Abstract: A method for preparing glass strand pellets by stirring chopped glass strands in the presence of 10 to 25% of water, the strands being sized with a size containing an organosilane. The method performs stirring for long enough for an increase in density to be at least 67%, the stirring being performed using a single stirring equipment that at each instant imparts to the strands or forming pellets it contains the same stirring frequency, the pellets finally formed containing, after drying, at least 95 wt % glass. A film-forming agent is in contact with the glass strands during the stirring at the latest.

Abstract: Rotary press machine including dies, pairs of upper and lower punches with a part of each lower punch being movable in a respective die to selectively enable formation of a cavity in the die, a feeding system for feeding powder material into the cavities, when present, in a feeding stage, a pressing system for pressing the upper and lower punches together in a pressing stage and a tablet ejection system for ejecting formed tablets from the dies in a tablet ejection stage. The upper and lower punches are rotated sequentially through the feeding stage, the pressing stage and the tablet ejection stage to thereby enable formation of tablets if powder material is feed into the cavities in the dies. To enable selective formation of tablets and thereby optimize production thereof, an adjustment mechanism is provided and enables selective formation of the cavities in the dies.

Abstract: A three-dimensional printing materials system and method can produce both appearance models and small numbers of functional parts in an office environment. The method can include building cross-sectional portions of a three-dimensional article, and assembling the individual cross-sectional areas in a layer-wise fashion to form a final article. The individual cross-sectional areas can be built by using an ink-jet printhead to deliver an aqueous solvent or binder to an adhesive particulate mixture, causing the particles of the mixture to adhere together, and to previous cross-sectional areas. The binder can include at least one of nonaqueous organic monomeric compound, anionically ionizable polymer, cationic polymer, polymer, waterborne colloid, or inorganic solute.

Abstract: It is an object of the present invention to obtain a PTFE molding excellent in flexing resistance without decreasing the tensile strength and tensile elongation. The present invention is a modified polytetrafluoroethylene molded article obtained by molding a modified polytetrafluoroethylene molding powder, wherein the modified polytetrafluoroethylene molding powder is not melt-moldable, the modified polytetrafluoroethylene constituting the modified polytetrafluoroethylene molding powder contains 0.01 to 1% by mass of a perfluorovinyl ether unit represented by the formula (I): (wherein X is a perfluoroalkyl group containing 1 to 6 carbon atoms or a perfluoroalkoxyalkyl group containing 4 to 9 carbon atoms) and the heat of crystallization thereof is 18.0 to 25.0 J/g as measured using a differential scanning calorimeter, and the modified polytetrafluoroethylene molded article has a heat of fusion of not more than 28 J/g and a flex life of at least 200×104 cycles.

Abstract: An isotropic fiber-reinforced thermoplastic resin sheet wherein a chopped strand prepreg comprising a thermoplastic resin and a reinforcing fiber is layered so that the fiber orientation is random, the prepreg having a fiber volume fraction (Vf) of 20% to 50%, a length in the fiber axis direction of 15 to 45 mm, and a thickness of no greater than 0.13 mm, and the layered material is molded into sheet form by heating and pressing, and a molded plate obtained from the isotropic fiber-reinforced thermoplastic resin sheet. Even if the volume fraction of the reinforcing fiber is relatively low, a fiber-reinforced thermoplastic resin sheet and a molded plate that are excellent in terms of mechanical properties and their uniformity can be obtained.

Abstract: The present invention provides a non-woven felt material that includes a blend of cotton shoddy and synthetic fibers, and a method of making the same. The blend of cotton shoddy and synthetic fibers is carded and needled to form a batt. The batt is compacted and unified into its stable final shape by heating and soft-pressing, which causes at least a portion of the synthetic fibers to soften and/or melt and thereby bond the needled cotton shoddy and synthetic fibers together. The non-woven felt material according to the invention is strong, tear resistant, yet provides a non-slip, cushioned walking surface that readily absorbs and contains spilled oils, water and/or glycols.

Abstract: The present invention relates to a method of producing a plank product and related components having a controllable and realistic wood-grain appearance, the planks and related components having at least one accent color, the method including the steps of: a) introducing into an extruder a powdered or pelletized base material and accent color pellets, the base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, the accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) including a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.

