- Main characteristics
- Formation cycle duration
- Forming zone size
- Form height
- Vibration frequency
- Compression force
- Power consumption
- Service staff
- How much does a vibropress cost
- Payback of the vibropress
In this article, we will take a closer look at the technical characteristics of vibrating presses, which you should pay attention to when choosing them. We will also tell you about the prices of these devices and what they depend on..
This parameter shows how many units of products the machine can produce during an hour or eight-hour shift, which is very important for calculating the self-sufficiency of the equipment. For flat products, the performance level may be indicated in square meters. First of all, productivity depends on the degree of automation, which affects the speed of changing pallets and removing finished stones from the working area, on the timely supply of concrete mixture to the matrix. The best indicators for lines, which include various auxiliary mechanisms, are the least of all products obtained on manual installations. It is important to understand that the performance of the equipment changes dramatically depending on the size and volume of the products, for example, the equipment for paving slabs can include dozens of cells, and only a few wall blocks can be made in one cycle on the same equipment. Therefore, performance is sometimes suggested to be compared by the number of pallets filled in a certain period of time. Thus, the Rifey-Polyus installation can produce 450 wall blocks, 50 m2 paving slabs and up to 50 curbs. For comparison: Ufa VPRS 2 makes no more than 1000 blocks in 8 hours, but this is theoretically, the machine still needs to be provided with a concrete mixture.
Formation cycle duration
For models that are similar in other characteristics, productivity differs from the duration of the formation cycle. The working cycle of forming in modern vibropresses does not exceed one minute, the rate is considered to be 30-40 seconds (stationary machine TYTAN P-300), stationary vibropress of the third size class “Mastek” by “Monolith” company forms stones in no more than 25 seconds. High-tech complexes with several vibrators, microprocessor control and hydraulic drive provide ultra-fast operation – about 9-15 seconds per cycle. Very short cycle times can be specified by handheld device manufacturers, but the shaping process is usually curtailed..
Forming zone size
The area of the working vibrating table determines the size of the pallet that is used for a particular press, and this, in turn, shows how many stones of a particular configuration can be obtained in one cycle. The larger the forming zone, the more versatile and productive the unit will be. So “Condor” with a formation zone of 400×400 mm produces 70 wall blocks per hour, and the semi-automatic “BP-150” (table 1040×570 mm) – over 300 blocks. A large table assumes the presence of several vibrators in order to impart enough impact force to the concrete mixture – all this is reflected in the power, weight, dimensions of the equipment.
Often this figure is given along with the dimensions of the platform. It shows how high the stone can be formed by the vibropress. We need to know not only the maximum value, since the minimum height of the mold can also be structurally limited. For example, the TYTAN 2 machine works with molds with a height of 80 to 320 mm – this means that it is designed for the manufacture of wall blocks, curbs and other large elements..
This characteristic is rarely indicated by manufacturers. The simplest models are equipped with a VI 99 vibrator with a vibration frequency of 50 Hz, but higher frequencies are used to better compact the concrete mixture and obtain a stronger product. For example, “Mastek-Standard” operates at a frequency of 75 Hz. Even more advanced models can be controlled by computer systems and change the amplitude of oscillations depending on specific conditions. Vibropress “Rifey-Buran” can tune to a frequency of 100 Hz and introduce into resonance the smallest particles (which is very important in the production of paving slabs without gravel), improving their distribution in the mixture.
The more pressure is applied to the concrete mix, the more durable the stone is. The compressive force of manual and electromechanical (or even more so hydraulic) machines differs hundreds of times – 0.1 kg / cm2 against 300 or more kilograms per centimeter. In order to achieve the design strength of the product, it is necessary to load a mass with a large percentage of cement and various additives into weak units, which affects the cost of production. The normal compaction ratio is 0.97–0.98 with a cement consumption of about 450–470 kg per cubic meter of mixture.
The simplest equipment for semi-dry pressing is equipped with one vibrator, the power of which is 0.5 kW. With the use of multiple vibration sources, different drives and accessories, the power of the forming unit inevitably increases. Thus, medium-sized machines will require a power supply from 3 kW (“GID-4”) to 15 kW (“Condor”), and large mechanized lines – from 20 (“Rifey-Udar”) to 100 (“Gevit-Block”) kilowatts per hour. The power of the installation dictates specific requirements for the network parameters: there are single-phase machines that operate from a 220 volt outlet, others must be connected to a three-phase 380 V network.
