Welcome to Silver Steel Mills – Powering the Future of Construction in Pakistan

At Silver Steel Mills, we are proud to be Pakistan’s trusted manufacturer and supplier of block making machines, concrete batching plants, and pre-engineered steel structures. With cutting-edge technology and engineering expertise, we provide durable, efficient, and high-performance machines tailored for all scales of the construction industry—from small startups to mega infrastructure projects.

How to Change Mould & Adjust Sensor on SSM Block Machine – Complete Guide for Perfect Interlocking Bricks

Introduction – Why Correct Mould Adjustment Matters

Producing high‑quality interlocking bricks, pavers, or hollow blocks requires more than just a powerful machine. The mould depth, compression ratio, and sensor positioning directly affect brick strength, dimensional accuracy, and surface finish. A wrongly adjusted mould can lead to weak bricks, uneven shapes, and production waste.

At Silver Steel Mills, we manufacture the SSM series fully automatic block machines (SSM 15, 18, 24, 35, 50). Our machines are designed to accept different moulds for various brick types: interlocking, hollow, solid, curbstone, fly ash brick, and tuff tile.

This comprehensive guide – based on actual field procedures from our senior technicians – explains step by step how to:

• Change moulds for different brick heights (e.g., from 60 mm pillars to 115 mm interlocking bricks)

• Adjust mould box depth using the 1.7 compression ratio formula

• Position and tighten the top templates and four support screws

• Calibrate the three sensors (bottom, middle, top) for automatic cycling

• Test the machine to ensure perfect bricks every time

⚠️ Note: This procedure applies to all SSM series machines. Always isolate power before mechanical adjustments. Wear safety gloves.

Part 1: Understanding Mould Depth & Compression Ratio

The mould depth (how deep the mould box is) determines how much raw material is filled before pressing. After hydraulic compression, the material is compacted, and the final brick height is less than the mould depth. The ratio between mould depth and final brick height is called the compression ratio.

Formula:

Mould Depth (mm) = Desired Brick Height (mm) × 1.7

For example, to produce 115 mm high interlocking bricks:

• 115 × 1.7 = 195.5 mm (round to 200 mm mould depth).

For 60 mm high pillars:

• 60 × 1.7 = 102 mm mould depth.

“Using the exact 1.7 compression ratio ensures optimal brick density and strength. Too shallow – bricks crumble. Too deep – machine overworks and bricks crack.” – Silver Steel Mills Senior Engineer

Part 2: Removing the Existing Mould

Suppose your SSM machine was previously set up for 60 mm pillars and you now need to produce 115 mm interlocking bricks. Follow these steps:

Step 2.1 – Unlock and Loosen Screws

1. Loosen the four main screws holding the mould box to the machine’s template plate. These are usually on the top and bottom corners.

2. Remove the top mould templates – they are fixed by chains or bolts. Detach them carefully.

3. Lift the old mould out of the machine using a crane or hoist (if heavy). For smaller moulds, two workers can slide it out.

Step 2.2 – Prepare the New Mould

The new mould (for 115 mm interlocking bricks) typically has a height of 115 mm (the brick’s final height). But as per the compression ratio, the mould box depth must be set to 200 mm.

Part 3: Installing the New Mould & Adjusting Depth

Step 3.1 – Drop Down the Mould Box

Because the new mould is taller (115 mm vs. 60 mm), you must increase the mould box depth from 60 mm to 200 mm.

• Loosen the vertical adjustment screws on the machine’s side pillars.

• Lower the entire mould box assembly by approximately 130–140 mm (the difference between 200 and 60).

• Use a measuring tape or laser guide to confirm the internal depth is exactly 200 mm.

Step 3.2 – Fix the Mould to the Templates

1. Insert the mould into the mould box cavity.

2. Place the top mould template (the iron plate that presses down on the material) onto the mould. Ensure it fits snugly.

3. Tighten the four top screws (corner fasteners) to lock the top template in place. Tighten them gradually and evenly – crosswise pattern – to avoid warping.

4. Tighten the screws on the back side of the mould box (there are usually four additional bolts).

Step 3.3 – Lock with Chains (for heavy moulds)

If the mould is heavy, use safety chains to support the top template. Hook the chains to the upper frame of the machine. This prevents the mould from dropping during vibration.

Part 4: Adjusting the Four Support Screws

Under the mould box, there are four adjustable support screws (one near each corner). Their function is to stop the mould box at the correct lowest position during the pressing cycle.

Step 4.1 – Position the Screws

• After setting the mould depth to 200 mm, the mould box will rest on these four screws.

• Turn each screw (using a wrench or a threaded rod) until its tip just touches the bottom iron template of the mould box.

• Do not overtighten – just snug contact.

