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Start a Clay Brick (BTKs) Plant365days365businessideas.blogspot.in /2011/11/common-fired-clay-brick-is-one-of.html
(192)Start a Clay Brick (BTKs) Plant
Common fired clay brick is one of the important building materials in India. Bricks are used aswalling material in most residential and commercial buildings. They are also used for otherapplications, e.g. road and canal construction. India is the second largest producer of bricks in theworld, and is next only to China in terms of brick production. An estimated 140 billion bricks wereproduced during the year 2000–01. Brick production is estimated to be growing at a rate of 4% peryear. Bricks are produced at village and rural enterprise levels. The sizes of brick units are muchsmaller in the rural areas. However, in peri-urban areas, the size of brick producing units is muchlarger, and clustering of brick making units is quite common. Regional variations are also observed inthe size and scale of the brick production units. The total number of brick making units is estimated ataround 100,000.Traditional technologies are used for brick production. In general, bricks are hand moulded, sun driedand fired in a kiln. The entire process of brick making is manual and estimated to provideemployment to 8 million workers.
Technologies used
Bull’s trench kilns (BTKs) and clamps are two prominent firing technologies used for brick making inIndia. The BTK is a continuous type kiln and has higher production capacities (15,000–50,000 bricksper day). It also has better energy efficiency compared to clamps. BTKs account for 70% of the totalbrick production in the country. Coal is the main fuel used in BTKs. The specific energy consumptionin firing bricks in BTKs ranges between 1.1 and 1.6 MJ/kg of fired brick. Clamps are used for smallerproduction levels. A variety of fuels such as coal, firewood, various types of agricultural residues anddung cakes are used in clamps. Large variations are observed in the shape, size, stacking of bricksand firing techniques in clamps. Generally, energy efficiencies of clamps are lower. The specificenergy consumption of clamps ranges between 1.5 and 3.0 MJ/kg of fired brick.
Energy use in brick firing
Brick firing is an energy-intensive process. The annual estimated coal consumption by the brickindustry is 24 million tonnes, which represents around 8% of the total coal consumption in India.Besides coal, the Indian brick industry also consumes a large quantity of biomass fuels. The share offuel in the total production cost of bricks is in the range of 35% to 50%. The total estimatedexpenditure on fuel by the Indian brick industry is in excess of one billion USD (1 USD= Rs 50).
Concerns in the brick sector
Stack emissions are a major source of air pollution by the brick industry. The brick industry also usesup good quality top soil from agricultural fields. The unplanned and unregulated exploitation of goodquality agriculture soil for brick making is a major area of concern. Production of 140 billion bricksper year (year 2000-01 estimates) requires around 540 million tonnes of soil. The depth ofexcavation is shallow and usually ranges from 0.5 – 2 metres. Assuming an average depth ofexcavation of 0.75 m, around 500 sq. km of agriculture land is adversely affected by brick productionevery year.The Indian brick industry produces mainly one product, i.e. red coloured, hand moulded, solid bricks.For long-term sustainability of the industry, it is important to diversify the product range and movetowards products that are less resource intensive and fulfil market requirements. Production of lessresource intensive clay products and use of alternate building materials can result in significantconservation of top soil.
Barriers
The barriers that are responsible for stagnation of the Indian brick sector are also inhibitingtechnology upgradation. The major barriers identified in the Indian brick sector are as follows:(i) PolicyThe existing codes and specifications for building materials are based on traditional brick making anddo not meet modern practices and technologies. With the availability of new building materials, thesecodes and specifications need to be reviewed and modified for large scale production and end-use.(ii) FinancialThere is lack of awareness and knowledge among brick kiln entrepreneurs necessary to prepareproject reports/ documents for seeking loans from financial institutions/ banks. The credit-worthinessof brick kiln entrepreneurs is also not very favourably viewed by banks. At present, there is no tailor-made financial instrument available to brick kiln entrepreneurs for investing in technologyupgradation. Higher transaction costs are envisaged by individual brick kiln entrepreneurs fordeveloping markets for resource efficient bricks. These financial barriers are responsible for brick kilnentrepreneurs not investing in technology upgradation and by banks related activities.
