INSTITUT FÜR ZIEGELFORSCHUNG ESSEN E.V.BRICK AND TILE RESEARCH INSTITUTE REGD.

fon +49 201 59213 01 · fax +49 201 59213 20www.izf.de e-mail: info@izf.de

MODERN CLAY BRICK MODERN CLAY BRICK PRODUCTIONPRODUCTION

In the last 60 years a variety of factors resulted in radical changes in the European brick industry.

Nowadays the modern clay brick production process in western countries is an optimal mechanized and automatic process, fully controlled to get the best quality products out of the process.

The modern production processes are based on different brick shapes and colors.

BRICK MAKING IN BRICK MAKING IN DEVELOPING COUNTRIESDEVELOPING COUNTRIES

In In contrast to this, the situation in developing contrast to this, the situation in developing countries, in terms of both brick making technology countries, in terms of both brick making technology and the organization of the work, showed no major and the organization of the work, showed no major changes in recent decades. changes in recent decades.

??? And what is the situation in India ?????? And what is the situation in India ???

THE INDIAN BRICK INDUSTRYTHE INDIAN BRICK INDUSTRYMost popular walling material (Size: 9” x 4⅟4“ x 3”) (23cm x 11cm x 7,6cm)

Annual production ≈ 200 billion bricks (2nd largest brick producer after China and the largest ‘soft-mud brick producer’ in the world)

No. of brick units > 100,000

Seasonal operation (6 to 7 months in a year)

Majority of units adopt hand-molding, sun-drying and BTK/clamp-firingprocessProvides direct employment to about 11 million workers (most of them migratory)coal consumption > 32 mil Tons / Year (3rd largest in the world)8 bis 10 Mio. Tonnen Biomasse consumption of top soil ≈ 540 mil Tons / Year only 60cm in the depthca. 200 km² (50.000 acre) per year (size of Stuttgart: 207 km²)

BRICK AND TILE INDUSTRY BRICK AND TILE INDUSTRY IN INDIA IN INDIA (100,000 units)(100,000 units)

TRADITIONAL BRICK FACTORYTRADITIONAL BRICK FACTORY(65,000 units)(65,000 units)

SMALL SCALE INDUSTRYSMALL SCALE INDUSTRY(20,000 units)(20,000 units)

MEDIUM SCALE INDUSTRYMEDIUM SCALE INDUSTRY(13,000 units)(13,000 units)

LARGE SCALE INDUSTRY LARGE SCALE INDUSTRY (10 units)(10 units)

THE INDIAN MARKET FOR BRICKSTHE INDIAN MARKET FOR BRICKSThe The Indian construction industry is expected to Indian construction industry is expected to grow at 25grow at 25––30 % during the next period30 % during the next period..

This This means a structural transformation of the means a structural transformation of the Indian Indian brick industry. brick industry.

It It will change its facewill change its face..

This This will create huge opportunities for machinery will create huge opportunities for machinery manufacturers and technology providers. manufacturers and technology providers.

Building market fast Building market fast risingrisingGovernment starts controllingGovernment starts controlling

Bigger production unitsBigger production unitsMechanization Mechanization of of factoriesfactoriesStart of concentrationsStart of concentrations

THE INDIAN THE INDIAN BRICKS INDUSTRYBRICKS INDUSTRY

THE THE TRADITIONAL INDIAN BRICKS TRADITIONAL INDIAN BRICKS INDUSTRYINDUSTRY

MIXINGMIXING

MOULDINGMOULDING

SHIFTINGSHIFTING

DRYINGDRYING

FIRINGFIRING

ENVIRONMENTENVIRONMENT

ALSO AN INDIAN BRICK ALSO AN INDIAN BRICK FACTORYFACTORY

CLAYCLAY

MOULDINGMOULDING

SHIFTINGSHIFTING

DRYINGDRYING

FIRINGFIRING

ENVIRONMENTENVIRONMENT

A MODERN BRICK FACTORYA MODERN BRICK FACTORY

MIXING MIXING GRINDINGGRINDING

MOULDING MOULDING SOFT MUDSOFT MUD

EXTRUDINGEXTRUDING

DRYINGDRYING

FIRINGFIRING

ENVIRONMENTENVIRONMENT

PROCESS TECHNOLOGYPROCESS TECHNOLOGYAutomatic

Semi automatic

Fully mechanized

Partially mechanized

Purely Manual India

Turkey

Africa

Colom

bia

Europe

US

A

THE LINK BETWEEN PROCESS THE LINK BETWEEN PROCESS TECHNOLOGY AND PRODUCTIVITYTECHNOLOGY AND PRODUCTIVITY

Nature of processing method

Requested number of workers for producing

1 million standard bricks per year

Number of standard bricks per worker per

year

Purely manual 20 50 000

Partially mechanized 14 71 400

Fully mechanized 6 166 700

Semi-automatic 1 1 000 000

Automatic 0,25 4 000 000

ECONOMIC AND SOCIAL ASPECTSECONOMIC AND SOCIAL ASPECTS

Factories are usually located in rural Factories are usually located in rural areas (close to raw material supplies).areas (close to raw material supplies).

They generally employ local labour, They generally employ local labour, often for generations, and so help often for generations, and so help stabilise local communities. stabilise local communities.

EXTRACTION OF CLAYEXTRACTION OF CLAY

The The product properties and the quality are product properties and the quality are determined by the determined by the raw material. raw material.

The The extraction of clay is in most cases directly connected to extraction of clay is in most cases directly connected to the production processthe production process..

Little Little waste waste results in changing quality of bricks.results in changing quality of bricks.

