Single-Stack Firing Process 

I. Process Description
1. The single-stack firing process eliminates the use of single-layer tunnel dryers, racks, drying trolleys, and secondary stacking on kiln cars.
2. The bricks are formed and directly stacked once onto kiln cars, where drying and firing occur sequentially within the tunnel kiln.

Typical process flow:
Clay preparation → Extrusion forming → Cutting → Direct stacking on kiln cars → Combined drying and firing in the tunnel kiln → Cooling → Finished brick output

II. Equipment Configuration
1. This process uses relatively simple equipment:
(1) Raw material preparation: Box feeders, crushers, double-shaft mixers, and rolling mills
(2) Forming: Vacuum extruder and continuous cutting machine
(3) Firing: Single tunnel kiln (both drying and sintering in the same tunnel)
(4) Auxiliary systems: Conveyors, fans, and automatic control systems (optional)
(5) Equipment quantity is typically 30–40% lower than that of a double-stack firing plant.

2. Product Range
(1) Single-stack firing is mainly suitable for:
• Standard solid clay bricks
• Perforated bricks
• Common load-bearing wall bricks
The moisture content of the green bricks must be well controlled (usually ≤10%) to prevent cracking during in-kiln drying.

3. Process Advantages
(1) Lower investment cost: total investment approximately 60–70% of a double-stack plant.
(2) Simpler layout and smaller land requirement.
(3) Lower power and maintenance costs.
(4) Faster construction and commissioning cycle.

4. Limitations
(1) Limited ability to produce high-end or thin-wall products.
(2) Requires precise control of drying and firing atmosphere to avoid defects.
(3) More dependent on raw clay quality and local climatic conditions.

III. Economic and Technical Comparison

IV. Summary and Recommendations
1. Single-Stack Firing is suitable for regions where:
(1) Local clay quality is stable;
(2) Market demand focuses on common construction bricks;
(3) Investors aim for low investment and quick returns.
2. Double-Stack Firing is recommended for:
(1) Enterprises pursuing premium brick quality, product variety, and export capability;
(2) Projects seeking long-term, sustainable development aligned with European energy-saving standards.
Both systems have their merits — Single-stack firing emphasizes cost-efficiency and simplicity, while double-stack firing focuses on technological advancement and product excellence.