1HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · Phone +49 7041 891-1 · Fax +49 7041 891-232 · [email protected] · www.haendle.com
International Conference on Mechanization in Brick Industry MBI 2011
Extrusion of hollow bricks -a first step of mechanization in
the Indian brick Industry
2HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Facts and data
Established 1870
HÄNDLE is and always has been a mid-range enterprise based in Mühlacker, Germany
Plant and equipment by HÄNDLE is used in all corners of the world for the manufacture of building bricks, pavers, roof tiles and ceramic tiles
HÄNDLE products are marketed in 98 different countries
90% of the HÄNDLE-built machines are exported, and somewhat over 70 % of the spare and wear parts are sent abroad, too. Back in the year 2000, that figure was still just 35 %
Total revenues for the year 2010 came to approx. 33 million Euros
The division machinery and equipment had a share of 51% and the after-sales services of 49% in the revenues
3HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Facts and data
119 employees / 15 apprentices
100 percent ownership, since 2003, of a small service company in Poland: HÄNDLE S.p.z.o.o in Torun
As of Jan. 1, 2008, data processing system upgraded with a full-scale, operations-integrated "ProAlpha" ERP system (total investment: approx. 750,000 Euro)
Overall investment volume of approx. 1.5 million Euro for machine-tool and welding-automation production equipment at HÄNDLE's Mühlacker facility in 2008
76 percent ownership, since Dec. 2010, of a service organization in Russia OOO HÄNDLE Service RUS in Nikolskoje
4HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Current situation of the brick industry in India
» More than 100.000 brick makers in India» 200 billion bricks/ year
5HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Current situation of the brick industry in India
» seasonal operation (7 - 8 months)» sun-drying » hand-moulded solid bricks» mainly small and medium scaled operations
6HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Current situation of the brick industry in India
» clamp-firing process» no automization
7HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Major challenges
Shortage of labour
Shortage of clay
Increased environmental specifications
Changing market situation (end-users, competition, etc.)
Rising of energy costs
etc.
8HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Extruded bricks – a way to overcome the challenge?
HÄNDLE de-airing extrusion unit Futura type PZG 40c/ 40
9HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Benefits of bricks in general
60% less weight than a solid concrete block
Excellent thermal insulation and sound insulation
Dimension stability
Moisture regulating
Long product life-cycle / sustainability
Environmentally friendly / ecological
Comfortable indoor climate
Non-flammable
10HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Benefits of extruded perforated bricks
Reduction of natural resource consumption
Reduction of operating costs
Health, comfort and safety for all residents
Energy optimization and reduction of energy consumption
Increased productivity of the occupants
Better indoor air quality
Excellent thermal insulation and sound insulation
Ease in handling
Most advanced technology
11HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Decisive parameters for the dimensioning of machines/ plants
Capacity and product data of the
customer
Optimal Optimal customized customized machine/ plantmachine/ plant
Laboratory testsand analysis
Process relevant ancillary conditions
Machine configuration
Design adaption according to specific
conditions
12HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
ProjectJay Jalaram Brick WorksMfgs of Quality BricksGodhra (Gujarat)
Project dataReference size 220 x 110 x 75 mmProducts full bricks and perforated bricksWeight 2.75 kg/ pcCapacity 22 t/ h fired (max) = 8,000 pc/ h
13HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
» Delivered raw material
» Humidity: 5% (based on dry material)
» max. edge length 100mm
14HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
HÄNDLE laboratory
15HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
Extrusion of a 3-hole brick Extrusion of a full brick
16HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
6-layer setting tower of full bricks after extrusion
Full bricks after drying on air
17HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
Results of the laboratory analysis
Very little clay (high non-clay mineral content)
Strong reaction to differences in moisture contents
moisture content has to be controlled carefully
Recommend extrusion moisture 18.5 % - 19.0 %
Possibility of layer setting
Sensitive during drying
18HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
Feeding box feeder Cutter
19HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
New de-airing extrusion unit at Jay Jalaram Bricks
20HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
Collection of extruded bricks Covered bricks during drying
21HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Case study
Fired extruded bricks Fired bricks
22HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Possible installations in India
23HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Possible installations in India
Extrusion without vacuum
Extrusion with vacuum
24HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Possible installations in India
Material with roots and stones
25HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
HÄNDLE, your German specialist for preparation and shaping: a strong partner to India’s brick and tile industry
26HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011
Laboratory and Pilot Plant
Conveying and Storing
Screening
Feeding and Proportioning
Crushing
Mixing and Homogenizing
Shaping - Extruding
Shaping - Molding
Spare parts and Service
HÄNDLE GmbHMaschinen und Anlagenbau
Industriestrasse 47
75417 Mühlacker (Germany)
Tel.: +49 (0)7041 891-1
Fax: +49 (0)7041 891-232
24 Hours Hotline + 49 171 7323636
www.haendle.com