CLAYCLAYA GOOD CLAY A GOOD CLAY is necessary for making is necessary for making

QUALITY BRICKSQUALITY BRICKSUse of surface soil is not recommended.Use of surface soil is not recommended.

Nature takes about 1 million years to make 10 inches Nature takes about 1 million years to make 10 inches of top soil. of top soil.

Use of this surface soil for brick manufacturing Use of this surface soil for brick manufacturing destroys it permanently.destroys it permanently.

This adversely affects the cultivation of the land, the This adversely affects the cultivation of the land, the flora and fauna and the environment around.flora and fauna and the environment around.

more ecologically worthwhile is digging in more ecologically worthwhile is digging in the depththe depth

CLAY QUARRYCLAY QUARRY

CLAYCLAY

A GOOD AND A GOOD AND CONSTANT CONSTANT CLAY CLAY MIXTUREMIXTURE is is

necessary for making necessary for making QUALITY BRICKSQUALITY BRICKS

BRICKS AND TILES

to extruder

to moulding

Box Box feederfeederExtruderExtruder

Double shaft Double shaft mixermixer

RollingRolling millmill

DisintegratorDisintegrator

Alternative Preparation Alternative Preparation of of ““easy clayeasy clay””

CLAY

PREPARATION OF CLAYPREPARATION OF CLAY

Manual process, Clay/water mix, in a mould Manual process, Clay/water mix, in a mould

Hand moulding Hand moulding can can simply be partly simply be partly mechanised mechanised

for equal quality for equal quality

HAND MOULDINGHAND MOULDING

MACHINE MOULDING OF BRICKSMACHINE MOULDING OF BRICKSThere are two types of bricksThere are two types of bricks

De Boer PressDe Boer Press

Semi hand moulded bricksSemi hand moulded bricks

Machine bricksMachine bricks

EXTRUDER EXTRUDER MOULDINGMOULDING

EXTRUDED HOLLOW BLOCKSEXTRUDED HOLLOW BLOCKSLight weightLight weight

Thermal insulationThermal insulation

Grip holesGrip holes

Cheaper masonryCheaper masonry

Less raw materialsLess raw materials

Less fuelLess fuel

EXTRUDED HOLLOW BLOCKSEXTRUDED HOLLOW BLOCKS

„Take architects and constructors (or researchers) into the boot“ to create the right design for•Thermal Insulation•Noise Protection•etc.

SIMPLE EXTRUDER MOULDINGSIMPLE EXTRUDER MOULDINGiin rural areasn rural areas

SIMPLE EXTRUDER MOULDINGSIMPLE EXTRUDER MOULDINGiin rural areasn rural areas

BADLY PREPARED CLAYBADLY PREPARED CLAYin rural areasin rural areas

WELL PREPARED CLAYWELL PREPARED CLAYin rural areasin rural areas

methodes processes

raw material conditions requirements shapes to be producedprocessing of cohasive bodies + + + + + + + + +

processing of low-plasticity bodies x x - x x + + + x x

bodies with high water content + + - - + +

bodies with low water content - + x x + + + +

high compact stability - x x x + + + + -

processing of deaerated masses x + + + + x + +

uniform compaction + + + x x + + x

high throughput + + + - - -

low piece numbers, non standard + + x + + + + x +

certain texturation (lamination) allowed + + + + x x +

texturation undesirable - x + + +

products display with high dimentional accu - x + + +

smooth surface - + + + + + x + +

rough surface + x x x x x + x

massive blocks + + + + + + -

tiles + + + + + + + + x

extrudes products (pipes, hollow bricks) - + + x

compacts for presses and rollers + + x

roofing tiles or tableware x + +

hollow-ware - x x x x + +

tableware + + + x +

+  =  applicable                 -  =  inapplicable                    x =  conditionally applicable    

isosta

tic pr

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electr

opho

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casti

ng

hand

mou

lding

extru

sion

ram

pres

sing

rollin

g

ramm

ing

dry p

ress

ing

LABORATORIESLABORATORIES

PLAY AN IMPORTANT ROLE IN PLAY AN IMPORTANT ROLE IN

IMPROVING THE PRODUCT IMPROVING THE PRODUCT

QUALITYQUALITY

LABORATORIESLABORATORIES

Testing facilities with trained Testing facilities with trained staff staff members members in the factoryin the factory

Laboratory kiln for testing purposes Laboratory kiln for testing purposes in the factoryin the factory

External laboratories with scientific background External laboratories with scientific background

““TECHNOLOGYTECHNOLOGY”” INSTITUTES INSTITUTES CAN HELPCAN HELP

kknowledge source for specific industrial branchesnowledge source for specific industrial branches

hhighigh--tech solutions for practical situationstech solutions for practical situations

eeasy access for small industriesasy access for small industries

ttraining for operational staffraining for operational staff

bbridge between Industry and Scienceridge between Industry and Science

ppre competitive research and developmentre competitive research and development

bbetter use of industrial R&D resourcesetter use of industrial R&D resources

eeasier international contacts asier international contacts

rrepresentative epresentative of industry to the governmentof industry to the government

““SHELTEREDSHELTERED”” PRODUKTION PRODUKTION for for ““ALL SEASONALL SEASON”” PRODUCTIONPRODUCTION

Roofing TilesRoofing Tiles

Facing bricksFacing bricks

Paving bricksPaving bricks

Hollow blocks

Thank you Thank you

for your kind attentionfor your kind attentionINSTITUT FÜR ZIEGELFORSCHUNG ESSEN E.V.

BRICK AND TILE RESEARCH INSTITUTE REGD.fon +49 201 59213 01 · fax +49 201 59213 20

www.izf.de e-mail: info@izf.de