A well-mechanized medium-sized machine requires at least two people to operate – this is the best indicator. Comparatively large complexes, even when using conveyors, mixers, bunkers and other additional equipment, are serviced by a team of at least 3-4 specialists. As for micro presses, at least 3 workers will also be required to achieve the declared performance.
How much does a vibropress cost
As you can see, there are a lot of options for vibrating presses, their equipment differs, the degree of mechanization and automation, productivity and functionality. Accordingly, a private developer or entrepreneur has the opportunity to choose in several price categories, depending on the needs and financial capabilities..
The most affordable are mobile (or desktop) mini-presses with a manual drive, the price of which is less than 100,000 rubles. For example, “Comanche” costs from 40,000 rubles, and “EST-5” – from 55 thousand. There are, of course, more budget models, but their quality and functionality raises many complaints from users..
Stationary vibrating units of the middle class with a hydraulic or electromechanical drive cost from 200,000 rubles. For example, the basic configuration of the well-known Condor vibrating press is estimated at 220 thousand, and the maximum – 800,000 rubles. The price for “KVADR 1СО2” is about 300,000, for “VIPR 1–2m” you need to pay about 680,000.
Large high-performance complexes cannot be cheaper than 1.5 million. Stationary lines of the Mastek series cost from 2,157,000 rubles, Rifey-Buran – 3,100,000, LP-500 – almost 8 million rubles.
The famous self-propelled molding unit from the company Monolit called “Laying” will cost the entrepreneur almost 1,150,000 rubles.
Payback of the vibropress
The question of payback of a vibrating press, which is purchased for the production of building materials for sale, depends on many factors. Considering the cost of molding equipment for commercial use, you should know that, according to experts, its cost is only a third of the cost of establishing production. High initial costs for the purchase of equipment and organization of production, of course, pay off, but only with a competent approach to the supply of raw materials and the availability of well-established sales channels.
Not always the most technologically advanced and efficient vibropress will be the best option. In order to select the size category of equipment, it is important to consider how densely populated the area in which you intend to work is. For example, it is believed that if there are less than 250,000 people per 100 square kilometers, then the most powerful equipment will not be able to load at full capacity..
Some entrepreneurs, in order to smoothly master a new business, first acquire a unit of the minimum configuration, and as they work they get additional equipment for it. An analysis of various business plans developed by manufacturers of vibratory presses shows that correctly selected machines (medium and large size group) with optimal load pay off in about 3-4 months.
For a private developer, the question is important: is there any point in spending money on purchasing a vibrating press and independently producing piece materials for building a house? It can be found out.
First you need to understand how much you can save on one stone if you make it yourself. The public business plans show the current market prices for semi-dry pressed products and show the manufacturing costs of the same products. Profit / savings are on average 40%.
Now let’s try to calculate how many, for example, hollow concrete wall blocks are needed for the construction of a one-story house with a wall area of 100 m2 (box size is approximately 10×10 meters). We will assume that 15 blocks are needed per square meter of wall, in total, 1500 units are needed for the construction of external walls. Let’s also take into account that inside there will be one load-bearing wall with an area of 20 square meters – that’s another 300 stones. Let’s round up the figure to 2000 blocks (something will be required, for example, for the construction of a porch or pediment).
With a market price of a block of 35 rubles per house, we will spend 2000 x 35 = 70,000 rudders. If we make materials on our own vibropress, we will save 35-40% of this amount at best, which is 28,000 rubles.
So, let’s try to draw conclusions. What kind of vibrating press can you buy for 28,000 rubles? There are handheld tabletop units on sale for that kind of money, but the products they can get are hardly usable (considering quality issues) to build your own home. They are “sharpened” only for one type of product.
More or less high-quality stones are obtained on equipment whose cost exceeds the threshold of 200,000 rubles (such as “Condor” from the company “Stroytekhnika”). But we also need pallets, racks, a reinforced concrete foundation for installation – about 70–90 thousand rubles more. It is extremely difficult to recoup such a vibropress in individual construction, in order to somehow “go to zero” it is necessary to unite with someone, to build all fences, auxiliary buildings and interior partitions from stone, to cover the yard with tiles. Such a range of products is quite real, you just need to purchase a die and a punch of a different configuration.