A Roadmap for Cleaner Brick Production in India - Red Ladrilleras

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Table 7: Comparison of Kiln Technologies (Financial Performance)TechnologyFCBTKFeaturesChimney height 27 to 30 m; kilncircuit capacity 0.5 to 1 millionbricks.Approx.Capital Cost*(US $)40,000 -60,000TypicalProductionsimple paybackperiodCapacity(millionunder Indianbricks/year)conditions4-8 3 yearsshed, extruder for firing bricksNote: * excluding the cost of land; simple pay-back assuming 100% capacity utilizationProduction Costand Selling PriceData was collected on production cost and revenue. Typical production and selling price ofbricks for different regions in the country are shown in Table 8. The profitability of brickenterprises is higher in southern and western India, due to higher selling price of bricks.16
Table 8: Typical Production and Selling Price DataIndo Gangetic Plains (Punjab,Haryana, UP, Bihar)Southern and western IndiaProduction cost: Rs 2.00- 2.50 /brickProduction cost: Rs 2.50 -3.50/brickSelling Price: Rs 3.00 – 4.00/ brickSelling Price: Rs 4.50 – 8.00/ brickFigure 3 shows the typical break-up of production cost for a FCBTK in Indo-Gangetic plainsand illustrates that fuel is the largest cost component followed by operations (mainlymanpower) cost. The production cost of natural draught zig-zag kiln is 15% lower than thatof FCBTK.Administration& legal6%Losses6%Raw Material15%Fuel45%Operation28%Total Production Cost:- Rs. 2.35/BrickFigure 3: Average Production Cost Break-up Data for Monitored FCBTKs in Indo-Gangetic RegionQuality of Fired BricksThe quality of fired brick depends both on the quality of green bricks as well as on the firingprocess.The tunnel kiln is ranked best in terms of fired brick quality. Factors contributing to thisimproved quality include:1. Fine control over the drying and firing process2. The ability to achieve uniform temperature distribution in the firing zone,3. Due to their large production capacity,they have mechanized brick production.Both the VSBKs had problems with brick quality, and the quality was lower in the IndianVSBK. This is due to a variety of factors:17
Page 2 and 3: Project TeamGreentech Knowledge Sol
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Page 12 and 13: Environment PerformanceThe environm
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A Roadmap for Cleaner Brick Production in India - Red Ladrilleras

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