Step 4.2 – Tighten Locking Nuts

Once all four screws are in contact, tighten the lock nuts against the screw bracket. This prevents the screws from vibrating loose during production.

“These four screws are critical. If they are not level, the mould box will tilt, and bricks will have uneven thickness.” – Silver Steel Mills Technician

Part 5: Calibrating the Three Sensors

Your SSM block machine has three sensors (usually inductive proximity switches) mounted on the side of the mould box. They detect:

Step 5.1 – Adjust Middle Sensor (Most Important)

After setting the mould depth to 200 mm, actuate the middle sensor manually:

• Lower the mould box until the middle sensor’s metal target touches the sensor face.

• You should see the LED light on the sensor turn ON. (If not, loosen the sensor’s mounting nut and slide it closer to the target.)

• This middle sensor tells the PLC that the mould is at the correct depth for pressing.

Step 5.2 – Adjust Bottom Sensor

• When the mould box is fully down, the bottom sensor should be activated.

• Its LED should light. If not, adjust its position vertically.

Step 5.3 – Adjust Top Sensor

• When the mould box is fully raised (after pressing and vibration), the top sensor should light.

• This signals the PLC to stop upward movement and proceed to eject the bricks.

“The sensor positions change every time you change the mould depth. Always re‑calibrate all three.”

Part 6: Testing the Mould and Sensor Settings

Before full production, run a dry test (without raw material) or a small batch.

Step 6.1 – Manual Material Feed Test

1. Fill the hopper with your soil/cement/sand mix.

2. Activate the conveyor to move material into the mould.

3. Observe that the mould fills completely (no spillage).

4. Trigger the hydraulic press – the mould should compress the material, then lift.

Step 6.2 – Check Brick Height

After the first brick is formed and ejected:

• Measure the brick height with a calliper. It should be 115 mm (±1 mm).

• If the brick is too tall, the mould depth is too shallow – increase depth slightly.

• If too short, decrease depth (or increase fill material).

Step 6.3 – Visual Inspection

• Surface finish should be smooth, with no cracks or loose edges.

• Corners must be sharp (indicates proper compression).

• Density – the brick should feel heavy and solid.

Part 7: Common Problems & Solutions

Why This Matters for Your Business

Correct mould adjustment and sensor calibration directly impact:

• Brick strength – meeting building code requirements (3000‑5000 PSI).

• Production speed – fewer machine stops, higher daily output.

• Material savings – less waste from rejected bricks.

• Customer satisfaction – builders demand uniform, strong bricks.

Silver Steel Mills ensures every SSM machine leaves our factory with detailed setup documentation. However, on‑site conditions (raw material density, moisture) may require fine‑tuning. That’s why we provide free technician support for the first 3 months after installation.

Case Study – Successful Mould Change on SSM 35 at Gulberg Greens, Islamabad

In 2021, a client at Gulberg Greens needed to switch from producing 60 mm paving tiles to 115 mm interlocking bricks for a new pedestrian walkway. Using the 1.7 compression ratio, our technician calculated the required mould depth (200 mm), adjusted the four support screws, and re‑calibrated the three sensors in under 2 hours. The first batch of bricks tested at 4,800 PSI – exceeding project specifications. The client has since ordered two additional SSM machines.

Conclusion – Master Your SSM Block Machine with Silver Steel Mills

Changing a mould and adjusting sensors is not difficult – but it must be done systematically. The compression ratio of 1.7 is the key to achieving high brick strength. Always:

1. Calculate required mould depth (brick height × 1.7).

2. Adjust the mould box depth accordingly.

3. Secure the mould with top templates and four support screws.

4. Re‑calibrate the three sensors (bottom, middle, top).

5. Run a test batch and measure brick height.

Silver Steel Mills supports you every step of the way – from delivery and installation to on‑site training and after‑sales service.

Automatic Block Machine Sensor Adjustment & Parameter Setup – Complete Step‑by‑Step Guide (SSM Series by Silver Steel Mills)

Introduction – Why Proper Sensor Adjustment Is Critical for Your Block Machine

An automatic block making machine operates through a sequence of precisely timed movements: material feeding, mould filling, vibration, hydraulic pressing, and ejecting the finished brick. Each of these steps is controlled by limit switches and proximity sensors that tell the machine’s PLC (programmable logic controller) where every moving part is at any given moment.

If these sensors are not adjusted correctly, the machine may:

• Feed too little or too much material

• Press with insufficient force

• Eject bricks before they are fully compacted

• Jam or collide moving parts, causing costly downtime

At Silver Steel Mills, we manufacture the SSM series of fully automatic block machines (SSM 15, 18, 24, 35, 50). We don’t just sell machines – we train your operators to calibrate and adjust sensors for perfect brick production every cycle.

