FLY ASH BRICK MACHINE MAKING  PLANT-TECHNICAL FEATURES

Our fly ash brick making machine has been designed to manufacture fly ash with FAL-G technology is a simple and effective technology available in our country. The heat of the plant is an indigenously designed, a relatively low cost and high productivity machine. Other components machines of the plant PAN-MIXER, BELT CONVEYOR, MANNUALLY OPERATTED HYDRAULIC PALLET TRUCKS, are economically and efficiently to give a maximum out put.

BRICK MAKING MACHINE
Brick making machine is hydraulically operated, automatically, P.L.C. controlled rotary type.  Which can be mastered with little basic electrical knowledge.The electronic circuit is a self diagnosing, gives the fault signal light which can be read by any person.Optional alpha numeric display, computer connection and modem can be fitted interact with our base computer through telephone line to locate faults in advance, periodically for easy maintenance, before any break down to avoid down time.The compressive force can be varied infinitely by turn of a knob.

Over loads which are possible, quite often during working, because of foreign material in raw material will be easily by-passed automatically with out damaging any system of the machine.
The machine structure is carefully designed to take up the heavy cyclic load.
Different size of moulds can be fitted, with a maximum size of 230X200X100 mm.
Monogram on the brick can be embossed.
Very high production at relatively low cost.
Efficient water cooling systems to ensure the continuous running of the machine.

FLY ASH BRICK MAKING PLANT DEMO
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PAN- MIXER
A sturdily constructed machine with heavy rollers to grind and mix the raw- material thoroughly.
Drive through trouble less, quality worm reducing gear box.
Changeable bottom wear plates and scrappers fitted with TC tips.
Easy bottom un-loading mechanism with rack & pinion door arrangements.

BELT-CONVEYOR
Frames and intermittent bin fabricated sturdily.
The fly-ash mix can be regulated according to the speed of the brick making machine.
Nylon with rubber top conveyor belts.
Friction less C.I. Rollers.

HUDRAULIC PALLET TROLLY
Novel and ergometric design to handle the brick with pallets for effortless and easy transportation of fly-ash bricks with reduced labour.

FAL-G MIX
The FAL-G mix is nothing but a slow setting pozzalona cement mix. The process  is same as mixing cement in cement  factories  where  as  the  clay  and lime stones are burnt with coal, gypsum is mixed and ground to make cement.
In FAL-G  mix  also  the  fly-ash which  is  a  burnt  clay  particles  (Oxides of clay) obtained  from burning of coal which contains clay from the mines. When hydrated lime powder, gypsum are and ground in a pan mixer given the slow setting pozzalona cement.  Sand is also added to bring down the cost of mix of brick in our process.

While   the  mix  is  pressed  at  low  moisture  content  in  the  BRICK MAKING MACHINE which is specially and indigenously designed to give high  pressure  load, at slow rate, in the order of 350 kg/square inch.
At this rate of pressure and with holding the pressure for a desired time given ultimate strength to the FAL-G bricks.

RAW MATERIALS AND AVAILABILITY:

FLY-ASH : The left out after burning of coal is generally available in Thermal power station, Papper mill or where steam boilers are used. The fly-ash available in industries are good quality and normally free of coast.  The FAL-G brick making units can be put up in a radius of 150 kms, from the fly-ash source.

LIME   : The lime used in this process in hydrated lime powder, which will be available locally. The cost of lime powder shall not exceed Rs.2,700/- for the economy of the FAL-G bricks to economize the cost of lime a small country lime kiln can be very well constructed at the site itself.

GYPSUM : The calcined gypsum is available at M/S Saravana Fertilizer and Chemicals, 27, Dharmalingapuram, Opp: TANFEC LTD, SIPCOT, Kudikadu, Cuddalore-607005. The locally available gypsum can be fired in a kiln to get calcined gypsum.

SAND : Sand is used as an economizer and to increase the strength of brick to some extent. Any locally available cheape sand can be used in making the bricks. Any colouring can be added to give desired colour, but cost will be high.

PROJECT AND FACILITY PROFILE.
(An over profile is given under. You may please work out as per local rates.)

MANUFACTURING CAPACITY-8,000-10,000 bricks/shift.
Minimum space required      :  0.5 acre with water facility(5,000 ltrs/shift)
Required power                        40 HP
Shed                                       75' X 40'(minimum shed required 12')
Labour                                     15 (skilled & un skilled)

COST OF PRODUCTION

To manufacture 10,000 bricks. Each brick weight 3kg (approx).
       70% FLY-ASH                 21  Ton.
       10% LIME                        03  Ton.
       05% GYPSUM                 1.5 Ton.
       15% SAND                       4.5 Ton.
% of the material can be varied according to cost and quality of raw materials available locally to bring down cost.
POWER 11UNITS/HOUR(approx)
WORKING CAPITAL       One month production.
BREAKE EVEN POINT    40%-45%

PROPERTIES OF FAL-G BRICK

Compressive strength achievable               60-250 kg/cm sq.
Water absorption                                      05-12%
Density                                                    1.5gms/cc

Co- efficient of softening (depending up on water consistency factor)

Unlike the conventional clay bricks have high affinity to cement mortar through it has smooth surface, due to the crystal growth between brick and the cement motar the joints will become stronger and in due of time it will become monolithic.
The strength will be consistent.