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400T Fly Ash Bricks Press press view 1
Extra High Density Fly Ash Bricks · Hydraulic Press Machine

400T Four Column Hydraulic Press for Extra High Density Fly Ash Bricks

400T Rated Capacity
100 mm/s Slider Down Speed
7–12 mm/s Slider Pressing Speed
100 mm/s Slider Return Speed
400T Fly Ash Bricks Press press view 1
400T Fly Ash Bricks Press press view 2
400T Fly Ash Bricks Press press view 3
400T Fly Ash Bricks Press press view 4

01 — Press System

400 Ton Four Column Hydraulic Press Machine

The 400-ton four-column hydraulic press machine for making wall construction fly ash bricks in a fully automated production line is an advanced heavy-duty manufacturing system engineered by Sinter Hydraulics India. Its rigid pre-stressed frame, proportional hydraulic controls, and automated material handling deliver uniform compaction force and maximum daily brick yields.

Use Case

Production of 30,720 Bricks/8 hour operations. Integrated into a fully automated production line, this press compacts semi-dry fly ash mixtures under heavy hydraulic force to continuously manufacture high-strength, dimensionally uniform bricks for fast-track 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 in fully automated commercial brick manufacturing facilities

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 400-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
  • Fully automated mold feeding, fast hydraulic press stroke cycle, synchronized multi-cavity brick ejection, and robotic palleting integration

Why 400 Ton Hydraulic Press?

  • Delivers high compaction tonnage to drive multi-cavity production while achieving compressive strengths exceeding 12 to 15 MPa
  • Four-column guide architecture maintains absolute platen parallelism under continuous automated operation, ensuring uniform brick thickness, sharp edges, and zero cracking

02 — Technical Specifications

SM 400 HP – HYDRAULIC PRESS MACHINE COMPLETE TECHNICAL DATA

The SM 400 HP heavy-duty hydraulic press delivers high-precision compaction force and rigid four-column guidance engineered for maximum-capacity fully automated fly ash brick production lines. Its pre-stressed frame, high-flow proportional hydraulics, and automated material handling eliminate density variations, ensuring high compressive strength and sharp brick geometry.

Capacity

  • Maximum continuous vertical compaction force capacity of 4000 kN
  • Dedicated hydraulic mold ejection mechanism force capacity of 800 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 500 mm
  • Adjustable mechanical and electronic stroke limitation positioning system

Working Hydraulic Pressure

  • Maximum continuous operating main hydraulic system fluid pressure of 250 bar
  • Peak shock safety valve pressure relief calibration threshold limit of 280 bar

Daylight Gap

  • Maximum open vertical daylight window working clearance of 850 mm
  • Minimum closed compaction mold height space of 350 mm

Approach Speed

  • Accelerated downward advance slide rapid travel speed of 250 mm/Sec
  • Controlled mold contact deceleration compaction velocity of 20 mm/Sec

Pressing / Drawing Speed

  • Precision high pressure fly ash brick compaction speed of 12 to 25 mm/Sec
  • Maximum resistance continuous pressing velocity of 28 mm/Sec

Return Speed

  • Smooth upward ram retraction extraction travel speed of 220 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 1400 mm
  • Total clear mold installation bed depth front to back of 1100 mm

Columns

  • High tensile forged alloy steel column diameter of 200 mm
  • Heavy duty wear resistant bronze guide bushings with automatic grease lubrication

Working Envelope

  • Total internal mold mounting area of 1400 by 1100 mm
  • Maximum allowable top platen compaction load resistance capacity of 400 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 55 kW
  • Dedicated auxiliary cooling and continuous oil filtration motor power of 5 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 400 HP — Model Specifications

  • Nominal Force: 4000 KN
  • Maximum Hydraulic Pressure: 25 MPa
  • Max Opening Height of the Slider: 1250 mm
  • Max Stroke of the Slider: 800 mm
  • Effective Bed Size: 1260 × 1160 mm
  • Slider Down Speed: 100 mm/s
  • Slider Pressing Speed: 7–12 mm/s
  • Slider Return Speed: 100 mm/s
  • Ejector Cylinder Nominal Force: 400 KN
  • Stroke of the Ejection Cylinder: 300 mm
Production Case Study

400 Ton Extra High Density Fly Ash Bricks Fully Automated Production Line

228 x 104 x 75 mmBrick Size
3,840 BricksOutput/Hour
12-15 MPaCompressive Strength
20 SecondsCycle 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 21 Cavity Fly Ash Bricks Die Mold Engineering

This precision multi-cavity die mold system features hardened alloy steel cavity liners, wear-resistant punch faces, and an integrated hydraulic top and bottom pressing arrangement. Engineered for 400-ton fully automated hydraulic press operations, it enables simultaneous high-density compaction of 21 standard fly ash bricks with sharp edges and uniform structural strength.