This guide is based on real field procedures used by our engineers when commissioning machines for clients like Nishat Power, CSCEC (CPEC Motorway), DHA Multan, and Gulberg Greens Islamabad. By following these steps, you can ensure your SSM block machine runs smoothly, produces high‑strength bricks, and minimises downtime.

⚠️ Important: Sensor adjustment should only be performed by trained personnel. Always isolate power before physically moving sensors.

Understanding the Key Sensors on an SSM Automatic Block Machine

Your SSM block machine uses multiple sensors to control the automatic cycle. The most important ones are:

Each sensor typically has an LED indicator that lights up when the sensor detects its target (metal plate or magnet). During adjustment, you will repeatedly check that these LEDs turn on/off at the correct positions.

Tools You Will Need

• Manual control box (handheld pendant) – to jog the machine step by step

• Allen key set – for loosening and tightening sensor brackets

• Flat screwdriver – for fine adjustment of sensor position

• Multimeter (optional) – to confirm sensor output if LED is not visible

• Masking tape & marker – to mark initial positions before changing

Step‑by‑Step Sensor Adjustment Procedure

Step 1: Prepare the Machine

1. Power off the main electrical panel.

2. Connect the manual control box (if provided) to the PLC port. This allows you to operate each function independently (jog mode).

3. Remove the controller box cover to access the terminal strip if needed, but normally you adjust sensors from the outside.

4. Identify all sensors using the machine’s wiring diagram (supplied with your SSM machine).

Step 2: Adjust the Arm Close Sensor (Safety Cover)

The machine will not start the automatic cycle unless the safety cover is fully closed and the arm close sensor is activated.

• Procedure: Close the cover manually. Loosen the sensor bracket. Slide the sensor forward or backward until its LED lights up. Tighten the bracket.

• Check: Open the cover – LED should turn off. Close – LED on.

• Why it matters: Prevents the machine from running while the cover is open, protecting operators.

Step 3: Set the Material Cut Forward & Backward Limits

The material cut (feeder) pushes raw mix from the hopper into the mould cavity. It must travel exactly to the front edge of the mould box, then return fully.

3.1 Adjust Forward Limit

1. Use the manual control box to move the feeder slowly forward.

2. Stop when the feeder’s front edge is flush with the mould cavity’s front edge.

3. Loosen the forward limit sensor bracket and slide the sensor until its LED lights up (triggered by the metal plate on the feeder).

4. Tighten the bracket.

5. Test by retracting the feeder fully, then send it forward again. It should stop exactly at the correct position.

Pro tip: If you want the feeder to go slightly further (e.g., for larger moulds), move the sensor slightly backward – the feeder will travel more before triggering the stop.

3.2 Adjust Backward Limit

1. Retract the feeder fully until it reaches the rear stop.

2. Adjust the backward limit sensor so that its LED lights up when the feeder is fully retracted.

3. Test forward/backward cycle several times.

Step 4: Adjust the Mould Top & Bottom Limit Sensors

These sensors control how high the mould box lifts (to eject bricks) and how far it descends (to press the material).

4.1 Mould Top Limit

1. Use the manual control to raise the mould box to its highest desired position (just before the hydraulic cylinder reaches its mechanical stop).

2. Adjust the top limit sensor so that its LED lights up at that height.

3. Lower the mould and raise again – it should stop automatically at the set position.

4.2 Mould Bottom Limit (Pressing Height / Brick Thickness)

This is the most critical adjustment because it determines the final height (thickness) of your bricks.

1. Place an empty pallet on the machine table.

2. Lower the mould box until it is just above the pallet – the gap between the mould bottom and the pallet will be the brick height.

3. For standard bricks (e.g., 100 mm thick), use a spacer or measure the gap with a ruler.

4. Adjust the bottom limit sensor to trigger exactly at this position.

5. Test by running a full cycle without material – the mould should stop at the same height every time.

Note: The SSM machine also has four mechanical screws (shown in the video) that act as hard stops. These backup the sensor and prevent over‑travel. After setting the sensor, adjust the screws so they just touch the stop plate – but do not rely on them as primary limits.

Step 5: Adjust the Pallet Feeder Sensors (If Equipped)

For automatic stacking, the pallet feeder must know when a pallet is in position and when the stack is full.

• Forward limit: Stops the feeder when the pallet is centred under the mould.

• Backward limit: Stops the feeder when it has fully retracted to pick up the next pallet.

Adjust them using the same method: jog the feeder to the correct position, then slide the sensor until its LED lights up.

After Adjustment – First Test Run Without Material

Before producing real bricks, run a dry cycle (no mix) to verify all sensors trigger correctly:

1. Close the safety cover – LED on.

2. Start automatic cycle.

3. Watch the sequence:

   • Feeder moves forward → stops at forward limit.

