Automated heavy duty dual fail safe mechanical anti drop ram safety locking blocks

SM 100 HP — Model Specifications

  • Nominal Force: 1000 KN
  • Maximum Hydraulic Pressure: 25 MPa
  • Max Opening Height of the Slider: 800 mm
  • Max Stroke of the Slider: 500 mm
  • Effective Bed Size: 630 × 550 mm
  • Slider Down Speed: 100 mm/s
  • Slider Pressing Speed: 7–15 mm/s
  • Slider Return Speed: 90 mm/s
  • Ejector Cylinder Nominal Force: 100 KN
  • Stroke of the Ejection Cylinder: 200 mm
Production Case Study

100 Ton Standard Density Fly Ash Bricks Production Line

228 x 104 x 75 mmBrick Size
1500 BricksOutput/Hour
6-8 MPaCompressive Strength
20 SecCycle Time
High compressive brick strength
Uniform dimension accuracy achieved
Hourly target output met
Low water absorption rate
Material rejection rate minimized
Smooth multi-cavity ejection completed
Reduced production power cost

03 — Die / Mold System

Precision 8 Cavity Fly Ash Bricks Die Mold Engineering

This precision multi-cavity die mold system features hardened alloy steel cavities, replaceable wear liners, and an integrated hydraulic top and bottom pressing arrangement. Engineered for 100-ton hydraulic press operations, it enables simultaneous high-density compaction of eight standard fly ash bricks with sharp edges and uniform structural strength.

Use Case

The 8-cavity fly ash brick die mold system integrates into 100-ton four-column hydraulic presses to mass-produce 228 x 104 x 75 mm construction bricks from semi-dry fly ash mixtures. Synchronized hydraulic compaction and ejection ensure continuous 12000 brick per 8 hour shift throughput with minimal dimensional variance.

Technical Specifications (Tooling)

Die Type: 8 Cavity Mold

  • Multi cavity precision steel die block engineered for simultaneous pressing of eight standard 228 by 104 by 75 mm fly ash bricks
  • Heavy duty bottom hydraulic ejector assembly with synchronized multi punch ejection pins

Die Materials

  • Premium high carbon high chromium D2 alloy tool steel inner mold cavities for extreme abrasion resistance
  • Heavy duty Hardox 450 steel top punch face plates and base bolster support plates

Tool Configuration & Construction

  • Precision CNC machined modular steel plate assembly with replaceable cavity liner inserts
  • Rigid structural steel outer mold frame designed to absorb lateral hydraulic compaction stresses up to 100 tons

Key Tooling Features

  • Integrated hydraulic top press punches paired with bottom ejection ram linkages for uniform density
  • Quick change modular cavity liner plates facilitating easy maintenance and zero downtime refurbishment

Alignment Accuracy

  • Upper punch to lower cavity mold entry guide clearance deviation kept strictly under a limit of 0.010 mm
  • Multi cavity bed flatness and parallelism variance across active area restricted within a tolerance of 0.010 mm

Surface Finish

  • Inner cavity mold surfaces precision wire EDM finished down to a surface roughness of Ra 0.40 microns
  • Friction reducing chrome plated punch faces ensuring smooth brick release and zero edge chipping

Tool Life

  • Expected operational span of 250000 pressing cycles per set of replaceable inner cavity wear liners
  • Total structural outer mold frame lifespan capacity reaching 1000000 production cycles before major overhauls
Case Study (Die Performance)

Precision 8 Cavity Fly Ash Bricks Die Mold

D 2 & HARDOX 450Die Material
56-60 HRCHardness
Vacuum HardeningHeat Treatment
Maximum brick density achieved
Sharp edge definition retained
Cavity wall wear minimized
Multi cavity ejection completed
Zero brick surface cracking
Machine operational downtime reduced
Extended mold service life

04 — Product Application

Where Standard Density Fly Ash Bricks Are Used

Fly ash bricks serve as eco-friendly, highly durable alternatives to traditional clay bricks across modern building and infrastructure developments. Their superior compressive strength, uniform dimensions, and low water absorption make them ideal for load-bearing walls and fast-track masonry construction.