Abstract: A powder injection molding composition is disclosed. The composition comprises caprolactam and a plurality of particles, where that plurality of particles is selected from a metal powder, a metal hydride powder, a ceramic powder, a ferrite powder, and mixtures thereof. The composition optionally firther comprises a wax and polymeric material.

Abstract: The invention refers to a process for the preparation of a self-dispersing or self-emulsifying tablet, wherein a heated granulation mixture containing an active lipophilic substance and a surfactant is granulated into granules, said granules are cooled to a semi-solid state, said semi-solid granules are mixed with one or more fillers to cover the surface of the granules, distribution, the sieved granules are mixed with tabletting aids, and said mixture is compressed into tablets. The granulation mixture can also contain a lipid and/or filler. The invention also refers to tablets prepared by said processes.

Abstract: A materials system and methods are provided to enable the formation of articles by three dimensional printing. The materials system includes particulate mixtures having a whitening agent and a solid particulate additive comprising an acid, the latter adapted for modifying a cure rate of an infiltrant. The materials system also includes aqueous fluids including optical brightening agents.

Abstract: An apparatus is provided for effectively preventing the scattering and the like of powder material, by maintaining a completely sealed condition, from the supply of the powdery material and the discharge of the molded articles to the cleaning of the interior. A housing 1 comprising, connected via a piping system 10, a vacuum device 11 for depressurizing said housing 1 interior; an atmosphere cut-off valve 12 installed on said piping system 10 for cutting off a piping interior atmosphere on said housing 1 side from a piping interior atmosphere on the vacuum device 11 side; a wetdown piping system 72 for wetting, within the atmosphere on the housing 1 side starting from said atmosphere cut-off valve 12, a compression molding mechanism 2 as well as powdery material stuck to the inside of said housing 1; and an outside air introduction mechanism 15 installed on said housing 1 for opening up an airtight condition of the housing.

Abstract: The present invention provides a non-woven felt material that includes a blend of cotton shoddy and synthetic fibers, and a method of making the same. The blend of cotton shoddy and synthetic fibers is carded and needled to form a batt. The batt is compacted and unified into its stable final shape by heating and soft-pressing, which causes at least a portion of the synthetic fibers to soften and/or melt and thereby bond the needled cotton shoddy and synthetic fibers together. The non-woven felt material according to the invention is strong, tear resistant, yet provides a non-slip, cushioned walking surface that readily absorbs and contains spilled oils, water and/or glycols.

Abstract: The invention concerns an impact machine for forming a body with desired shape of a formable working material through impact action in a forming operation, said impact machine comprising a machine stand (6), an upper unit which comprises either a lower impact unit (3), which comprises a counter-impact device, or a stationary anvil, and a central unit between the upper and the lower units.

Abstract: This invention relates to a process of a lightweight, heat insulating, high compressive strength, water insoluble material by heat treatment at temperatures between 650-950° C., possessing a low bulk density (from 300 to 800 kg/m3) and improved heat insulating capacity (?=0.07 to 0.25 W/m·deg.) when it has been used to form an article having a compressive strength of from 0.49 to 5.59 Mpa. The starting chemical composition comprising more than 90% by weight of either perlite, pumice or pumice related group of materials or mixture of them and an additive in quantities less than 10% by weight containing Na2O and B2O3.

Abstract: Systems, methods and apparatuses for manufacturing dosage forms, and to dosage forms made using such systems, methods and apparatuses are provided. Novel compression, thermal cycle molding, and thermal setting molding modules are disclosed. One or more of such modules may be linked, preferably via novel transfer device, into an overall system for making dosage forms.

Abstract: A method for the manufacture of compacts from comminuted material (12) such as lignocellulose material and/or other combustible material for burning in hearths, wherein the material (12) is placed into openings (11) of a mold (4) and then compressed to form compacts. The filling of a mold (4) with the material (12) and the compaction of the material (10) to form compacts (10) is performed in the pressing chamber (18) of a multi-platen press (1) with plungers (7) plunging into many openings (11) of a mold (4), and after compaction the mold (4) with the ram (3) is raised and additionally urged against the ram, while the finished compacts are driven out of the mold and then are pushed out of the press chamber (18) into a container (16) by an ejecting device. Moreover, an installation for the practice of the method includes a hopper (9) and a multi-platen press (1) with a mold raising-and-lowering device (14).