(iii) Business skills
The majority of the brick kiln entrepreneurs use traditional methods of green brick production, brickfiring and marketing. They lack capacities in regard to modern practices in marketing, businessopportunities and kiln management. There is also lack of trained manpower to cope with newtechnology changes.
(iv) TechnologyThere is limited availability of technology know-how forresource efficient bricks, as very few technologyproviders are available in the country. With brick kilnoperations in India generally being carried out at thesmall scale level, individual brick kiln entrepreneurs find itdifficult to access such know-how.(v) Awareness barrierThe present level of awareness of entrepreneurs andend-users on modern technologies (machineries) andbuilding products is low. The benefits from the productionof resource efficient bricks - such as energy savings,reduction in top soil consumption and air pollution - arealso not well known to brick entrepreneurs. The end-users such as builders, architects, etc. too lackinformation on the benefits of using REBs in buildingconstruction (insulation properties of REBs, saving in mortar during construction, etc.).
Project Rationale
Use of obsolete technologies and use of solid bricks with traditional practices are seen as majorthreats to the Indian brick industry. Under the business-as-usual scenario, Indian brick industry willcontinue to operate with traditional technologies and practices, which are poor in energy efficiencyand environmental performance as well as resources-intensive. The following have been identifiedas major problems faced by the Indian brick industry:
Limited information on resource efficient technologiesLack of resource efficient model brick kiln units at cluster levelsNon-availability of trained manpowerLimited access to financeUnexplored market for alternate building productsOld specifications and codes for building materialNon-availability of institutional mechanism.
The project preparatory phase clearly indicated several opportunities in the Indian brick industry toimprove resource efficiencies and promote production of resource efficient bricks such asperforated bricks, hollow blocks and fly ash bricks. This would require significant changes andupgradation in the existing brick making processes, for which ready-made solutions are notavailable.
Project Strategy
The project has planned to undertake interventions in all regions of the country, i.e. North, East,West, South, and North East. The project interventions would help in introducing ‘ResourceEfficient Brick’ (REB) products such as hollow blocks, perforated bricks and fly ash bricks indifferent regions of the country. This will lead to switch over from the traditional hand mouldingmethod to the use of machinery (mechanization or semi-mechanization) by the brick kiln units.
What are REBs?
REBs are products that consume less energy and resources for their production than traditionalfired clay bricks, and also have better quality and insulation properties. There are different types ofREBs, such as perforated bricks, hollow blocks and fly ash bricks.
Project ImplementationIn order to reach out to various regions and brick clusters, the project has set up Local ResourceCentres (LRCs) in different regions of the country, i.e. North, South, East, West and North-East.The activities of the LRCs encompass the following:
Create awareness among architects, builders, other end-users and governmentdepartments in order to facilitate the uptake of REBs.Prepare and disseminate promotional material on REBs.Establish facts such as strengths and properties of various REB products.Facilitate adoption of REB technologies (both mechanization and semi-mechanization) byinterested entrepreneursPrepare DPRs (detailed project reports) for availing loans from financial institutions andbanks.
Why REBs are Important?
Traditional brick manufacture uses up huge quantities of top soil and fuels. It is becomingincreasingly difficult for brick entrepreneurs to tackle the challenges posed by the growing scarcityor non-availability of top soil in their vicinity, escalating fuel prices, and difficulty in finding workers.At the same time, the construction sector is witnessing an increasing use of products such asREBs that offer better qualities than traditional bricks in certain parameters. Present dayconstructions usually have RCC (reinforced concrete cement) columns, with bricks mainly used aspartition walls. Unlike earlier, bricks are no longer being used as load bearing walls in the majorityof buildings.
Traditional brick manufacture uses up huge quantities of top soil and fuels. It is becomingincreasingly difficult for brick entrepreneurs to tackle the challenges posed by the growing scarcityor non-availability of top soil in their vicinity, escalating fuel prices, and difficulty in finding workers.At the same time, the construction sector is witnessing an increasing use of products such asREBs that offer better qualities than traditional bricks in certain parameters. Present dayconstructions usually have RCC (reinforced concrete cement) columns, with bricks mainly used aspartition walls. Unlike earlier, bricks are no longer being used as load bearing walls in the majorityof buildings.
