Why Can’t Carbon Reduction In Building Materials Factories Avoid the Word “Servo”? Qunfeng Provides a Solid Answer

Against the backdrop of the steady advancement of the global strategy of “carbon peaking and carbon neutrality,” the construction and building materials industry is undergoing a profound green transformation. The “Work Plan for Stabilizing Growth in the Building Materials Industry (2025-2026),” jointly issued by six departments, including the Ministry of Industry and Information Technology, clearly proposes to “strengthen the deep integration of technological innovation and industrial innovation” and “promote transformation through digitalization and greening.” The building materials industry has already achieved carbon peaking and is now on a new journey toward carbon neutrality. “Cost reduction and efficiency improvement, low carbon and energy conservation” are no longer just bonuses for companies, but essential questions for long-term development. Faced with this stringent “dual carbon” test, how can building materials factories break through? Qunfeng Machinery, with its advanced intelligent block-making equipment system, provides a powerful answer.

Servo Drive, Precision Empowerment: The QS Series Molding Main Unit Creates a “Low-Carbon Engine”

Traditional electro-hydraulic block-making machines generally suffer from drawbacks such as high system reactive power loss and high electricity costs during operation. To overcome this energy consumption bottleneck, Qunfeng Machinery’s QS series fully automatic high-end servo wall and floor tile forming machine deeply integrates cutting-edge servo drive technology, possessing excellent response speed and stepless control capability. The core advantage of this main unit lies in its true “on-demand output”; the system can precisely match the corresponding power and frequency according to the specific needs of different stages of block forming (such as material spreading, vibration, and pressing). This efficient power allocation method effectively avoids the energy waste caused by the continuous high-speed operation of traditional equipment. This not only helps building material factories significantly reduce their daily power consumption, but also significantly reduces the ineffective wear of mechanical parts, extends the service life of equipment, and practices low-carbon intelligent manufacturing from the source of production.

It is worth mentioning that the QS series is equipped with the third-generation patented servo vibrator from Qunfeng, which has achieved significant breakthroughs in several core performance aspects. Through the adoption of innovative materials and optimized structural design, the vibrator’s moment of inertia is reduced by 15%, its start-up speed is increased by more than 20%, and its system energy consumption is reduced by over 12%.Multiple motors, integrated with a motion controller, achieve ultra-dynamic response and millisecond-level servo synchronization, significantly improving vibration efficiency. Compared to the previous generation, overall production efficiency is increased by 3% to 5%. This third-generation patented servo vibrator, embodying the spirit of continuous innovation from Qunfeng Machinery, was successfully applied to the concrete product molding process in March 2022, demonstrating excellent reliability and wide adaptability in practice.

High-Efficiency Conversion and Circular Empowerment: Reshaping the Commercial Value of Solid Waste Resources

True green building materials production must be based on the closed-loop utilization of resources. Qunfeng Machinery is committed to making the most of every piece of industrial solid waste, demonstrating its outstanding raw material compatibility and processing capabilities.

Throughout the entire production line, the intelligent precision batching machine from Qunfeng, which holds a nationally certified metrological standard, plays a crucial role. It employs a high-precision three-point sensor, enabling it to achieve fast and slow precision batching based on preset mixing ratios for different solid waste aggregates. Subsequently, the materials enter a vertical shaft planetary mixer, where they undergo a complex “revolution + rotation” trajectory to achieve 360-degree uniform mixing at the microscopic level without any dead angles. Whether it’s fly ash, slag, mineral slag, or complex urban construction waste, all can be efficiently converted with the help of this “golden combination.” While ensuring the quality of the finished product, the equipment significantly increases the solid waste blending ratio, effectively alleviating the ecological problem of industrial waste “besieging” cities, and significantly reducing the traditional raw material procurement costs for building materials companies, achieving a win-win situation for both ecology and economy.

Robust Quality, Crafted With Precision: Defining Green Standards Through High-Precision Molding.

