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CLEANER BRICK PRODUCTION
FEASIBILITY STUDY
MALAWI 12th June 2012
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Implemented by:
Supported by:
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CLIMATE Green brick making
May – October
Low humidity and temperature
Firing process
June – October
Assessment Quicker drying time, more production
Efficient drying
Extended firing season
Conducive to brick production in VSBK system
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SOIL Soil quality
Soil Quality is inconsistent
Varied type ranging from lateritic to black
Presence of sand and granular materials
High FeO content
Higher vitrification temperature
Sufficient reserve
Assessment
Detailed analysis required for optimization of production process
Suitable for brick making in VSBK with modifications
Improved strength
Consistent colour
Lower breakage
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BRICK MAKING PROCESS
Green brick
Cutting of soil, watering and ageing for 24 hours
Moulding with double / four moulds
Slop moulding process followed
Shape, size and finish not satisfactory and uniform
Very high water content and shrinkage
Proper moulding process not followed
Assessment Room for sufficient improvement
Mixing and moulding training
Use of sand moulding
Improved cutting devices
Introduction of mechanization in mixing
………..will lead to vastly improved quality
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FIRING PROCESS
Observations Traditional method – scoved clamps
Fixed chimney BTK
Assessment Reduced energy consumption
Improved and consistent quality
Extended brick production
Lower emission levels
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PRODUCT QUALITY
Observations High breakage
No consistent colour and strength
Different sizes of fired bricks
Poor shape and finish
Various fired brick qualities
Assessment
Introduction of VSBK technology as a system and not only as a
firing technology
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KILN CONSTRUCTION
Observations Availability of construction materials
e.g. cement, lime, bricks, sand etc.
Expert masons available
Refractory materials available
Steel materials available
Availability of mechanical workshops
Assessment
Training and capacity building of masons for specialized kiln
construction
Capacity building of local mechanical workshops in producing
VSBK equipments and accessories
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ENERGY CONSUMPTION
Observations Sufficient quantity of coal available
Coal is of high calorific value and high volatility
Fire wood consumption 15 t / 40,000 bricks
SEC : 3.5 – 4 MJ/kg
increased deforestation
Assessment Potential to explore a lower CV and low volatile coal
… lower price
Introduction of internal fuel
… extremely reduced energy consumption
Introduction of VSBK (SEC : 0.8 MJ/kg)
… energy reduction by 75%
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ENVIRONMENT SCENARIO
Observations Extremely high consumption of energy
Incomplete and inefficient combustion of fuel
Inefficient firing process and habit
Absence of any pollution control measures
Absence of E&E monitoring agencies
Assessment Introduction of VSBK
….. potential to reduce SPM by 90%
Training of firemen in benchmark firing process
Creation of awareness on health hazards due to high emission
levels
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MARKET SCENARIO
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PRODUCTION COST
Raw Material
Internal Fuel : 2650 MK
Others : 100 MK
Green Brick making Charges : 700 MK
Maintenance : 450 MK
Green Brick Lifting : 400 MK
Firing Expenses :
Coal : 1660 MK
Labour : 720 MK
Overheads : 570 MK
Wastage : 250 MK
Total : 7500 MK
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Per Brick
•Production Cost
• If waste used
Lilongwe
•7.5 MK
•4.85 MK
Blantyre
•7.75 MK
•5 MK
Mzuzu
•5.3 MK
•3.8 MK
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ECONOMICS
Parameter
• Investment
• Production (300 days)
• Production Cost
• Entrepreneurs' Share
• Selling Price
• Turnover
• Annual Profit
• RoR
1 Shaft
• 8 million
• 1.2 million
• 7.5 MK / brick
• 1.5 MK / brick
• 12 MK / brick
• 14.4 million
• 3.6 million
• ~3 years
2 Shaft
• 15 million
• 2.4 million
• 7 MK / brick
• 1.5 MK / brick
• 12 MK / brick
• 28.8 million
• 8.4 million
• ~2 years
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SOCIAL AND INSTITUTIONAL
ASPECTS
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WORKING CONDITIONS
Number of Workers varies from 1 to 15
Only men are engaged in the brick industry
Age profile : young
12 hours per day / 6-7 days week
Relatively unstable work force
No division of labour
Salaries uniformly paid at 250 MK per day
Current skills of kiln workers are sub-standard
or un-skilled
Mainly on-the-job training
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ASSESSMENT
Improvement of working conditions : Safety &
Health
Job creation for local workers
Through training
Leads to improved output of workers
Leads to lower labour costs
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INSTITUTIONAL
Stakeholders:
Private sector (willingness to invest)
Governmental bodies (room for improvements; green
growth strategy)
End-consumers (ability to pay more depending on
quality)
Mainly small-scale enterprises
No licensing observed
New SME promotion policy
Standards for brick quality not enforced
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POTENTIAL
To strengthen private entrepreneurs economic
development approach (small enterprise support)
To improve Governmental services and
enforcement of laws (private business is
protected by the State, and in turn Government
gets more taxpayer money)
To develop and execute regulations for improved
working conditions, standards, and quality of
bricks for higher productivity
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THANKS