Customer Background: A medium-sized construction material manufacturer in Turkey operating two ZENITH 844 block-making machines, producing a large volume of paving stones and hollow blocks daily for the local and European markets.
The Challenge: The moulds they previously used from a local supplier lacked sufficient wear resistance. Under high-intensity production, the moulds required replacement or major repair every three months on average, causing frequent production line stoppages. Each stoppage meant not only high maintenance costs but, more critically, delays in order fulfillment, resulting in significant annual capacity loss and extra expenses.
Turui Solution: Quanzhou Turui Machinery provided them with custom-made High-Chromium Alloy Steel moulds for paving stones and hollow blocks, specifically designed for the ZENITH 844 machine. Based on a thorough understanding of the customer's raw materials (which contained some abrasive substances), Turui engineers optimized the steel formula and heat treatment process and applied a thickened hard chrome plating, significantly enhancing wear and corrosion resistance.
Results & Value:
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Significantly Reduced Change Frequency: The service life of Turui moulds was greatly extended, increasing the replacement interval from 3 months to over 6 months—a 50% reduction in frequency.
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Minimized Downtime: Production line downtime was reduced by approximately 65 hours per year, making production planning more stable and reliable.
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Improved Overall Efficiency: More stable mould performance reduced machine adjustment times and the rate of defective products, increasing annual overall production efficiency by 18%.
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Excellent Return on Investment (ROI): Although the initial purchase cost of a set of Turui moulds was slightly higher, the customer recouped the investment within the first year due to their extended lifespan and reduced downtime losses.
Client Testimonial: "The durability of Turui's moulds has exceeded our expectations. They provided not just a product, but a sustainable cost-control solution for us. Now we can focus more on market development without worrying about production line issues." – Production Manager of the factory.
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