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We are introducing the business of
manufacturing Fly Ash Bricks with a view
point of eliminating Fly Ash as an
Environment Pollutant which provides the
huge benefit to organization as well as to

cTo provide and promote business and

services that strengthen the brick manufacturing
sector for the ultimate benefit of its customers
and society."

To be in the forefront of creating awareness

about environment, & to be the largest player in
the field of fly-ash brick production.
‡ Andhra Pradesh
‡ Generally bricks creates environmental pollution.
‡ The bricks which currently most us aware is made up
of the soil of specific quality, but due to which earth
erosion takes place and we waste natural resources.
‡ Approximately 10,000 hectares of top soil is being
lost every year for brick manufacturing and road
‡ If we continue in this format, very soon, we will not
have sufficient soil to produce our minimum required

‡ This job is too laborious and involves cost.

‡ Natural seasons affect the quality and cost.
‡ Demand consumption and increasing cost We come up
with ›    

‡ This bricks help to reduce the pollution.

‡ The main raw material is fly ash which is available in
abundant quantity and free of cost at the thermal power
‡ Disposal of fly ash is headache.
‡ It is highly polluting material.
    
‡ Nearly 73% of India¶s total installed power
generation capacity is thermal, of which coal-based
generation is 90% ± the remaining comprising diesel,
wind, gas, and steam.
‡ The 85 utility thermal power stations, besides the
several captive power plants, use bituminous and sub-
bituminous coal and produce large quantities of fly
‡ High ash content (30%±50%) contributes to these
large volumes of fly ash.
‡ It is a very difficult material to handle in dry state
because it is very fine and readily airborne even in
mild wind.

‡ It disturbs the ecology of the region, being a source of

soil air and water pollution.

‡ Long inhalation of fly ash causes silicosis, fibrosis of

lungs, bronchitis, pneumonitis etc.

‡ Flying fine particles of ash create great nuisance for

people living near power stations, corrode structural
surfaces, and affect horticulture.

‡ Eventual settlement of fly ash particles over many

hectares of land in the vicinity of power station brings
about perceptible degeneration in soil characteristics.
‡ With the rapid rise in thermal generation,
environmental pollution as a result of massive fly ash
generation, poses a new problem.

‡ Fly ash is reported to cause ailments like allergic

bronchitis, silicosis, and asthma.

‡ Fly ash contaminates surface water and may also have

an effect on underground water, affects the aquatic life,
is harmful for plants, and corrodes exposed metallic
structures in its vicinity.

‡ At thermal power plants, fly ash is currently collected /

disposed off by using wet or dry systems. In cases,
where fly ash collection systems are not very efficient, a
portion of it escapes into the atmosphere causing
environmental pollution.

‡ In the wet system, fly ash is mixed with water and

sluiced to settling ponds or dumping areas near the plant.
Being cheaper than any other manner of fly ash removal,
it is the widely used method at present in India
   


‡ Size of blocks is 290x185x125mm
‡ Faster construction
‡ Less mortar consumption
‡ Most suitable for boundary walls
‡ Plastering not required
‡ Decorative, like stone masonry
‡ Ash content 26%

‡ Plain and chequered tiles 22mm thick are manufactured in
different sizes and colors as per requirement.
‡ a    
Dry ash is collected from different rows of electrostatic
precipitators. It is available in two different grades of
fineness in silos for use as resource material by different
‡ !"##"$  
Bottom ash is collected from the bottom of the boiler
and transported to hydro bins and then ash mound for
use in road embankment.
‡ ë"%a#"%a   
Conditioned fly ash is also available in ash mound for
use in land fills and ash building products.
       

 %# $# 
‡ Capacity, Bricks /Yr. 90,00,000
‡ Bricks / day 30,000
‡ No. of Shifts / day 2
‡ Working days / Yr. 300
‡ Land Area, 2 Acre
   
‡ First year operation-30% of Capacity
(27,00,000 units)
‡ Production in batches
± One batch of 1000 bricks.
± Total 2700 batches yearly.
‡ Second year operation- 50% of capacity
$ %"&
‡ Managerial 8
‡ Skilled 32
‡ Unskilled 12

&$ #  
'# ( )***+,
‡ Fly ash 2.5
‡ Sand 0.4
‡ Lime 0.35
‡ Chemical accelerator 0.01
' )***+,
‡ Power, KWH 10.33
‡ Water, KL 4
‡ Coal , T 0.18  %#-$ ë % 

‡ Plant & Machinery 42,00,000     

‡ License Fees 4,00,000     ! 
‡ License Period 10 Years 
‡ The process involves wet mixing of fly ash, sand, lime
and an accelerating agent.
‡ The mixture is shaped into the standard size of bricks in a
hydraulic press to pressures varying between 100 to 200
kg/cm², as against below 50 kg/cm2 for conventional
‡ The moulded bricks are dried in two stages, i.e.,
atmospheric drying for a period of 24 hrs., followed by
curing with steam in a steam chamber.
‡ Depending upon the temperature of steam available the
curing time is scheduled as 6 hrs. between 95 to 105 oc.
‡ Technology for the project may be obtained from
either the Central Fuel Research Institute, APSEB's
Consulting Cell Or from the equipment suppliers.

