Hollow Clay Bricks Production Industry An Experience Softmud
"Hollow Clay Bricks Production Industry- An Experience" Soft-mud Moulding Hand Made Hollow Blocks O P Badlani Extruded Wire Cut Chairman Prayag Clay Products Pvt Ltd,
Highlights Introduction to Prayag Clay Products Pvt Ltd Transformation to Natural Draught Zigzag Technology Production of Hollow / Perforated Bricks – Challenges faced & My Experience shared
Introduction to Prayag Clay Products was founded in 1937 in Varanasi, Uttar Pradesh. Presently Prayag Clay Products operates two brick production units in Varanasi and produces following products Traditional Bricks (Hand moulded) Machine made Solid bricks Modular Bricks Hollow blocks Perforated Bricks Decorative Clay tiles (Roofing n wall cladding) Clay Pavers (Flooring)
Journey so far 1937 1978 1999 • Prayag Clay products founded in Varanasi. First unit began production in 1938 • Established second manufacturing facility in Varanasi • Established third manufacturing facility in Varanasi • Shifted from Fixed chimney Bulls trench technology to High Draught Zigzag firing 2001 technology 2003 • Installed first brick extrusion machine for mechanizing the Moulding process 2006 • Shifted all three kilns to Natural Draught Zigzag Technology -08 2009 • Started production of decorative tiles and clay pavers -10 2010 • Installed India’s first Soft Mud Moulding machine for production of mechanized solid bricks -11 2013 • Installed Extruder for first unit for production of hollow blocks
Prayag Natural Draught Zigzag Technology Developed the Prayag Natural Draught Zigzag Technology and successfully converted all the 3 high draught Zigzag kiln to work on natural draught The converted kilns have been measured as lowest SPM emitting kiln by independent agencies. Established a training institute (Ne. Bri. TA) for training and dissemination of technology More than 400 kilns successfully converted in India Training Programmes for brick kiln owners and workers
Comparison of FCBTK vs Zigzag natural draft based on average values of monitoring results of all kilns
Installed Ist Extruder for production of Wirecut Perforated Bricks
Soft Mud Moulding Machine Soft mud moulding machine
Drying Shed for Mechanized Solid Bricks
Fan Drier Brick Drying shade
Dust pressing machine for Clay Tiles & Pavers
Bio Mass Gasification Plant for Power Generation Gasifier for power generation
2 nd Extruder Plant for Hollow Blocks & Perforated Bricks
Open Drying
Perforated 3 Holes & 8 Holes
Perforated Bricks being set in Zigzag kiln for firing
Future Plans – Hollow Blocks
Block size 200 mm x 400 mm
Features of Smart Bricks LIGHT WEIGHT – Enabling faster construction HIGH COMPRESSIVE STRENGTH – Efficient & long lasting THERMAL & SOUND INSULATION – Ensure comfortable in-door living environment ENERGY EFFICIENCY - Lower ‘U’ values assure better thermal insulation thus providing comfortable indoor climate – reduce energy demand for air conditioning ; ‘U’ Value : 1. 0 W/m²K. GREEN BUILDING PRODUCT – 100% Natural, sustainable & rated by the Indian Green Building Council (IGBC) & the Green Rating for Integrated Habitat Assessment (GRIHA)
Next. Gen Brick Training Academy Established a training institute Ne. Bri. TA for training. Training Programmes for brick kiln owners. Training Programmes for brick kiln supervisors & workers.
Prayag Kiln Technologies PKT for dissemination of Natural Draught Zigzag Technology. More than 400 kilns (Newly constructed + Retrofitted) in the past 8 years have been successfully operational in India We are registered LSP (Local Service Provider) for Natural Draught Zigzag Technology under BEE
THANK YOU O. P. BADLANI PRAYAG CLAY PRODUCTS Pvt. Ltd. VARANASI, INDIA
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