ENGINEERED QUALITY

Welcome

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Presentation Ceratec

Key figures :

• 90 years into brick making• 420 employees• Engineering dep. of 110 people led by Dr. Ir. Luc Deconinck• Connected with the universities: Leuven, Brussels, Ghent.• Turn over: 60 milj Euro in 40 countries

Ceratec is an experienced integrating, engineering business and produces complete turnkey plants and equipment for the clay building materials industry.

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Overview presentation

1. Current situation India – key challenges

2. Production process hollow bricks - perforated facing brick

3. Example of taking the first steps in mechanisation

4. First reference in India: Jay Jalaram bricks

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1. Current situation – key challenges

Price evolution of resourcesin the Indian heavy clay industry

0500

1000150020002500300035004000

2000 2002 2004 2006 2008 2010

0

500000

1000000

1500000

2000000

2000 2002 2004 2006 2008 2010

0

100

200

300

400

500

2000 2002 2004 2006 2008 2010

Average price of coalAverage price of land for brick making

Average price of salaries

Still Positive margins?

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comparison total cost brick to sales price of a brick

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0.5

1

1.5

2

2.5

3

3.5

2000 2004 2008

sales

prod. cost

Conclusion:• Margins are sligthly

under pressure• Volume of bricks has

been grown drastically

� Why then invest in brick making equipment?

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Why invest in the brick industry?

Reasons:• Labor problems (strikes, not enough workers,...• Very much depending on weather conditions• Big projects~average selling quantities are increasing (same

quality?, contract pricing?,…)• Brick industry is losing weight towards the flyash bricks, cement

blocks,...

.Key challenge 1: The Indian brick industry needs « continuity and reliability » in order to be ready for the 21th century

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How continuity and reliability?

Delivering bricks at 350 days/year with the same high quality and equal priceDrying 350days/year Need of more

energyCompensate with perforation in the bricks

Firing 350days/year

Perforated bricks: up to 30%

Hollow blocks: up to 70%Need of top level extruder

The need of a good clay preparation

Key challenge 2: Installing a brick plant = big long term investment

Although, it is possible to split up in different steps in order to spread the total investment

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2. Production process: hollow bricks and perforated facing bricks

A. Perforated facing bricks

• Huge variety of bricks:• Colours• Textures• Additives• Sanding, …

• Aesthetic appeal = personal : added value to sell bricks

• Very low cost to maintain the aesthetic value of a brick

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B. Filling up hollow clay bricks (perforation is horizontal)

- Less concrete is needed

- Light weight block is easier to transport

- the weight of the whole concrete structure of the building is less

- Hollow block = green brick(sustainable product)Higher insulation values and less clay is needed to make the block

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3. Example of taking the first steps in mechanisation

• Clay preparation lines

• Step by step investment

Preparation

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• Extruder with top level vacuum chamber

• Pressure/humidity control• In line cutter/multiwire

cutter

Shaping

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• Dryers– Combined sun drying– Chamber dryer– Tunnel dryer– Fast dryer (hollow bricks)

Drying

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• Automatic solid fuel feeding for BTK and Hoffman kiln or gas burners

• Total design of the kiln

Firing

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• Refurbished preparation machines

• Spare parts service• In-house workshop

Supporting services

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4. First reference in India

RefenceJay jalaram bricks,

Capacity: 10.000 bricks per hour.Type: facing bricks (perforation degree 19%)Mechanization:

first step: boxfeeder, double shaft mixer, extruder, cutter and the process technology for drying and firing second step: Chamber dryer, wet side handling equipment, dry side handling equipment, multiwire cutter

Region: Gujarat, Gohdra

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Thank you for your attention

If there are any questions, please feel free tocheck out our website: www.ceratec.eumail to info@ceratec.be; hendrik.vancolen@ceratec.be

phone to +32 56 56 57 58

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