Brick Manufacturing Process in Charaktala Brick Factory

L/O/G/O
Ashish Jajodia Geet Suri Prahlad Agarwal Sandip Goyal Sasikiran Battepatti Twinkle Jaithalia

Contents
Direct Materials Required Processes Financials Types of kiln Visual Guide

Direct Materials
‡ Clay
‡ Extracted from river side ‡ Extracted from ground in construction sites ‡ Extracted from unused agricultural land

‡ Coal
‡ Fine quality which contain high carbon

‡ Direct Labour

Process
Step 1 Step 6 Step 2 Step 3 Step 4 Step 5

Winning Preparation Shaping Drying

Firing Quality Control

Financials(1/3)
Variable Cost Fixed Cost 

The cost of soil/clay is Rs. 1000 for 200 cubic foot. (including transportation) Cost of per labor per day is Rs. 225 Cost of a firing man is Rs. 225 per batch of bricks The cost of coal is Rs. 3000 per batch of bricks 

Depreciation of dies and trolleys. Depreciation of grinding and coal crushing machine. Depreciation of the kiln. Rent/lease of land. Salary of supervisor and other administrative staffs.

Financials(2/3)
‡ 1400 bricks are made from 200 cubic foot soil/clay ‡ In one day 2 labors can make 1000 green bricks ‡ One batch is of 3000 bricks ‡ In one day 4 firing men are required for firing ‡ Fresh bricks are sold at Rs 4200 ± Rs 5700 per 1000 bricks depending upon the quality

Financials(3/3)
‡ Cost per 1000 bricks
‡ ‡ ‡ ‡ ‡ Rs. 715 for soil (Rs1000/1400)*1000 Rs. 450 for 2 labors for making green bricks. Rs. 1000 for coal (Rs3000/ 3000)*1000 Rs. 300 for firing crew ((Rs225*4)/3000)*1000 Rs. 200 for shifting, assorting and arranging bricks.

± Total cost for 1000 bricks is Rs. 2665

‡ Gross profit
‡ Average Sales (Rs. 5100) ± direct cost (Rs. 2665) = Rs. 2435 per 1000 bricks

Types of kilns
‡ Clamp Kiln ± ANCIENT TECHNOLOGY - 4,000 B.C. The Most Commonly Used Kiln In The Developing World. These Kilns Have A Devastating Impact Both On The Environment And Workers. ‡ Tunnel Kiln - Invented Germany 1877 Most Common In Developed Countries, Since Their Invention Tunnel Kilns Have Now Become Highly Automated. ‡ Bulls Trench ± Invented England 1876 Commonly Used In India. It Has No Roof And Can Only Be Used Outside The Monsoon Season. ‡ Vertical Shaft Kiln ± Invented China 1958 Reasonably Fuel Efficient However The Kiln Is Limited Due To A Low Throughput.

Bull¶s Trench Kiln
Advantages Disadvantages

‡More fuel efficiency compared to periodic kilns ‡Low initial investment ‡High capacity

‡Production rigid to market fluctuations ‡Experienced firing crew ‡Moveable chimneys have a short working life ‡Less optimum firing conditions

Diagrammatic Process of Vertical Shaft Kiln

Moulding

Mixing of raw material

Drying

Dried bricks

Mouth of the kiln

Firing Process

The end of the process

Finished bricks

Transport

Thank You!
L/O/G/O