Abstract: The present invention is directed to method of bonding mineral fibers in a mineral fiber material, according to which an acid is applied to the mineral fiber material in an amount sufficient to dissolve mineral material from the fiber to form a silica containing binder on the mineral fiber, and curing the mineral fiber material to bond the fibers.

Abstract: A method for manufacturing press molded bodies having at least two separate layers of material is disclosed. The method comprises providing a pair of cooperating parallel arranged rollers (1, 2) defining a nip (3) therebetween and having cavities defined on their outer surfaces, each cavity on one of the rollers (1, 2) cooperating with another cavity of the other roller (2, 1) to form die means, the axes (4, 5) of the rollers (1, 2) being arranged substantially horizontally, feeding at least two contiguous separate streams of different particulate materials into die means adjacent to the nip (3), so that each die means will be filled with portions of different material and counter-rotating the rollers (1, 2) so that the materials contained in the die means will be compressed into press molded bodies (briquettes) having at least two separate layers of material. An apparatus for the manufacture of press moulded bodies is also disclosed.

Abstract: A process for making engineered lignocellulosic-based panels with superior strength and dimensional stability. The process comprising adding to green lignocellulosic particles a low-nitrogen content, high molecular weight, phenol-formaldehyde resin before the green particles are dried. The resin is added in an amount from about 1 to 25 weight percent based on the dry weight of the green lignocellulosic particles. The resin has a nitrogen content of from about 0 to 3%, a viscosity of from about 20 to 2000 cps at 20° C., and a molar ratio of formaldehyde/phenol of from about 1.2 to 3.0. The green lignocellulosic particles treated with the resin are dried until the particles have a moisture content of from 1 to 8%. A second resin is added to the dried particles and then the dried particles are consolidated under heat and pressure to form the engineered panel.

Abstract: A method for manufacturing ceramic bails for water treatment capable of exerting microbicidal activity in water and solution is provided. The method includes producing a first composition by dissolving borax (Na2B4O7.10H2O) and copper sulfate (CuSO4.5H2O) in an equivalent ratio of 1:1 to water, and drying the solution to produce a first composition, producing a second composition by adding silica to a first mixture of nitric acid and silver mixed in an equivalent ratio of 1:1 while heating the first mixture, adding more than 3 weight percents of the first composition to 200 weight percents of distilled water based on 100 weight percents of a ceramic ball while heating the distilled water, adding more than 8 weight percents of the second composition to a second mixture of the first composition and the distilled water when a total weight of the second mixture is reduced by a half, and drying the second mixture; and dehydrating the second mixture at a temperature of 400° C. to 500° C.

Abstract: A process for producing tablets comprising one or more active substances, in which pulverulent to granular starting components are shaped and then solidified, wherein the solidification takes place by reacting a component A and a component B with one another, components A and B being mixed with the starting components, applied to them or added after shaping.

Abstract: Densified composites of silicon nitride and silicon carbide that exhibit high creep resistance are obtained by mechanically activating a mixture of amorphous powders of silicon nitride and silicon carbide and sintering the mechanically activated mixture in the presence of an electric field under high pressure. The grain size in the resulting composite is less than 100 nanometers for all components of the composite, and the composite exhibits high creep resistance.

Abstract: This invention relates to an environmentally friendly insulating material, or more specifically an insulating mat for insulating buildings, houses etc. and a method for the manufacture thereof. The mat is non-allergenic and almost 100% recyclable, and is characterized in that it consists of fabric remnants which are shredded into shoddy, mixed with a fibrous polyester with a low melting point and flax fibres to form a homogeneous mass, which is then moulded into the desired shape and then heat-treated until the polyester fibres melt, bonding the fabric and flax fibres together.

Abstract: The present invention relates to a method and an installation for producing growth substrate blocks, particularly for blocks for cuttings for horticultural use, where loose substrate material is compacted in a forming chamber (18) and thus forms useable block bodies. With the present invention a compulsory moistening of the blocks with suitably heated water is performed, after which these are made ready for use almost immediately, so that an actual conditioning no longer is necessary or can be reduced considerably. The blocks can be moistened and heated from the inside to a desired temperature in a both quick and energy saving way. The moistener, which preferably is water, can contain various additives such as nutrients or the like.

