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1HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · Phone +49 7041 891-1 · Fax +49 7041 891-232 · [email protected] · www.haendle.com

International Conference on Mechanization in Brick Industry MBI 2011

Extrusion of hollow bricks -a first step of mechanization in

the Indian brick Industry

2HÄNDLE GmbH Maschinen und Anlagenbau · 75417 Mühlacker (Germany) · www.haendle.comECTS Technology Symposium India 2011

Facts and data

Established 1870

HÄNDLE is and always has been a mid-range enterprise based in Mühlacker, Germany

Plant and equipment by HÄNDLE is used in all corners of the world for the manufacture of building bricks, pavers, roof tiles and ceramic tiles

HÄNDLE products are marketed in 98 different countries

90% of the HÄNDLE-built machines are exported, and somewhat over 70 % of the spare and wear parts are sent abroad, too. Back in the year 2000, that figure was still just 35 %

Total revenues for the year 2010 came to approx. 33 million Euros

The division machinery and equipment had a share of 51% and the after-sales services of 49% in the revenues


Facts and data

119 employees / 15 apprentices

100 percent ownership, since 2003, of a small service company in Poland: HÄNDLE S.p.z.o.o in Torun

As of Jan. 1, 2008, data processing system upgraded with a full-scale, operations-integrated "ProAlpha" ERP system (total investment: approx. 750,000 Euro)

Overall investment volume of approx. 1.5 million Euro for machine-tool and welding-automation production equipment at HÄNDLE's Mühlacker facility in 2008

76 percent ownership, since Dec. 2010, of a service organization in Russia OOO HÄNDLE Service RUS in Nikolskoje


Current situation of the brick industry in India

» More than 100.000 brick makers in India» 200 billion bricks/ year



» seasonal operation (7 - 8 months)» sun-drying » hand-moulded solid bricks» mainly small and medium scaled operations



» clamp-firing process» no automization


Major challenges

Shortage of labour

Shortage of clay

Increased environmental specifications

Changing market situation (end-users, competition, etc.)

Rising of energy costs

etc.


Extruded bricks – a way to overcome the challenge?

HÄNDLE de-airing extrusion unit Futura type PZG 40c/ 40


Benefits of bricks in general

60% less weight than a solid concrete block

Excellent thermal insulation and sound insulation

Dimension stability

Moisture regulating

Long product life-cycle / sustainability

Environmentally friendly / ecological

Comfortable indoor climate

Non-flammable


Benefits of extruded perforated bricks

Reduction of natural resource consumption

Reduction of operating costs

Health, comfort and safety for all residents

Energy optimization and reduction of energy consumption

Increased productivity of the occupants

Better indoor air quality

Excellent thermal insulation and sound insulation

Ease in handling

Most advanced technology


Decisive parameters for the dimensioning of machines/ plants

Capacity and product data of the

customer

Optimal Optimal customized customized machine/ plantmachine/ plant

Laboratory testsand analysis

Process relevant ancillary conditions

Machine configuration

Design adaption according to specific

conditions


Case study

ProjectJay Jalaram Brick WorksMfgs of Quality BricksGodhra (Gujarat)

Project dataReference size 220 x 110 x 75 mmProducts full bricks and perforated bricksWeight 2.75 kg/ pcCapacity 22 t/ h fired (max) = 8,000 pc/ h


Case study

» Delivered raw material

» Humidity: 5% (based on dry material)

» max. edge length 100mm


Case study

HÄNDLE laboratory


Case study

Extrusion of a 3-hole brick Extrusion of a full brick


Case study

6-layer setting tower of full bricks after extrusion

Full bricks after drying on air


Case study

Results of the laboratory analysis

Very little clay (high non-clay mineral content)

Strong reaction to differences in moisture contents

moisture content has to be controlled carefully

Recommend extrusion moisture 18.5 % - 19.0 %

Possibility of layer setting

Sensitive during drying


Case study

Feeding box feeder Cutter


Case study

New de-airing extrusion unit at Jay Jalaram Bricks


Case study

Collection of extruded bricks Covered bricks during drying


Case study

Fired extruded bricks Fired bricks


Possible installations in India



Extrusion without vacuum

Extrusion with vacuum



Material with roots and stones


HÄNDLE, your German specialist for preparation and shaping: a strong partner to India’s brick and tile industry


Laboratory and Pilot Plant

Conveying and Storing

Screening

Feeding and Proportioning

Crushing

Mixing and Homogenizing

Shaping - Extruding

Shaping - Molding

Spare parts and Service

HÄNDLE GmbHMaschinen und Anlagenbau

Industriestrasse 47

75417 Mühlacker (Germany)

Tel.: +49 (0)7041 891-1

Fax: +49 (0)7041 891-232

24 Hours Hotline + 49 171 7323636

[email protected]

www.haendle.com

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