Project Report Project Report Of Of

Fly-Ash Bricks Udyog Fly-Ash Bricks Udyog

INDEX

(1) Introduction

(2) Test Certificate for strength of Bricks

(3) Name of the Unit

(4) Name of the Proprietor

(5) Address

(6) Constitution

(7) Service Provided a) Complete information about unit b) Schematic representation of Installation of the unit

(8) Raw Materials and availability

(9) Importance of Fly ash lime and gypsum mix

(10) Man Power & Transport Requirement

(11) Marketing and Development scope of the Unit

(12) Details of Installation

(13) Means of Fiancé

(14) Cost of Product

(15) Important Note

INTRODUCTION

Karmyog Industries is a 12 years old player in construction machinery manufacturing. We have expanded not only in India but also in International market. Our main aim is complete customer satisfaction. For that we have always been improving our machinery designs and quality in past 10y years. Our USP is quality and durability of machineries.

This Project Report is the extract of 12 years constant efforts. And it can be also said the experience of Karmyog Industries. In this report we have mentioned details of a fresh project start-up for producing Fly Ash bricks. As we are manufacturing machineries for producing bricks, each time before dispatching our unit to customer we verify it by producing a trial run of bricks. So we have excellent command on not only manufacturing machine but also brick production. Reader must concentrate reading the project on each little thing mentioned. We have carefully designed it to be a helpful guide to you for your plant installation. We are sure our efforts will prove the best to fulfill your ambitions.

(1) Name of the Unit :

(2) Name of the Proprietor:

(3) Address :

(4) Constitution:

(5) Service Provided: Karmyog Industries

Flyash Brick Making Plant-Technical Features

OUR Fly ash brick making plant has been designed to manufacture fly ash bricks with Eco-friendly technology. It is a simple & cost effective technology available in the country. The heart of the plant is an indigenously designed, a relatively low cost & high productivity machine. Other component machines of the plant Pan Mixture, Conveyor, Pallet trucks, Wheel Borrows & wooden Pallets are economically & efficiently designed to give a maximum output.

BRICKMACHINE1. Brick Machine is hydraulically operated, automatic, controlled by

electronic circuits. This can be mastered with little basic electrical knowledge.

2. Brick making machine develops 50 T of compressive force over the bricks uniformly and hold the pressure for required time allowing the materials to flow and form.

3. The machine structure is carefully designed to take up the heavy cyclic loads.

4. Monogram on the brick can be embossed.5. Very high production at relatively low cost.

PAN MIXTURE1. A sturdily constructed machine with heavy rollers to grind and mix

the material thoroughly.2. Drive through trouble less, quality worm reduction gear box.

3. Easy bottom unloading mechanism with door arrangement.

CONVEYOR

1. Frames and intermittent bins fabricated sturdily2. The fly ash mix can be regulated according to the speed of the brick

making machine.3. Nylon with rubber top conveyor belts.4. Friction less idlers.

HOPPER

A collecting Hopper is provided on the upper side of the main body.It collects mixed material from conveyor belt & stores it. The required quantity of the mixed material is then dispatched automatically from hopper & bricks are manufactured.

PALLET TRUCKSNovel and ergo metric design to handle the bricks with pallets for effortless and easy transportation of fly ash bricks with reduced labor.

Control PanelA fully automatic FA Bricks machine includes control panel with PLC system to help automation of raw material feeding, mixing, conveyor belt operating to bricks formation & bricks output. One skilled worker can handle the system & it helps in reducing of dependency on labors as well as getting work done faster.

Al gypsum is mixed and ground to make cement.

In Fa-G mix also the fly ash witch is a burnt clay particles (Oxidizes of clay ) obtained from burning of coal which contains clay from the mines when hydrated lime powder, gypsum are mixed and ground in a pan mixture gives the slow setting puzzling cement. And 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 Machine which is specially and indigenously designed to give high pressure load, at slow rate, in the order of 250 kg/ Square inch.

At this rate of pressure and with holding the pressure for a desired time gives ultimate strength to the Fal-G bricks.

7. Man Power & Transport Requirement In order to run the unit efficiently the concern proposed to employ the request staff as per annexure attached. The location of the unit is also well connected by transport facilities.

8. Marketing and Development scope of the Unit The scope of this kind of unit is very bright in the coming days. Government of India is more insisting all the existing Bricks kilns to use Fly Ash for the Bricks where those kilns are not in use of Fly Ash. How ever this unit is basically bas on Fly Ash and cement. So in the coming days Govt. is doing mandatory to all the govt. construction works to use only Fly Ash Bricks. So the demand for this product will increase in the future. Also Fly Ash Bricks in quality is much better than klin brick. The Fly Ash Brick is more stronger and long life than other. So use of these Bricks is increasing day by day. So the future scope of this unit is very bright. CPWD MIS has been already incorporated these bricks in their specifications for use in all types of their constriction. Bureau of Indian standards has formulated code viz (S 12894 special for Fly Ash Bricks.)

Details of Installation

Means of Fiancé

Own Capital 50,000/-Bank Finance (a) Term Loan

(b) Cash Credit Limit

17,00,000/-

7,00,000/- 24,00,000/-Total 24,50,000/-

Particulars Specifics AmountLand Required

4000Sq.Mtrs Leased

Building RCC FlooringShed

20X80ft 20X80ft

5,00,000/-

Machinery 1 Unit 15,00,000/-Wooden Pallets 200 60,000/-Electric Fitting, Securities & Other Misc. Assets

90,000/-

Electricity 33HP for Machine 2HP for Submersible Water Pump5 HP for Lighting & Misc Usage

Working Capital 3,00,000/-

Labors 8 Labors per shift (unskilled) 1operator skilled

Cost of Product

The production per shift (8hrs) 11520 bricks requires material 31.67Ton Weight per bricks 2.75 to 3 Kg (APPX)

Production of Bricks using LIME:

Production of Bricks using CEMENT:

Important Note:-

Product Code: IS 12894-2000 Product Costing: Depends upon the area cost of raw material. Unit (Machine includes): Bricks making machine, Conveyor

belt, Hooper, Pan Mixture &Green Bricks Railing.

RAW MATERIAL

RATIO QUANTITY(TON)

RATEINR/TON

TOTAL INR

Fly Ash 55% by weight 17.42 180/- 3135.6/-Sand 25% by weight 7.92 70/- 554.4/-Lime 15%by weight 4.75 2000/- 9500/-

Gypsum 05% by weight 1.58 800/- 1262/-Electricity .10/brick 1152/-

Labor .15/brick 1728/-TOTAL 17,332/-

RAW MATERIAL

RATIO QUANTITY(TON)

RATEINR/TON

TOTAL INR

Fly Ash 62% by weight 19.64 180/- 3535.2/-Sand 30% by weight 9.50 70/- 665/-

Cement 08%by weight 2.53 4500/- 11404/-Electricity .10/brick 1152/-

Labor .15/brick 1728/-TOTAL 18,484.2/-