Use Case

The 21-cavity fly ash brick die mold system integrates into fully automated 400-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, automated feeder box movement, and multi-pin ejection ensure continuous 30720 brick per 8 hour shift throughput with minimal dimensional variance.

Technical Specifications (Tooling)

Die Type: 21 Cavity Mold

  • Multi cavity precision steel die block engineered for simultaneous pressing of twenty one 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 400 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 400000 pressing cycles per set of replaceable inner cavity wear liners
  • Total structural outer mold frame lifespan capacity reaching 1800000 production cycles before major overhauls
Case Study (Die Performance)

Precision 21 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 Extra High Density Fly Ash Bricks Are Used

Extra high-density fly ash bricks serve as premium, structural-grade masonry units designed for high-stress building and heavy civil infrastructure projects. Produced under extreme hydraulic tonnage, their superior compressive strength, low porosity, and chemical resistance make them ideal for severe load-bearing and harsh environmental conditions.

Industry Applications

Extra high-density fly ash bricks are widely deployed across heavy civil infrastructure, high-rise urban construction, industrial plant manufacturing, and specialized sub-grade engineering projects. High-tonnage hydraulic press compaction guarantees consistent compressive strength exceeding 20 to 30 MPa, high abrasion resistance, and near-zero water permeability, drastically extending structural lifespans and lowering long-term facility maintenance costs.

High-Rise Framing and Structural Load-Bearing Walls

Delivers exceptional structural load capacity for multi-story residential towers, commercial complexes, and load-bearing foundations. Provides high dimensional precision that minimizes joint mortar thickness while accelerating structural masonry construction speeds.

Heavy Industrial Facilities and Chemical Plants

Used in constructing factory containment walls, furnace surrounding enclosures, warehouse floors, and industrial storage bays. Withstands severe mechanical impact, vibration stress, and corrosive chemical exposures far better than standard building bricks.

Heavy Civil Engineering and Hydraulic Works

Engineered for retaining walls, bridge abutment linings, storm drainage channels, and coastal protection barriers. Offers near-zero water absorption, preventing freeze-thaw spalling, salt efflorescence, and moisture degradation over long operational life cycles.

Underground Infrastructure and Sub-Grade Works

Applied in utility tunnel linings, basement retaining structures, deep foundation masonry, and sewage treatment enclosures. Resists high subterranean hydrostatic pressure, soil sulfate attacks, and continuous moisture contact without losing structural integrity.

Finished Product Gallery

400T Fly Ash Bricks Press finished product 1
400T Fly Ash Bricks Press finished product 2
400T Fly Ash Bricks Press finished product 3
400T Fly Ash Bricks Press finished product 4
400T Fly Ash Bricks Press finished product 5
400T Fly Ash Bricks Press finished product 6

05 — Key Advantages

Why Choose the 400-Ton Sinter Hydraulic Press

The 400-Ton Sinter Hydraulic Press delivers maximum compaction force and rigid four-column guidance to produce ultra-high-density fly ash bricks in industrial-scale automated production lines. Its rapid hydraulic cycle times, 21-cavity mold capacity, and optimized power consumption maximize daily throughput while driving down unit manufacturing costs.

Technical & Commercial Benefits

01

Maximum 400-Ton Compaction Force Delivering Compressive Strength Above 15 to 22 MPa

Applies ultra-heavy hydraulic pressing force to compress dense fly ash mixtures into solid, void-free bricks. Superior compaction density gives the finished bricks maximum structural load-bearing capacity and exceptionally low moisture absorption rates.

02

Rigid Four-Column Guide Frame Maintaining Superior Platen Parallelism

Constructed with heavy-duty induction-hardened alloy columns that ensure exact alignment between the upper punches and lower mold cavities. Precise guidance prevents off-center pressing across all 21 cavities, eliminating brick corner chipping and structural stress cracks.

03

21-Cavity Ultra-High Capacity Tooling Achieving Up to 30720 Bricks Per Shift

Engineered to support massive 21-cavity precision molds operating on fast 20-second pressing cycles in fully automated production lines. High daily volume enables brick manufacturers to effortlessly handle large-scale civic and commercial infrastructure projects.

04

Synchronized Hydraulic Top and Bottom Compression Ensuring Uniform Density

Employs balanced double-action hydraulic pressure application to compact raw material simultaneously from both top and bottom directions. Dual-direction pressing eliminates internal density gradients, ensuring uniform compressive strength throughout every brick.

05

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

Fitted with hardened D2 alloy steel cavity liners and polished punch faces designed to resist continuous abrasion from fly ash and aggregate mixes. Superior tooling durability extends operational lifespan, significantly cutting maintenance expenses and machine idle time.

06

Energy-Efficient Proportional Hydraulics Lowering Electricity Cost Per Brick

Utilizes high-flow variable axial piston pumps and fast cartridge valves to achieve rapid advance speeds up to 250 mm/Sec. Low overall motor power consumption of 55 kW reduces electricity costs per unit, dramatically increasing overall plant profitability

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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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