Abstract: The invention relates to a process for producing wood fiberboard by pressing wood fibers which have been treated with binder, in which the wood fibers are boiled and milled at elevated temperature under steam pressure in a refiner unit, subsequently are transferred to a blow-line, then dried and finally pressed under pressure and, if desired, at elevated temperature to produce boards, wherein the treatment with binder is carried out using a multi-component binder, preferably with one component A) containing functional groups which are nonreactive at elevated temperature and a second component B) containing functional groups which are reactive at elevated temperature the component A) being added in the refiner unit at a temperature of from 120° C. to 200° C. prior to the milling step, during the milling step, or shortly after the milling step in the front section of the blow-line and component B) being added at a lower temperature of not more than 150° C.

Abstract: A backing or an intermediate layer for a surface covering is described which comprises a fused recycled material, wherein the material comprises a thermoplastic material, for instance, a vinyl material from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both. Surface coverings containing the backing or intermediate layer of the present invention are also described as well as methods of making the backing or intermediate layer and methods of making the surface coverings containing the backing or intermediate layer of the present invention.

Abstract: The invention is directed to methods involving rewetting of expandable polymers with a wettable liquid to allow for enhanced expansion at or below room temperature without breakage, and in some cases, allows one to achieve a greater expansion ratio than that allowed at elevated temperatures using known methods. The wettable liquid can be formed of a drug and/or an agent, such that the resulting polymer contains and emits the drug upon positioning at a target location of a patient body. The expandable polymer can also have the drug or agent added to its structure at a polymer resin preparation stage, through use of an aqueous solution mixed with one or more fluoropolymers, or in a mixing stage. The present invention also allows one to achieve material with unique properties and handling characteristics. These properties included decreased material thickness, increased density, an altered node/fibril morphology, and a more consistent web in the case of flat material.

Abstract: A pressed thermal insulation body is made by a method comprising the steps of: (1) providing a dry composition consisting of: (a) 10 to 100 percent by weight of volatilised silica containing a dispersion of 0.5 to 6 percent by weight of carbon; (b) 0 to 40 percent by weight of infra-red opacifier; (c) 0 to 50 percent by weight of particulate inorganic filler material; and (d) 0 to 25 percent by weight of reinforcing filaments; (2) pressing the dry composition from step (1) to form a body of a desired shape and density; and (3) heat treating the pressed body at a temperature in the range from 400 degrees Celsius to 1000 degrees Celsius to effect hardening.

Abstract: A method for making a dry plating built-up film comprises providing silicon carbide as a starting source and subjecting to dry plating while changing a concentration of a reactive gas continuously or intermittently to deposit and form, on a substrate, a thin film having different refractive indices along its thickness. A method for making a sputter built-up film is also described, which comprising providing silicon carbide as a target and subjecting to sputtering while changing making electric power against the target continuously or intermittently to deposit and form a thin film having different refractive indices along its thickness.

Abstract: A method of fabricating shoe insole is disclosed. The method comprises mixing the material including rice husk and wheat husk about 35 to 60%, natural rubber about 25 to 45%, artificial rubber of 10 to 20%, and occupied 92% above of the insole; mixing product of (a) with an appropriate amount of additive including rubber curing additive and activitized promoter for less than 8%; treating the product of (b) to form plate-like structure as environment friendly material plate; and molding and fixing at elevated temperature to form an insole.

Abstract: The invention is directed to methods involving rewetting of expandable polymers with a wettable liquid to allow for enhanced expansion at or below room temperature without breakage, and in some cases, allows one to achieve a greater expansion ratio than that allowed at elevated temperatures using known methods. The wettable liquid can be formed of a drug and/or an agent, such that the resulting polymer contains and emits the drug upon positioning at a target location of a patient body. The present invention also allows one to achieve material with unique properties and handling characteristics. These properties included decreased material thickness, increased density, an altered node/fibril morphology, and a more consistent web in the case of flat material.

