International Conference on Mechanization in Brick Industry MBI 2011

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1 Extrusion of hollow bricks - a first step of mechanization in the Indian brick Industry International Conference on Mechanization in Brick Industry MBI 2011 HÄNDLE GmbH Maschinen und Anlagenbau Mühlacker (Germany) Phone Fax info@haendle.com 1

2 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 2

3 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, operationsintegrated "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 percent ownership, since Dec. 2010, of a service organization in Russia OOO HÄNDLE Service RUS in Nikolskoje 3

4 Current situation of the brick industry in India» More than brick makers in India» 200 billion bricks/ year 4

5 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 5

6 Current situation of the brick industry in India» clamp-firing process» no automization 6

7 Major challenges Shortage of labour Shortage of clay Increased environmental specifications Changing market situation (end-users, competition, etc.) Rising of energy costs etc. 7

8 Extruded bricks a way to overcome the challenge? HÄNDLE de-airing extrusion unit Futura type PZG 40c/ 40 8

9 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 9

10 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 10

Process relevant ancillary conditions Optimal customized machine/

11 Decisive parameters for the dimensioning of machines/ plants Capacity and product data of the customer Laboratory tests and analysis Process relevant ancillary conditions Optimal customized machine/ plant Machine configuration Design adaption according to specific conditions 11

12 Case study Project Jay Jalaram Brick Works Mfgs of Quality Bricks Godhra (Gujarat) Project data Reference size Products Weight Capacity 220 x 110 x 75 mm full bricks and perforated bricks 2.75 kg/ pc 22 t/ h fired (max) = 8,000 pc/ h 12

13 Case study» Delivered raw material» Humidity: 5% (based on dry material)» max. edge length 100mm 13

14 Case study HÄNDLE laboratory 14

15 Case study Extrusion of a 3-hole brick Extrusion of a full brick HÄNDLE GmbH Maschinen und Anlagenbau Mühlacker (Germany) 15

16 Case study 6-layer setting tower of full bricks after extrusion Full bricks after drying on air 16

17 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 % % Possibility of layer setting Sensitive during drying 17

18 Case study Feeding box feeder Cutter 18

19 Case study New de-airing extrusion unit at Jay Jalaram Bricks 19

20 Case study Collection of extruded bricks Covered bricks during drying 20

21 Case study Fired extruded bricks Fired bricks 21

22 Possible installations in India 22

23 Possible installations in India Extrusion without vacuum Extrusion with vacuum 23

24 Possible installations in India Material with roots and stones 24

25 HÄNDLE, your German specialist for preparation and shaping: a strong partner to India s brick and tile industry 25

26 Laboratory and Pilot Plant Conveying and Storing Screening Feeding and Proportioning Crushing Mixing and Homogenizing Shaping - Extruding Shaping - Molding HÄNDLE GmbH Maschinen und Anlagenbau Industriestrasse Mühlacker (Germany) Tel.: +49 (0) Fax: +49 (0) Hours Hotline Spare parts and Service info@haendle.com 26

Modernisation of Indian Brick Manufacturing Sector: Use of Energy Efficient Technologies

Modernisation of Indian Brick Manufacturing Sector: Use of Energy Efficient Technologies Sachin Kumar, The Energy and Resources Institute (TERI) N Vasudevan, The Energy and Resources Institute (TERI) Dr.