Advantages of REBs
REBs offer a number of advantages in production as well as end-use applications. These includethe following.
Uniform product size and better finishLow water absorption (<10%)Improved crushing strength of extruded products (300 to 350 kg/cm2)Resource savings – energy (up to 20%), and top soil (up to 30%)Reduction in masonry costs and plaster requirementsReduced cooling/heating load requirements.
Project Outcomes
The following outcomes are envisaged through the various activities proposed under the project:
Enhancing public sector awareness on resource-efficient productsAccess to finance for brick kiln entrepreneursImproved knowledge on technology, including marketingAvailability of resource efficient technology models in five clusters through Local ResourceCentresImproved capacity of brick kiln entrepreneurs
Project Outputs
Higher energy efficiency in brick productionImproved resource efficiency and reduced land degradationReduced local and cluster level pollutionHigh level of awareness among various stakeholdersAdditional benefits:
Improvements in building efficiency with reduction in heating and cooling loads, dueto the air gaps in resource efficient bricksReduced drudgery and improved health of moulders and other workers.
The addresses shown below do not represent a complete list. This list will beupdated on a regular basis.
Indian manufacturers
De Boer Damle (India) Pvt. Ltd.“Anant”, Plot No. 98, Lane 5, Natraj Society, Karvenagar, Pune 411 052Maharastra, IndiaTel: +91 20 25446127 begin_of_the_skype_highlighting +91 2025446127 end_of_the_skype_highlighting E-mail: [email protected]: +91 20 25446127 begin_of_the_skype_highlighting +91 2025446127 end_of_the_skype_highlightingBrochure Fortune EngineersGLOBAL BIZ LINKSC-403 Shrinandnagar VVejalpur, Ahmedabad-380051Contact:Mr Neeraj AroraTel: 91 79 26823411 begin_of_the_skype_highlighting 91 7926823411 end_of_the_skype_highlightingMob: 91 9558818695Email: [email protected]
Lakshmi & Co30, Amman Kovil StreetVenkatapuram, GCT PostCoimbatore – 641013Tamil Nadu, INDIATel: 91 422 2436129 begin_of_the_skype_highlighting 91 422
2436129 end_of_the_skype_highlightingFax: 91 422 2452104Email: [email protected]: http://www.lakshmiandco.com
Neptune Industries Limited Office:1A, First floor, Ankur complexBehind Town Hall, Ellis BridgeAhmedabad – 380 006Gujarat, INDIATel: 91 79 26576234 begin_of_the_skype_highlighting 91 7926576234 end_of_the_skype_highlightingFax: 91 79 26576234 begin_of_the_skype_highlighting 91 7926576234 end_of_the_skype_highlightingEmail: [email protected]: http://www.neptune-india.com Works:297, G I D C Phase-2Modhera Road, Mehsana-384004Gujarat, INDIATel: 91 2762 224551 begin_of_the_skype_highlighting 91 2762224551 end_of_the_skype_highlighting, 224331Fax: 91 2762 252070Contact:Mr Sandeep Dave Email:[email protected] Dhaval Patel Email: [email protected] Vijaya Prakash Industries NH-17, Near Sarada Mandiram P O Kolathara Calicut - 673655, KeralaContact: Mr K K Vijayan Tel: 91 495 2482542 begin_of_the_skype_highlighting 91 4952482542 end_of_the_skype_highlighting, 91 495 2485373begin_of_the_skype_highlighting 91 4952485373 end_of_the_skype_highlighting Mob: 91 9447075373
Walter Craven Ceramic Products (India) LimitedOffice:1, G T Road, Bhadrakali,Uttarpara, Hooghly – 712232West Bengal, INDIA
Works:18 & 19-B, G T RoadUttarpara, Hooghly – 712232West Bengal, INDIA Tel: 91 33 64517357 begin_of_the_skype_highlighting 91 3364517357 end_of_the_skype_highlightingFax: 91 33 26632764Email: [email protected]: Mr M k Banerjee