Abstract: A process for recycling of powder coating waste comprising the steps of (1) compressing powder coating waste to powder coating compacts having a volume of 0.5 mm3 to 15 cm3 by applying pressing forces; (2) placing the formed powder coating compacts into a vessel, rotating the vessel about a rotational axis inclined at an angle of 20 to 70 degrees relative to the horizontal and (3) heating the powder coating compacts while being moved in the rotating vessel until through-glassed powder coating bodies are formed.

Abstract: A process for producing a honeycomb structure, which comprises adding water to a mixed raw material of a raw material powder and a binder, kneading the mixture to obtain a plastic mixture, molding the plastic mixture into a honeycomb shape to obtain a green honeycomb structure, drying the structure by a step including hot-air drying, and firing the resulting dried honeycomb structure, wherein the binder contains hydroxypropyl methyl cellulose as a major component. The process can produce a crack-free high-quality honeycomb structure rapidly at a low cost.

Abstract: Briefly, in accordance with one embodiment of the present invention, a process for making a magnetic composite which comprises providing a polymeric resin and a magnetic powder, the magnetic powder having a mean particle size with a value for standard deviation that is less than the value for the mean particle size of the said magnetic powder, the said magnetic composite being made by mixing said magnetic powder with said polymeric resin and molding the said mixture into a desired shape and a size and said magnetic composite having a magnetic permeability between 30 and 50. In another embodiment the present invention is a composition for a magnetic composite comprising a polymeric resin and a magnetic powder, the said powder having a mean particle size with a value of standard deviation that is less than the value of the mean particle size of the magnetic powder, wherein said magnetic composite has a magnetic permeability between about 30 and about 50.

Abstract: A low cost, glass preform for use in making SRIM molded composite parts is formed by introducing a commercially available, b-stageable thermosetting powder binder either a preformed matting structure or to a continuous glass fiber strand that is subsequently chopped to form a matting structure. The b-stageable thermosetting powder binder will selectively migrate to the junction of two the glass fiber strands contained in the matting at elevated temperatures without crosslinking to adhere the two strands together, therein forming a preform having good retention characteristics. The preform may then be introduced to a mold and combined with a liquid thermosetting matrix resin to form a composite part.

Abstract: A method of making polymeric particulates wherein polymeric scrap material, virgin polymeric material and mixtures thereof are supplied to intermeshing extruder screws which are rotated to transport the polymeric material along their length and subject the polymeric material to solid state shear pulverization and in-situ polymer compatibilization, if two or more incompatible polymers are present. Uniform pulverized particulates are produced without addition of a compatibilizing agent. The pulverized particulates are directly melt processable (as powder feedstock) and surprisingly yield a substantially homogeneous light color product.

Abstract: Sheets, films, and articles of manufacture from a corn zein resin. A wet corn zein resin is formed including corn zein and a fatty acid, and the wet zein resin is cold rolled into sheets. The sheets are dried, and the dried zein resin is processed to form sheets, films, and/or articles of manufacture.

Abstract: The present invention provides a functional film for transfer, by means of the application method, having a functional layer capable of exhibiting various functions, for example, a transparent conductive layer being low in electric resistance value, an article provided with the functional layer, and a method for producing the article provided with the functional layer. A functional film at least having a functional layer (4) on a support (1), said functional layer being releasable from the support (1), wherein the functional layer (4) is a compressed layer of functional fine particles. The compressed layer of the functional fine particles is obtained by applying a liquid in which the functional fine particles are dispersed onto the support (1) followed by drying to form a layer containing the functional fine particles, and compressing the layer containing the functional fine particles.

Abstract: A cushioning molded product is provided which is produced by binding a vegetable fiber with a copolymer of a saccharide and an aliphatic dicarboxylic acid to conduct molding. Further a process is provided for producing a cushioning molded product from a copolymer of a saccharide and an aliphatic dicarboxylic acid, and a vegetable fiber, the process comprising (a) mixing or adhering the copolymer and the vegetable fiber, and (b) molding the resulting mixture into an intended shape by heating the mixture to bind the vegetable fiber with the copolymer.