‡ Technology agreements would preferably be

entered into that guarantee the performance of the
equipment, with equipment suppliers.
‡ Currently the demand for bricks is very high than
the supply.
‡ D & S gap is 250 billion bricks per annum
‡ Raw material used for regular red bricks is
‡ Strategic step:
± Introducing Fly Ash Bricks to reduce demand
and supply gap.
± Subsidies and orders from govt.
‡ Colouring the bricks red
‡ Uniform in size, shape
‡ High strength
‡ Light in weight
‡ Good resistance to salinity and termite
‡ Water absorption is less
‡ Penetration
± Initially Rs. 1400 per 1000 bricks.
± Later concession for large quantity buying.
± Discounts on large buying
± Aggressive Selling
± Trade promotion
± Publicity
± Large volume of institutional sales

‡ Market is dominated by red bricks.

‡ Current estimates show the gap between demand and

supply of bricks to be of the order of 250 billion
bricks per annum.

‡ It is new product to the market.

‡ This project helps to reduce environment pollution.
‡ Use of this bricks results in savings in construction
cost by 25%.

‡ These bricks are already getting popular with reputed

Govt. agencies and builders.

‡ This unit too requires a No Objection certificate from

the AP Pollution Control Board.

‡ We are going to sale 27,00,000 units of bricks first


‡ In second year the sales target will be 45,00,000 units

of bricks.
‡ Gujarat Electricity Board

‡ Ahmedabad Urban Development Authority

‡ Ahmedabad Municipal Corporation etc.

‡ Segmentation
± Based on the geographic
‡ As our plant will be located in AP area, firstly going to
capture this area.
± Based on the Demographic

‡ Name of Company:
± µFastec Industrial¶
‡ Product Brand Name:
± Flytec Bricks
‡ Targeting
± Builders
± Consultants
± Architects
± Govt.
‡ Positioning
± Positioned as Environmental Clearance
Promoter's Rs. 40 lacs
Borrowed fund Rs. 60 lacs

Total fund Rs.100 lacs

(Outsider funds can be arranged from NABARD / SIDBI,

which are easily providing industrial loan.
Here we plan to arrange some funds from friends, relatives)
Land & Building 24,00,000
Plant & Machinery 42,00,000
License and Deposit 4,00,000
Furniture and Fixtures 3,00,000
Miscellaneous 9,00,000
Cash/ Bank 18,00,000
TOTAL 1,00,00,000
Income Statement

 .. i
 '/*)/0)1, i
Sales @ Rs. 1.4 Per unit 2700 3780000 4500 6300000
Less- Cost of goods sold: 2700
Fly ash @ Rs. 100 Per ton (675000) (1125000)
Sand @ Rs. 500 Per ton (540000) (900000)
Lime @ Rs. 100 Per ton (94500) (157500)
Chemical accelerator @ Rs.2000 Per ton (54000) (90000)

Wages & Salaries (552000) (552000)

Power, water and coal (189877) (316462)
Depreciation on
Plant and machinery @ 25% (1050000) (1050000)
Furniture and fixture @ 15% (48000) (48000)
Building @ 10% (240000) (240000)
Interest on borrowed fund @ 5% (300000) (300000)
License fees (400000) (400000)
Gross Profit/Loss (363377) 1121038

Less- Tax @ 30% - 336311.4

Net Profit Nil 784726.6

^orking note:

Salary to manager -20,000

^ages to skilled worker -10,000
^ages to unskilled worker-6,000
‡ ROI 7.8% ( for 2nd year)
‡ Profit Margin
Nil (1st year), 12.45%(2nd year)
For 2nd year
Total sales (2 year)=6300000
Total variable cost=2588962
Total fixed cost=2590000
‡ BEP (in sales value)=4397283.5
‡ MOS=1902716.4

‡ FASTEC with its dedicated efforts is trying to emerge

as an organization, which can empower its fellowmen
to eliminate environmental pollutants.
FASTEC in the long run will try its best to
generate an environment- a pollution free