CLEANER BRICK PRODUCTION

FEASIBILITY STUDY

MALAWI 12th June 2012

Implemented by:

Supported by:

CLIMATE Green brick making

May – October

Low humidity and temperature

Firing process

June – October

Assessment Quicker drying time, more production

Efficient drying

Extended firing season

Conducive to brick production in VSBK system

SOIL Soil quality

Soil Quality is inconsistent

Varied type ranging from lateritic to black

Presence of sand and granular materials

High FeO content

Higher vitrification temperature

Sufficient reserve

Assessment

Detailed analysis required for optimization of production process

Suitable for brick making in VSBK with modifications

Improved strength

Consistent colour

Lower breakage

BRICK MAKING PROCESS

Green brick

Cutting of soil, watering and ageing for 24 hours

Moulding with double / four moulds

Slop moulding process followed

Shape, size and finish not satisfactory and uniform

Very high water content and shrinkage

Proper moulding process not followed

Assessment Room for sufficient improvement

Mixing and moulding training

Use of sand moulding

Improved cutting devices

Introduction of mechanization in mixing

………..will lead to vastly improved quality

FIRING PROCESS

Observations Traditional method – scoved clamps

Fixed chimney BTK

Assessment Reduced energy consumption

Improved and consistent quality

Extended brick production

Lower emission levels

PRODUCT QUALITY

Observations High breakage

No consistent colour and strength

Different sizes of fired bricks

Poor shape and finish

Various fired brick qualities

Assessment

Introduction of VSBK technology as a system and not only as a

firing technology

KILN CONSTRUCTION

Observations Availability of construction materials

e.g. cement, lime, bricks, sand etc.

Expert masons available

Refractory materials available

Steel materials available

Availability of mechanical workshops

Assessment

Training and capacity building of masons for specialized kiln

construction

Capacity building of local mechanical workshops in producing

VSBK equipments and accessories

ENERGY CONSUMPTION

Observations Sufficient quantity of coal available

Coal is of high calorific value and high volatility

Fire wood consumption 15 t / 40,000 bricks

SEC : 3.5 – 4 MJ/kg

increased deforestation

Assessment Potential to explore a lower CV and low volatile coal

… lower price

Introduction of internal fuel

… extremely reduced energy consumption

Introduction of VSBK (SEC : 0.8 MJ/kg)

… energy reduction by 75%

ENVIRONMENT SCENARIO

Observations Extremely high consumption of energy

Incomplete and inefficient combustion of fuel

Inefficient firing process and habit

Absence of any pollution control measures

Absence of E&E monitoring agencies

Assessment Introduction of VSBK

….. potential to reduce SPM by 90%

Training of firemen in benchmark firing process

Creation of awareness on health hazards due to high emission

levels

MARKET SCENARIO

PRODUCTION COST

Raw Material

Internal Fuel : 2650 MK

Others : 100 MK

Green Brick making Charges : 700 MK

Maintenance : 450 MK

Green Brick Lifting : 400 MK

Firing Expenses :

Coal : 1660 MK

Labour : 720 MK

Overheads : 570 MK

Wastage : 250 MK

Total : 7500 MK

Per Brick

•Production Cost

• If waste used

Lilongwe

•7.5 MK

•4.85 MK

Blantyre

•7.75 MK

•5 MK

Mzuzu

•5.3 MK

•3.8 MK

ECONOMICS

Parameter

• Investment

• Production (300 days)

• Production Cost

• Entrepreneurs' Share

• Selling Price

• Turnover

• Annual Profit

• RoR

1 Shaft

• 8 million

• 1.2 million

• 7.5 MK / brick

• 1.5 MK / brick

• 12 MK / brick

• 14.4 million

• 3.6 million

• ~3 years

2 Shaft

• 15 million

• 2.4 million

• 7 MK / brick

• 1.5 MK / brick

• 12 MK / brick

• 28.8 million

• 8.4 million

• ~2 years

SOCIAL AND INSTITUTIONAL

ASPECTS

WORKING CONDITIONS

Number of Workers varies from 1 to 15

Only men are engaged in the brick industry

Age profile : young

12 hours per day / 6-7 days week

Relatively unstable work force

No division of labour

Salaries uniformly paid at 250 MK per day

Current skills of kiln workers are sub-standard

or un-skilled

Mainly on-the-job training

ASSESSMENT

Improvement of working conditions : Safety &

Health

Job creation for local workers

Through training

Leads to improved output of workers

Leads to lower labour costs

INSTITUTIONAL

Stakeholders:

Private sector (willingness to invest)

Governmental bodies (room for improvements; green

growth strategy)

End-consumers (ability to pay more depending on

quality)

Mainly small-scale enterprises

No licensing observed

New SME promotion policy

Standards for brick quality not enforced

POTENTIAL

To strengthen private entrepreneurs economic

development approach (small enterprise support)

To improve Governmental services and

enforcement of laws (private business is

protected by the State, and in turn Government

gets more taxpayer money)

To develop and execute regulations for improved

working conditions, standards, and quality of

bricks for higher productivity

THANKS