Abstract: A method for manufacturing plastic-substitute goods by using natural materials is disclosed. Agricultural byproducts and wood byproducts such as rice husks, rice plant stems, corn plant stems, bean plant stems, wheat plant stems, saw dust and the like and the washed and dried sludge produced from the alcoholic factory are crushed into a particular size, then the crushed particles are mixed with natural adhesives (such as corn starch, potato starch and the like), and are coated with melamine resin or urea resins, and then a molding is carried out by applying a pressure in a molding machine, thereby manufacturing the plastic-substitute goods. The raw materials of the present invention are readily available from the rural areas, and the molding is carried out at a temperature of 100-300 degrees C.

Abstract: The punch coated with Cr-Dopé-N is advantageous as a punch for preparing tablets containing an acidic substance or an adhesive substance and is excellent in corrosion resistance and releasing property.

Abstract: In addition to a loading apparatus (10) for loading material through the upper mouth of the mold cavity (6), the unit comprises a blower device (30) for blowing air, means for moving said device while held a short distance from the upper surface of the material (B′) loaded into the mold cavity, such as to lift in a gauged manner a thin layer of material from the top thereof, and means (51, 55) for collecting the material lifted by the blower device (30), in order to remove it from the mold cavity. In particular, the blower device (30) comprises a relatively narrow, long blowing port (31) arranged to emit an air jet in the form of a thin sheet extending in a horizontal direction, and means (33, 34) for feeding compressed air to said blowing port (31), which is moved while maintained a short distance from the upper surface of the material (B′) loaded into the mold cavity (6) in order to lift a thin gauged layer of material.

Abstract: Mold apparatus and method of production and ejection of molded wood strand three-dimensionally curved articles of manufacture, molded from a loosely felted flake mat, using an ejector pin assembly within said mold apparatus having ejector pins with pin head diameters of at least about 0.750 inches or greater, that exert a loaded ejector pin pressure of from approximately about 100 psi to about 1000 psi, to eject the molded wood strand article from the mold apparatus without causing excessive indentation and densification within the mat during mold processing.

Abstract: A method of manufacturing a tablet containing coated granules comprising compressing the coated granules containing biologically active substance and having a temperature exceeding a room temperature, whereby the tablet can be prevented from rupture of a part of a coating film of the granules at the time of tablet compression.

Abstract: A method of producing molded wood flake or strand three-dimensionally curved products using draft angles of 10 degrees or larger with little or no blistering or wood flake springback from over densification. A loosely felted mat of wood flakes is placed between top and bottom molds which slidably engage one another at pinch points to pinch and sometimes remove excess flashing/pinch trim.

Abstract: The present invention relates to a method of producing a plank product and related components having a controllable and realistic wood-grain appearance, the planks and related components having at least one accent color, the method including the steps of: a) introducing into an extruder a powdered or pelletized base material and accent color pellets, the base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, the accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) including a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.

Abstract: Uniformly sized granules are formed using the present extruder and granulation process. The extruder contains a spiral worm screw for guiding a granulation material to an apertured plate. The spiral worm screw is rotated within a chamber and is formed from a guiding slant which terminates at a blunt edge near the apertured plate. The blunt edge rubs the granulation material against the apertured plate which softens the material foming a semi-solid material. The semi-solid material is then gently pushed through the apertured plate using just the required pressure. The granules are formed when the semi-solid material hardens after exiting the apertured plate.

Abstract: An apparatus for fabricating small compacts of formulations of a drug candidate, and a method for determining if a drug candidate, alone or in a formula mix, is suitable for dry granulation by a roller compactor based on physical measurements generated in part from such small compact.

Abstract: Relative coarse flakes fabricated from used and manufacturing scrap asphalt shingle material are finish processed into ground cover and/or erosion control products. Processing of the flakes include (i) softening the surface of the flakes, (ii) embedding a surface treatment material into the softened surface of the flakes, and either (iii) supplying the flake as loose ground cover, or (iv) compressing the flakes into a portable mat.

Abstract: A method of installing a refractory lining in a coreless or channel electric induction furnace. For installation of a refractory lining in a furnace wall, the method comprises the steps of providing a dry refractory material between a liner form placed within the furnace and a furnace wall, placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace, inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration, and compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having low amplitude, high frequency vibration after inducing flow of the dry refractory material.