Practicing low-carbon and environmentally friendly practices is about upgrading processes, not compromising quality. Leveraging the high-frequency vibration and high-pressure compaction technology of the QS series servo mainframe, Qunfeng Machinery produces building materials with a highly dense internal structure.

Taking permeable bricks, urgently needed for sponge city construction, as an example, through precise CNC machining molds and efficient pressing, the formed blocks maintain excellent compressive strength, freeze-thaw resistance, and wear resistance while ensuring scientific porosity (guaranteeing high permeability). Furthermore, this equipment can stably mass-produce PC imitation stone bricks, decorative hollow bricks, and extra-large hydraulic slope protection bricks with rich textures and diverse colors, fully meeting the diverse high-standard application scenarios of municipal roads, landscaping, and heavy-duty flooring.

Intelligent Central Control and AI System: Digital Empowerment of Full-Process Quality Control

Qunfeng Machinery deeply integrates intelligent technology into the entire production process. The equipment is equipped with the Siemens S7-1500 flagship control system and a visual 3D operating interface, enabling real-time dynamic display of equipment operating status and intelligent monitoring throughout the entire process, significantly reducing the barrier to manual operation and the risk of misoperation. A built-in product formula database allows for one-click storage and quick retrieval of equipment operating parameters, improving changeover and debugging efficiency by over 60% and easily meeting the flexible production needs of multiple product categories and specifications.

In the quality control process, Qunfeng has equipped itself with an intelligent AI block inspection device, which can accurately identify and intelligently detect defects such as height differences, cracks, damage, and color differences in finished blocks. Simultaneously, it works with robotic arms to automatically replace defective blocks, enabling unmanned and highly precise quality control. Furthermore, the AI block inspection system can transmit inspection data back to the main unit in real time, automatically optimizing production parameters. An automatic waste block cleaning device directly removes substandard blocks from the production line, achieving an intelligent closed-loop process throughout production.

At the back end of the production line, Qunfeng adopts an ultra-high 24-layer rotating mother-daughter cart design, which improves the efficiency of block transfer, reduces energy consumption, and requires less factory space.The high-load full-servo palletizing system has a maximum load of 750kg and an average palletizing efficiency that is 13% higher than the previous generation, significantly improving the efficiency at the end of the production line.

Core Strengths And Global Reach: Qunfeng Intelligent Manufacturing Empowers a Green Future

Fujian Qunfeng Machinery Co., Ltd. primarily engages in the research and development and manufacturing of building materials machinery, including concrete product production lines, aerated concrete block production lines, and solid waste recycling and processing production lines. The company boasts a 215,000-square-meter production base, making it one of China’s largest, most automated, and highest-capacity intelligent block-making machine manufacturing bases. After 30 years of innovative development, Qunfeng Machinery has successfully created value for over 10,000 customers in 120 countries and regions worldwide. Qunfeng Machinery has two major R&D centers, bringing together hundreds of industry elites from home and abroad. It has accumulated nearly 300 valid authorized patents and has participated in the drafting and revision of more than 40 national and industry standards, making it a standard setter and promoter in the industry.

In the wave of green transformation, Qunfeng Machinery has always regarded “commitment to global environmental protection” as the core driving force for its corporate development, transforming technological innovation into practical actions to address climate challenges. Choosing Qunfeng Machinery’s automated intelligent molding equipment is not only a breakthrough for building materials companies to reduce costs and increase efficiency and successfully pass the “dual carbon” test, but also a profound investment in long-term sustainable development. In the future, Qunfeng Machinery will continue to uphold its unremitting pursuit of technological and environmental protection concepts, empowering green infrastructure with its core strengths, and working hand in hand with industry partners to build a better low-carbon ecosystem.

References:

How to improve the production efficiency of block factories? Deconstructing the "Four Highly Efficient Engines" of the Production Line

Block Making Machine Industry Observation: Looking at the competitive barriers of leading companies through Qunfeng Machinery’s capacity expansion and technological accumulation