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Upgrading technologies, Describes the proper level of Modernisation of brick indsutry


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This was a presentation made b y me at SMIDEX 2014 at Colombo, Sri Lanka on 22nd May 2014. Mr. George Mathews .a mechanical engineering consultant from Pune, Maharashtra and Mr. K> K> Vijayan the …

This was a presentation made b y me at SMIDEX 2014 at Colombo, Sri Lanka on 22nd May 2014. Mr. George Mathews .a mechanical engineering consultant from Pune, Maharashtra and Mr. K> K> Vijayan the managing partner of Vijayaprakash Industrials, Calicut, Kerala also was with me in presenting the paper in the SMIDEDX 2014.

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  • 1. Upgrading the Technologies is a MUSTThis presentation is made in association with M/s. Vijayaprakash Industrials, India
  • 2. Vijayaprakash Industrials
  • 3. Why to Mechanise? How to Mechanise?
  • 4. We’ll have an open discussion on various aspects of modernising brick industry in Sri Lanka
  • 5. Human beings go on producing many things for their convenient living.
  • 6. Most of the time they snatch away the provisions of life of their fellow inhabitants in order to achieve this.
  • 7. Hence we have to take extra care not to loot the nature beyond our provisions. Take only what you ought to
  • 8. Technological advancements make this possible.
  • 9. So upgrading the technology we use for producing various commodities is a MUST.
  • 10. It’s more so in the case of terracotta products. Clay once burned is burned for ever.
  • 11. So before you place a clay product into the kiln make sure that you have prepared the clay well and used only the right amount of clay.
  • 12. Waste at all levels is to be minimised
  • 13. We searched the whole world for arriving at solutions to produce more number of clay products from the available clay and couldn’t find a proper solution.
  • 14. Some assured increased productivity with quality, but were too energy consuming.
  • 15. Some caused a lot of irretrievable waste of many resources. Some required huge investments.
  • 16. We returned home.
  • 17. We happened to see some of our traditional potters producing good quality clay potteries, clay idols, manikins and other such things from clay.
  • 18. We watched their process , rather watched it with a renewed interest
  • 19. Their process of clay preparation was of real interest. They even produce thin clayware with bare hands.
  • 20. Freshly hand moulded green ware in clay
  • 21. Their basic technology of clay preparation was unique.
  • 22. The quality of the end product greatly depends on the quality of clay preparation
  • 23. Have you ever noticed how these traditional potters prepare the clay?
  • 24. First they collect the clay and store it in heaps. They pound the clay well after mixing with water.
  • 25. Then they keep it for one or two days as such for curing
  • 26. After that they will slice the clay column with a knife or blade. While slicing it into thin wafers they will carefully remove the hard particles from the clay
  • 27. The sliced clay is again pounded and mixed with water and sand adequately.
  • 28. They take great care in making it really homogenous.
  • 29. You may know, even thin clayware made centuries ago are still available without any damage.
  • 30. From some places earthenware are excavated out while digging for agricultural or construction purposes
  • 31. So we thought a little deep about this clay preparation method; introduced a way to follow the same method using machines.
  • 32. Box Feeder is designed to mix all clay, proportionate it well and make sure the flow of clay to ensuing machines is even, that means no overload no under load.
  • 33. Box Feeder
  • 34. Our high speed fine grinding rollers further mixes it and grinds the hard particles which make the water penetration easier
  • 35. High Speed Fine Grinding Roller
  • 36. VPI Twin Barrel Clay Mixer
  • 37. Clay mixer has two chambers. The open chamber has beater shaped paddles which expands the clay and in the closed chamber, augers compresses the clay.
  • 38. Clay mixer is fitted with slicers at its mouth which slices the clay into finer flakes and renders it really manageable.
  • 39. Pan mill helps you to crush the large lumps of clay, which ensures better mixing.
  • 40. Comparing the two process
  • 41. Panmill Grinds the Hard particles
  • 42. VPI Panmill
  • 43. Panmill pushes the clay down in noodle form
  • 44. So waste is utilised well in this processing method
  • 45. We have gone one more step ahead
  • 46. Our De-airing Pug Mill removes the air column caught inside the clay and pugs it well.
  • 47. This stage in the processing increases the elasticity of the clay to very great extent
  • 48. So the clay is ground, mixed, watered, cured, and in the final stage using an extruder you can extrude out any product with high quality standards
  • 49. Extrude any product
  • 50. Made truly elastic Soft Mud Extrusion with De-airing Pugmill
  • 51. A few more steps Forward! Some additional Mechanisation suggestions for additional quality and productivity
  • 52. Loading
  • 53. Pre-crushing and Curing
  • 54. Bucket Excavator
  • 55. Wire-cutting
  • 56. We have seen some buildings here in Sri Lanka
  • 57. Look at the walls of these buildings
  • 58. Powder Process/Dry Process
  • 59. This is not just an upgradation of technology, but it’s a bare essential processing modification every clay industry has to adopt
  • 60. It’s our responsibility towards our coming generations; it’s a MUST.
  • 61. Vijayaprakash Industrials, India, can provide you the required technical help to upgrade yourself to produce the most resource efficient bricks and other clayware
  • 62. Bricks, Hollow bricks, wall facing tiles, roofing tiles, paver blocks etc.
  • 63. A Truly wide range of Products
  • 64. You can now produce more number of clay products with improved quality using lesser amounts of raw materials, energy and other resources
  • 65. Upgrade the technology. It’s the need of the hour, rather a responsibility of every entrepreneur. it’s a MUST.
  • 66. THANK YOU