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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 managing partner of Vijayaprakash Industrials, Calicut, Kerala also was with me in presenting the paper in the SMIDEDX 2014.

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

  1. 1. Upgrading the Technologies is a MUSTThis presentation is made in association with M/s. Vijayaprakash Industrials, India
  2. 2. Vijayaprakash Industrials
  3. 3. Why to Mechanise? How to Mechanise?
  4. 4. We’ll have an open discussion on various aspects of modernising brick industry in Sri Lanka
  5. 5. Human beings go on producing many things for their convenient living.
  6. 6. Most of the time they snatch away the provisions of life of their fellow inhabitants in order to achieve this.
  7. 7. Hence we have to take extra care not to loot the nature beyond our provisions. Take only what you ought to
  8. 8. Technological advancements make this possible.
  9. 9. So upgrading the technology we use for producing various commodities is a MUST.
  10. 10. It’s more so in the case of terracotta products. Clay once burned is burned for ever.
  11. 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. 12. Waste at all levels is to be minimised
  13. 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. 14. Some assured increased productivity with quality, but were too energy consuming.
  15. 15. Some caused a lot of irretrievable waste of many resources. Some required huge investments.
  16. 16. We returned home.
  17. 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. 18. We watched their process , rather watched it with a renewed interest
  19. 19. Their process of clay preparation was of real interest. They even produce thin clayware with bare hands.
  20. 20. Freshly hand moulded green ware in clay
  21. 21. Their basic technology of clay preparation was unique.
  22. 22. The quality of the end product greatly depends on the quality of clay preparation
  23. 23. Have you ever noticed how these traditional potters prepare the clay?
  24. 24. First they collect the clay and store it in heaps. They pound the clay well after mixing with water.
  25. 25. Then they keep it for one or two days as such for curing
  26. 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. 27. The sliced clay is again pounded and mixed with water and sand adequately.
  28. 28. They take great care in making it really homogenous.
  29. 29. You may know, even thin clayware made centuries ago are still available without any damage.
  30. 30. From some places earthenware are excavated out while digging for agricultural or construction purposes
  31. 31. So we thought a little deep about this clay preparation method; introduced a way to follow the same method using machines.
  32. 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. 33. Box Feeder
  34. 34. Our high speed fine grinding rollers further mixes it and grinds the hard particles which make the water penetration easier
  35. 35. High Speed Fine Grinding Roller
  36. 36. VPI Twin Barrel Clay Mixer
  37. 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. 38. Clay mixer is fitted with slicers at its mouth which slices the clay into finer flakes and renders it really manageable.
  39. 39. Pan mill helps you to crush the large lumps of clay, which ensures better mixing.
  40. 40. Comparing the two process
  41. 41. Panmill Grinds the Hard particles
  42. 42. VPI Panmill
  43. 43. Panmill pushes the clay down in noodle form
  44. 44. So waste is utilised well in this processing method
  45. 45. We have gone one more step ahead
  46. 46. Our De-airing Pug Mill removes the air column caught inside the clay and pugs it well.
  47. 47. This stage in the processing increases the elasticity of the clay to very great extent
  48. 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. 49. Extrude any product
  50. 50. Made truly elastic Soft Mud Extrusion with De-airing Pugmill
  51. 51. A few more steps Forward! Some additional Mechanisation suggestions for additional quality and productivity
  52. 52. Loading
  53. 53. Pre-crushing and Curing
  54. 54. Bucket Excavator
  55. 55. Wire-cutting
  56. 56. We have seen some buildings here in Sri Lanka
  57. 57. Look at the walls of these buildings
  58. 58. Powder Process/Dry Process
  59. 59. This is not just an upgradation of technology, but it’s a bare essential processing modification every clay industry has to adopt
  60. 60. It’s our responsibility towards our coming generations; it’s a MUST.
  61. 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. 62. Bricks, Hollow bricks, wall facing tiles, roofing tiles, paver blocks etc.
  63. 63. A Truly wide range of Products
  64. 64. You can now produce more number of clay products with improved quality using lesser amounts of raw materials, energy and other resources
  65. 65. Upgrade the technology. It’s the need of the hour, rather a responsibility of every entrepreneur. it’s a MUST.
  66. 66. THANK YOU