   • Vibration starts (optional for dry run, you can disable).

   • Mould descends → stops at bottom limit.

   • Hydraulic press applies pressure (skip if no material).

   • Mould lifts → stops at top limit.

   • Feeder retracts → stops at backward limit.

   • Pallet advances → stops at forward limit.

4. If any step does not stop automatically, re‑adjust the corresponding sensor.

Live Demonstration – Smooth, Fully Automatic Brick Production

Once sensors are calibrated, the SSM automatic block machine runs like a robot. The video transcript shows an actual test run:

• The feeder moves forward twice to ensure the mould is completely filled.

• The safety cover closes automatically (or manually with sensor interlock).

• The hydraulic cylinder presses down with 150‑300 tons of force.

• The mould lifts, and the finished brick is ejected onto the pallet.

• The pallet indexer moves to the next station.

The resulting bricks have a very smooth, beautiful face – almost decorative. As the video narrator says, “The face of the paver is very beautiful. It’s decorative.”

Why does the face look so smooth? Because the SSM machine uses dual high‑frequency vibration motors and a precision‑ground mould. The sensor adjustment ensures the mould stops at exactly the right height, preventing over‑compaction or under‑compaction.

Common Problems & Troubleshooting

Why Silver Steel Mills’ SSM Machines Are Easier to Calibrate

Unlike cheaper imported machines, our SSM series features:

• Clearly marked sensor brackets with elongated holes for fine adjustment.

• LED indicators on every sensor – you can see immediately if the sensor is triggered.

• Manual control box included – allows you to jog each axis without running the full cycle.

• Four adjustable mechanical stops as a safety backup – prevents damage even if a sensor fails.

• Detailed wiring and sensor location diagrams supplied with every machine.

These features mean your operators can re‑calibrate the machine in minutes, not hours.

Operator Training – Included With Every SSM Machine Purchase

At Silver Steel Mills, we don’t just deliver a machine. Our engineers stay at your site for 2‑3 days to:

• Install and commission the machine.

• Train your operators on sensor adjustment, daily maintenance, and troubleshooting.

• Run the first batches of bricks with you.

• Provide a written manual with all sensor positions and spare parts list.

“The most important thing is not the machine quality itself – it’s how to use it. If you know how to adjust the sensors, you will always get perfect bricks.” – Silver Steel Mills Senior Technician

Conclusion – Master Your SSM Block Machine with Proper Sensor Setup

An automatic block machine is only as good as its sensor calibration. By following this step‑by‑step guide, you can ensure that your Silver Steel Mills SSM machine produces consistent, high‑strength bricks – whether you are making pavers, hollow blocks, or solid bricks.

Key takeaways:

• Always check sensor LEDs after any adjustment.

• Use the manual control box to jog the machine safely.

• Adjust the mould bottom limit sensor to set exact brick height.

• The four mechanical screws are backups – adjust them after sensors.

• Run a dry cycle before producing with material.

Are you ready to take your block production to the next level? Contact Silver Steel Mills today for a free site survey and live demonstration of our SSM series automatic block machines. We serve clients across Pakistan – from Lahore to Karachi, from Peshawar to Quetta.

Frequently Asked Questions (FAQ)

Q1: How often should I recalibrate the sensors?

A: After the first 50 hours of operation, check all sensor positions. Thereafter, recalibrate only if you change product (e.g., switch from bricks to pavers) or if brick quality changes.

Q2: What happens if a sensor fails?

A: The machine will stop at that stage of the cycle. The PLC will show an error code. Replace the sensor (spare sensors are included with your SSM machine).

Q3: Can I adjust the mould height while the machine is running?

A: No. Always stop the machine and isolate power before making any mechanical adjustments.

Q4: Does Silver Steel Mills provide remote support for calibration?

A: Yes. We offer phone and video call support. Our engineers can guide you through sensor adjustment step by step.

Q5: What if I lose the wiring diagram?

A: Contact us with your machine serial number, and we will email you a new diagram.

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Our block making machines are engineered for strength, efficiency, and versatility. Whether you’re producing solid blocks, hollow blocks, pavers, or fly ash bricks, we have the right solution.

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We specialize in prefabricated steel buildings, providing quick, cost-effective solutions for commercial and industrial needs.

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We provide full installation, after-sale support, and consultancy services in:

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Trusted by Leading Clients

Our machines are already deployed in:

• CPEC construction projects

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Contact Silver Steel Mills Today!

Head Office: Industrial Area, Lahore, Pakistan
Call:  
Web: www.SilverSteelMills.com
Email: info@SilverSteelMills.com