Industry Applications

Fly ash bricks are widely deployed in commercial real estate, residential housing, industrial plant construction, and civic infrastructure works. High-tonnage hydraulic press compaction guarantees consistent compressive strength exceeding 10 to 15 MPa, sharp corner definition, and thermal efficiency, significantly lowering overall construction mortar costs and project execution timelines.

Residential and Commercial Building Construction

Provides high-strength masonry units for load-bearing external walls, internal partition walls, and high-rise framed structures. Ensures uniform brick dimensions that reduce mortar consumption and speed up structural masonry laydown times.

Industrial Plants and Warehouse Infrastructure

Used to construct heavy-duty boundary walls, fire-resistant enclosure partitions, and factory storage facilities. Delivers exceptional structural integrity and thermal insulation to withstand demanding industrial environmental conditions.

Government and Public Infrastructure Projects

Integrated into mass housing schemes, educational institutions, healthcare facilities, and civic infrastructure developments. Meets green building standard certifications by utilizing thermal power station waste products to replace topsoil clay bricks.

Pavements, compound walls, and land development

Employed in durable perimeter security wall construction, retaining barriers, and agricultural compound enclosures. Resists weather degradation, efflorescence, and moisture penetration better than traditional red clay bricks.

Finished Product Gallery

100T Fly Ash Bricks Press finished product 1
100T Fly Ash Bricks Press finished product 2
100T Fly Ash Bricks Press finished product 3
100T Fly Ash Bricks Press finished product 4
100T Fly Ash Bricks Press finished product 5
100T Fly Ash Bricks Press finished product 6

05 — Key Advantages

Why Choose the 100-Ton Sinter Hydraulic Press

The 100-Ton Sinter Hydraulic Press delivers consistent compaction force and rigid four-column guidance to produce high-strength, dimensionally uniform fly ash bricks. Its fast cycle times, multi-cavity mold compatibility, and energy-efficient hydraulic operation maximize daily production output while minimizing per-unit manufacturing costs.

Technical & Commercial Benefits

01

High 100-Ton Compaction Force Delivering Compressive Strength Above 10 to 15 MPa

Applies uniform hydraulic pressing force to compress semi-dry fly ash mixtures into dense, void-free bricks. Exceptional compaction density ensures high structural load-bearing capacity and lowers water absorption below standard threshold limits.

02

Rigid Four-Column Guide Frame Maintaining Superior Platen Parallelism

Constructed with solid, induction-hardened alloy steel columns that ensure exact upper punch alignment with the lower mold cavity. Rigid guidance eliminates uneven thickness across all cavities, preventing brick edge chipping and structural stress cracks.

03

Multi-Cavity Mold Capability Achieving High Throughput Up to 12000 Bricks Per Shift

Engineered to support 8-cavity precision molds with rapid 20-second pressing cycles to meet aggressive daily output targets. High production speeds allow brick manufacturers to scale operations efficiently and fulfill large-scale infrastructure orders.

04

Synchronized Hydraulic Top and Bottom Compression Ensuring Uniform Density

Utilizes double-action hydraulic pressure distribution to compress raw material evenly from both top and bottom directions. Balanced compaction eliminates internal density gradients, ensuring consistent structural strength throughout the entire brick body.

05

Wear-Resistant Hardox and D2 Tool Steel Molds Minimizing Maintenance Downtime

Fitted with hardened alloy steel mold liners and polished punch faces designed to withstand severe abrasion from fly ash and sand mixtures. Durable cavity tooling drastically extends mold lifespan, reducing replacement frequency and maintenance overhead.

06

Energy-Efficient Hydraulic Power Pack Lowering Electricity Consumption Per Brick

Features optimized axial piston pumps and fast-response cartridge valves to deliver rapid approach and return speeds up to 200 mm/Sec. Low motor power requirement of 15 kW significantly reduces operational energy costs, maximizing long-term commercial ROI.

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Our engineering team will size the press, die system, and automation to your target output, tile profile, and material spec. Quotations typically within 48 hours.

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