Project Report

Of
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.

BRICKMACHINE
1. 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 MIXTURE
1. 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 sturdily

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

Control Panel
A 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

Particulars Specifics Amount

Land Required 4000Sq.Mtrs Leased

Building 20X80ft 5,00,000/-

RCC Flooring 20X80ft
Shed
Machinery 1 Unit 15,00,000/-
Wooden Pallets 200 60,000/-
Electric Fitting,
Securities & Other 90,000/-
Misc. Assets
Electricity 33HP for Machine
2HP for Submersible
Water Pump
5 HP for Lighting &
Misc Usage
Working Capital
3,00,000/-
Labors 8 Labors per shift
(unskilled) 1operator
skilled

Means of Fiancé

Own Capital 50,000/-

Bank Finance
(a) Term Loan 17,00,000/-

(b) Cash Credit Limit 7,00,000/- 24,00,000/-

Total 24,50,000/-
 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:

RAW RATIO QUANTITY RATE TOTAL

MATERIAL (TON) INR/TON 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/-

Production of Bricks using CEMENT:

RAW RATIO QUANTITY RATE TOTAL
MATERIAL (TON) INR/TON 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/-

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.