Refractory Brick Production Line and Factory Setup

A refractory brick production line is a complete industrial system designed to transform refractory clay, bauxite and silica into finished refractory bricks under controlled process conditions. The line produces high-temperature resistant bricks ready for packaging and distribution.

From an industrial perspective, refractory brick manufacturing is important because it combines crushing, mixing, hydraulic pressing, drying and high-temperature firing in a tunnel kiln (1300–1500 °C). The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary raw materials typically include refractory clay (chamotte), bauxite, silica, binders and packaging materials. The core machinery set consists of jaw crushers, mixers, hydraulic presses (100–300 bar), tunnel dryers and tunnel kilns. Typical capacity ranges from 5000 to 18 000 tonnes per year.

The Industrial Department supports investors who want to establish a new refractory brick plant as well as existing plant owners who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The refractory brick production line is engineered as an integrated process system covering crushing, mixing, pressing, drying, firing and packaging. Design capacity is determined during the engineering phase and can typically range from 5000 to 18 000 tonnes per year depending on market requirements.

Product types include various grades of refractory bricks for high-temperature applications. The overall process flow follows a defined sequence: crushing of raw materials, mixing with water and binders, hydraulic pressing, tunnel drying (100–150 °C), tunnel kiln firing (1300–1500 °C) and packaging.

Main machinery groups include jaw crushers, mixers, hydraulic presses, tunnel dryers and tunnel kilns. Supporting infrastructure covers electrical power (150–400 kW), process gas (500–1500 m³/h) and water (20–50 m³/day).

Manpower requirements depend on the degree of automation (typically 15–30 persons per shift). Quality control covers dimensional accuracy, strength, refractoriness and packaging integrity. Finished bricks are stored under ambient conditions before distribution.

Technical Specifications

Specification	Description
Product	Refractory bricks (depending on raw mix and kiln configuration)
Production Capacity	5000–18 000 t/year (depending on project capacity and selected equipment sizing – to be determined during engineering phase)
Required Area	1000–3000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 150–400 kW
Gas Consumption	500–1500 m³/h
Water Consumption	20–50 m³/day
Manpower	15–30 persons per shift
Main Machines	Jaw crusher, mixer, hydraulic press (100–300 bar), tunnel dryer, tunnel kiln
Packaging	Pallets or bulk according to selected equipment
Storage	Ambient storage (final design defined in engineering)

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial refractory brick production line can manufacture various grades of refractory bricks depending on raw mix design and firing parameters. Packaging formats are selected according to target markets.

Raw Materials for Refractory Brick Factory

Raw material selection and quality control are critical for refractoriness, strength and thermal shock resistance. The main materials are refractory clay (chamotte), bauxite, silica and binders.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by refractory brick factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Refractory Brick
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial refractory projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

Crushing – Refractory clay, bauxite and silica are crushed in a jaw crusher.
Mixing – Crushed materials are mixed with water and binders.
Pressing – The mix is pressed into green bricks under high pressure (100–300 bar).
Drying – Green bricks are dried in a tunnel dryer at 100–150 °C.
Firing – Dried bricks are fired in a tunnel kiln at 1300–1500 °C.
Packaging – Finished bricks are packaged for dispatch.

Machinery & Equipment

Jaw Crusher – Primary size reduction of raw materials. Position: first process stage. Importance: prepares feed for mixing. Quality impact: particle size distribution affects pressing and firing. Maintenance: jaws, liners and drives. Sahi Rasa Support: design, manufacturing/procurement, installation, repair and spare parts.
Mixer and Hydraulic Press – Mix and form green bricks. Position: after crushing. Importance: determines density and dimensional accuracy. Quality impact: mixing and pressure control strength and size. Maintenance: blades, hydraulic system and moulds. Sahi Rasa Support: design, installation, repair and overhaul.
Tunnel Dryer – Removes moisture at 100–150 °C. Position: after pressing. Quality impact: residual moisture affects firing success. Maintenance: fans, burners and conveyors. Sahi Rasa Support: design, installation, repair and automation.
Tunnel Kiln – Fires the bricks at 1300–1500 °C. Position: after drying. Importance: determines refractoriness and strength. Quality impact: firing curve controls final properties. Maintenance: cars or rollers, burners and refractory. Sahi Rasa Support: design, installation, repair, overhaul and automation.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, crushing, mixing, pressing, drying, kiln, packaging, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect process flow, heat management and safety. Exact area allocation is determined during the engineering phase according to capacity.

Utilities

Electricity: 380 V three-phase, typically 150–400 kW
Gas: 500–1500 m³/h
Water: 20–50 m³/day
Environmental controls according to local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC or PMC approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing refractory plants can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for crushers, presses, dryers and kilns.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn parts, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines, improving packaging rate or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and process loops, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for refractory projects.

Packaging

Palletizing, labeling, coding and loading are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for refractory projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new refractory brick factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a refractory brick production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Refractory Brick

FAQ

What is the typical cost of setting up a refractory brick plant?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Jaw crusher, mixer, hydraulic press, tunnel dryer and tunnel kiln.
What production capacity can be designed?
Capacity is determined during the engineering phase according to market demand and investment criteria (typical range 5000–18 000 t/year).
How much space is needed?
Typical process area ranges from approximately 1000 to 3000 m², subject to final layout.
What are the main raw materials?
Refractory clay (chamotte), bauxite, silica and binders.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.