Our vision is to see Indian Clay Brick Industry transform from a very old age method of making Bricks into a modern manufacturing sector. We want this industry to come out of the shell and leave all ills of the trade like child labor and inhuman conditions at brick-kilns. We want to save precious Natural Resources and at the same time, we want Indian Brick Sector to remain the largest employment provider in the country.
Our mission is to evolve Indian specific technology which will integrate the modern world with the existing small enterprises. We want to provide affordable and yet effective solutions to the entrepreneurs, to move towards more environment friendly products. We are working hard to provide round the clock technical backup to our customers, so that they can overcome even the toughest hurdle. We want this sector to conserve our national natural resources, like top layer of soil and coal. We want the Fired Clay products to remain a leading material in buildings. This sector is facing stiff competition from other products like Concrete Hollow Blocks, Fly ash based products like Fly ash lime gypsum bricks and Autoclaved Aerated Concrete Blocks. We all know the ill effects of fly ash and stability, heat conservation issues for concrete products, while we have seen fired clay products since 2000 years now. Clay products have always been a first choice.
Broadly there are two methods to produce bricks. Soft-mud molding and bricks by wire cutting extruded clay mass.
Soft-mud Technology: This first method is very resource intensive. It is more prevalent in poor countries in Africa and in Indian sub-continent. This process needs a lot of water while making a clay water mass. This mass is then molded into brick shapes by means of steel or wooden molds and using manual labor or machines. It requires approximately 50 men to produce 30000 bricks per day. The working hours are odd as well as long. The living conditions are generally in-human. In India this manual labor comes in forms of groups which usually includes women and children. They are made to live in very small spaces and are seldom provided facilities like clean drinking water, electricity and sanitation. Normally these groups are under the hold of a group leader who charges huge amount in advance from the factory owners to secure those groups availability and production. These group leaders or some individual members of the group, sometimes approach the administration claiming themselves to be bonded laborers. They do this to nullify the amount received by them in advance.
This soft-mud process is adopted in machines too. There are machines available that can mold the wet mass into bricks of desired size and shape. Since the moisture content in the raw material is to the tune of 30% w/w, the fresh molded bricks have no strength in them. The cannot be handled mechanically or manually till the loose substantial amount of moisture and turn leather hard. Due to this, the fresh molded bricks have to be left in open spaces or on the pallets for fairly long time, depending on the climatic conditions. This needs extra space and resources like pallets and racks.
Extrusion Process and wire cutting: This method is very energy intensive. In this process, the clay is first wetted overnight, so that enough water seeps into the deepest pores. This clay is then fed in to the machines using a combination of different clay processing machines like The Box-Feeder, Primary Roller Crusher, Fine Roll Grinder, Wet-Pan Mill, Double axel mixer. The clay keeps shifting from one machine to another over the belt conveyors till a homogeneous mix in desired state is ready. This clay is then put into the Extruder. The extruder extrudes this clay into a column of clay through an opening. Different mouths can be attached to its mouth to make different products. This clay column is cut into smaller pieces by pushing the clay mass through high tension wires. The bricks in this process have less moisture (about 14-20%), making it possible to handle the bricks immediately. Mostly the bricks are so hard that they may be stacked immediately in 6-12 layers. The whole process needs only half the workers as compared to soft-mud process.
Both processes have their advantages and dis-advantages.
In the soft-mud process, the main advantage is that due to high moisture content and loose bonding, there are enough capillaries in the brick which allows flawless drying even under the direct sun light. The other advantage being easiness to make logo bricks, which are very popular in India. In the dis-advantages, we can count on the no of working hours of workers or the investment in pallets. Other being more prone to weather conditions, like in manual process, if rain comes most of the molded bricks are wasted. This makes this process possible only in dry seasons, making brick sector a seasonal industry. Moreover, the workers for this work are in very short supply.
The main advantage of the extrusion process is less dependence on skilled molders. Secondly, the product diversity and beauty is there. Thirdly, it is comparatively easy to blend different kinds of clay and adding internal fuel in exact proportions is easier. Although this process needs huge power, still the average cost per brick is cheaper in this type. Being highly compressed, the bricks through this process consume at least 10% less coal as compared to soft-mud bricks. The compressive strength of the product is at least twice than its counterpart. This process allows high degree of automation at comparatively low costs.
In the dis-advantages, availability of power near production sites is a major deterrent, second comes its drying. Being highly compressed, the extruded bricks are very less porous. This makes their drying very typical. Depending on the quality of clay, we have different processes to suit our individual clients. Another dis-advantage is that logo brick is almost impossible in this process. Due to polished external surfaces, sometimes the market acceptance is low as the buyers doubt the ability to bond with cement and plaster, even though it has no scientific backing.
Our Quality policy is precise and definite. Best Service at Best Price. At Brick Technologies (INDIA) we always work towards customer’s individual needs and satisfaction. We manage all this and more with a smile.