Foreign manufacturers
BEDESCHI spaVia Praimbole, 3825010 Limena (Padova), ITALYContact:Tel : 39 49 7663100Fax : 39 49 8848006Website: http://www.bedeschi.itEmail : [email protected]
Ceratech SA/ NVRue du Touquetstraat 228B-7782, PloegsteertBELGIUMTel: 32 56 565758, 32 56 565653Fax: 32 56 565505E mail: [email protected]: http://www.ceratc.eu
Craven Fawcett LimitedBelle Vue, WakefieldWest Yorkshire WF1 5EQENGLANDTel: 44 1924 375444Fas: 44 1924 290245Web: http://www.cravenfawcett.comEmail: [email protected]
HAENDLE GMBH Maschinen und AnlagenbauIndustristrasse 4775417 Muehlacker, GERMANYTel: 49 7041 891-1 begin_of_the_skype_highlighting 49 7041 891-1 end_of_the_skype_highlightingHotline : 49 171 7323636 begin_of_the_skype_highlighting 49 1717323636 end_of_the_skype_highlightingTelefax : 49 7041 891-232Website: http://www.haendle.comEmail: [email protected] , [email protected]
KELLER HCW GmbHPOB 2064 - 49470 Ibbenbüren-Laggenbeck Germany Tel: +49 (0) 54 51 85-0 begin_of_the_skype_highlighting +49 (0) 54 51 85-0 end_of_the_skype_highlighting Fax +49 (0) 54 51 85-3 10 Website: www.keller-hcw.de Email: [email protected] Brochure [1] [2] [3] TALLERES FELIPE VERDES, SACtra. Igualada, P O Box 17208788 VILANOVA DEL CAMI,Barcelona, SPAINEmail: [email protected] : http://www.verdes.com
Kusum Brick Field
Kusum Brick Field
Kusum Brick Field is located in Hapur,Distt. Ghaziabad (UP) and is owned byMr Sanjay Dadoo, a 3rd generationbrick entrepreneur. His brick kiln unithas a production capacity of about50,000 bricks per day, with the brickproduction season usually extendingfrom December to July each year. Shiftfrom moving chimney to fixedchimney designTill 1997, Mr Dadoo had a movingchimney brick kiln. With environmentalregulations being enforced on the brickindustry by the Ministry of Environmentand Forests (MoEF), he switched overto a fixed chimney kiln equipped with gravity settling chamber (pollution controlsystem), based on the design provided by the Central Building Research Institute(CBRI), Roorkee. The switchover helped in better kiln operation, which eventuallyyielded fuel savings of about 10%. This motivated Mr Dadoo to explore othertechnology options that he could adopt to improve the market for his products.Adoption of semi-mechanization for production of perforated bricks and hollowblocksKusum Brick Field was producing only solid bricks. Mr Dadoo visited a number ofplaces like Malur (Karnataka), Baliapatam (Kerala), Morvi (Gujarat) and Vietnam toassess the technology options available in the Indian market and abroad. He acquiredsemi-mechanized brick moulding machinery from Gujarat, which he himself modified tosuit the local conditions. From 2005, he began to produce perforated bricks in his unit(along with traditional bricks). Slowly and steadily, he increased the share in productionof perforated bricks (Table 1).
Table 1 Production of perforated bricks of Kusum Bricks Field
Year Annual brick production
2005-06 8 lakh
2006-07 12 lakh
2007-08 15 lakh
2008-09 20 lakh
Some of the challenges faced by Mr Dadoo while adopting semi-mechanizationinclude:
No previous experience in extruder operation and handling of perforated bricksNo trained operator/ labourControlled drying is required for drying of extruded products, which otherwisewill lead to cracks, wastage and production losses.
Mr Dadoo has successfully solved the issues faced in technology adoption. Now, hehas plans to diversify his production to include other products such as hollow blocks.
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