How to Extend Block Mould Service Life: 7 Maintenance Tips for Brick Plant Operators
A block mould is a significant investment. Under normal production conditions, a well-engineered steel mould can deliver 80,000 to 100,000 cycles . However, achieving that lifespan depends not just on the quality of the mould, but on how it is operated and maintained. Premature wear and unexpected failures are often preventable with a disciplined maintenance program .
This guide outlines seven practical maintenance tips that brick plant operators can implement to extend mould service life and reduce costly downtime.
Tip 1: Clean the Mould After Every Shift
Concrete residue left on mould surfaces accelerates wear and causes dimensional inaccuracy . Hardened cement and aggregates act as abrasives, scratching the cavity surface and increasing friction during demoulding.
What to do: Remove all concrete residue from mould cavities and surfaces at the end of each shift. Use soft, non-abrasive tools such as brass, nylon, or wooden scrapers. Avoid steel tools that can scratch the cavity finish. For stubborn buildup, use a non-acidic mould cleaner specifically designed for concrete equipment .
Tip 2: Apply Release Agent Properly
A high-quality form-release agent serves two critical functions: it reduces friction between concrete and steel, making demoulding easier, and it acts as a barrier against corrosion .
What to do: Apply a commercial release agent to all forming surfaces before each production run. Spray evenly and avoid pooling in corners. For difficult mixes or high-adhesion applications, consider chrome-plated cavity options for smoother release . Never use diesel or waste oil as a release agent-they cause excessive buildup and damage rubber components.
Tip 3: Maintain Correct Machine Alignment
Uneven or non-parallel machine movement causes one side of the mould to wear faster than the other . This leads to dimensional drift, uneven compaction, and premature failure of presser feet and cavity walls.
What to do: Before starting production, verify that the mould box is correctly positioned, the tamper head enters without abnormal contact, and the upper and lower working surfaces are parallel . Check connection points and supports regularly. If abnormal contact marks appear on only one side of the mould, stop production and check alignment immediately .
Tip 4: Monitor Presser Foot Clearance
The clearance between the presser foot (tamper shoe) and the mould cavity is critical to product quality and mould life. The standard unilateral clearance is 0.2–0.4 mm . Increasing clearance indicates wear on the presser foot or cavity, leading to material leakage, product flash, and reduced compaction quality.
What to do: Measure presser foot clearance with a feeler gauge at regular intervals. If clearance exceeds 0.4 mm, replace the presser foot or refurbish the cavity. Do not continue production with excessive clearance .
Tip 5: Inspect Ejector Pins Regularly
Ejector pins are wear components that are subject to bending, tip wear, and sticking . Worn ejector pins cause incomplete ejection, product marking, and in severe cases, jamming that can damage the mould or machine.
What to do: Check that all ejector pins move freely and are not bent, broken, or showing excessive tip wear. Replace pins in sets when they show signs of wear-replacing individual pins can cause uneven ejection forces. Lubricate ejector pins with appropriate lubricant as recommended by the mould supplier .
Tip 6: Keep Detailed Maintenance Records
Documentation is a simple but often overlooked tool for extending mould life . Records help identify recurring issues, predict wear patterns, and support replacement decisions.
What to do: Record mould installation dates, inspection results, repairs, product measurements, and any observed problems. Photographs and videos taken during production can also help technical teams evaluate unusual wear or movement. Use this data to schedule proactive maintenance and plan replacement cycles .
Tip 7: Store Moulds Correctly
Improper storage can cause corrosion, warping, or physical damage that reduces service life before the mould even reaches the production line .
What to do: Clean moulds thoroughly, apply a rust-preventative coating, and store them in a dry, covered environment away from extreme temperatures . Store moulds flat on wooden pallets or racks to prevent warping. Do not stack heavy objects on top of stored moulds. Ensure the storage area is free from moisture and concrete dust .
