Clay Brick factory - road map for start up.

1. Kannan V K
Clay Brick Factory
Start up – way forward
Kannan V K
Chief Ceramic Manager
Heavy Clay Technologies
Bangalore

2. Kannan V K
Kannan V K
A Qualified Ceramic Engineer (M.Tech – Ceramic Engineering) with extensive
experience of over 2.5 decades in the Heavy Clay Industry (Clay Bricks, and
Vitrified Clay Pipes) in both semi-automated and highly automated environments.
Technical Leader with rich global experience in manufacturing and Plant & Project
management.
Worked with world leaders – Wienerberger ( India / Belgium / Holland). –erected
green field plant in India ( 300 TPD / Ceric Technology – France)
Trained at Wienerberger Academy – Belgium
Worked in Malaysia – heading 4 brick plants as Chief Ceramic Manager
Presently consulting for companies in Morocco, Malaysia, Sudan, Nepal,
Azerbaijan, India, etc.,
Specialties: Ceramics, Glass & Heavy clay industry (clay Brick / Vitrified clay
Pipe), Plant Mgmt, R&D, Process Control, Tunnel Kilns, Dryers, Solid Fuel Firing.
Green field project, New product development, process optimization, product
quality, trouble shooting.
About me
B.E., M.Tech ( Ceramic Engg)

3. Kannan V K
Heavy Clay
Technologies
Bangalore / India

4. Kannan V K
What’ there
 Various technologies
 Indian, European, European Used, Chinese, Mix of all
Freeze Points
Capacity, Products, Level of automation, fuel
Technology
Hand mould, Extrusion, Pressing, soft mud.

5. Kannan V K
Brick maker - Confused
Kiln
Dryer
Technology
Local Tech
Support ??
!!!
Budget
Profit / ROI

6. Kannan V K
The bridge

7. Kannan V K
Slip Tiles / Fascades High End
Product & Formats
M o d e r n / G r e e n / Re s o u r c e E f f i c i e n t ( R E B )
Size:
230*110*70mm
Weight:
3.0 kilos each
Strength:
20 Mpa
Water absorption
±15%
Clay Bricks Solid & Perforated
Facing Bricks External Facade
High Valued
More specific unit price
Surface treatment
Rich taste of aesthetic
Building Façade Application
University, Library, Villa, Museum,
Hollow Blocks Greenest Materials
Reference Size:
400*230*200mm
Volume Density
700 kg/m.cu appx.
Conductivity ƛ
＜0.12 w/m*K
Void
55~60%
Holes
Vertical or Horizontal
Format/ Capacity / Fuel / Automation level

8. Kannan V K
Road map from concept to go live for
a green field clay brick project
PHASE 1
PHASE 2
PHASE 3
Phase 2
Pre project
Phase 1
Business Plan
Phase 3
Project Finalization
Phase 4
Project & Go live
PHASE 4

9. Kannan V K
Business Plan
 A 30 Page document
 Complete CAPEX / ROI / BALANCE SHEET
 Includes
 Cost for RM
 Energy – Electrical & Thermal
 Manpower
 Maintanance & Consumables
 Plant & Machinery ……

10. Kannan V K
BP Contd…
Annex Index
Sl No. Description Annex No.
1 Summary Report - Project Overview Annex 1
2 Summary Report - Sales Value & Production Details Annex 1.1
3 Summary Report - Revenue / Sales / Net Profit Annex 1.2
4 Land & Building Annex 2
5 Plant & Machinary Annex 3
6 Preliaminiary Expenditure Annex 4
7 Utilities /Raw Materials Requirenment Annex 5
8 Manpower Requirenment Annex 6
9 Consumble Store Annex 7
10 Repair and Maintanance Annex 8
11 Projected Revenue details Annex 9
12 Project Cost and Source of Finance Annex 10
13 Bank Loan EMI schedule Annex 11
14 Depreciation schedule Annex 12
15 Profitability Estimate Annex 13
16 Projected Balance Sheet Annex 14
17 Cash Flow Statement Annex 15
18 Break Even Analysis Annex 16
19 Pay Back Period Annex 17
20 Internal Rate of Return Annex 18
21 Production Details Annex 19
22 Raw Materials - Consumption & Costing Annex 20
23 Energy - Cosumptions & Costing Annex 21
24 Manpower Details & Costing Annex 22
25 Manufacturing Cost Annex 23
26
Comparative Statement - Capex / Production Matrix /
Profit Annex 24
27 Organisation Chart Annex 25
28 Abbreviations Annex 26

11. Kannan V K
Capex….
300 TPD – Green field
60/40

12. Kannan V K
E3 – Certification
BEE
 Energy Efficient Enterprise (E3) Certification is an initiative to recognize burnt
clay brick manufacturers who adopt energy-efficient manufacturing and
encourage customers to source bricks from such E3 certified manufacturing
units.
 The adoption of the E3 certification is currently
voluntary for the Brick industry. Provided that
Bureau may in its sole discretion, make
E-3 certification mandatory.
 The overall objective of the “Energy Efficient
Enterprise” (E3) certification is to accelerate the
shift in the Brick manufacturing sector towards
energy efficiency through a market-based
approach.

13. Kannan V K
Energy Efficiency

14. Kannan V K
Clay Testing
Roof
Tile
55/15/30

15. Kannan V K
Plant layout
Factory area 3 Acres ( 12,140
Sqm)
Plant layout 0.86 Acres ( 3,500
sqm )

16. Kannan V K
Brick Machines

17. Kannan V K
Plant

18. Kannan V K
Clay Preparation & Extrusion

19. Kannan V K
Dryer car Loading

20. Kannan V K
Coal Crusher / Dryer Car

21. Kannan V K
Continuous Tunnel Dryer (CTD)

22. Kannan V K
Kiln Loading

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RHK – Entry

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RHK – Module

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Coal firing – Crushing &
burners

26. Kannan V K
RHK – Exit ( Fired Bricks)

27. Kannan V K
Kiln – Unloading (Fired Bricks)

28. Kannan V K
Scope / Local supply
 Civil / Electrical / Utilities / services
 Conveyors / stairs / guards / machine supports –
fabrication and supply
 Dryer cars / dryer walls / PUF panels etc.,
 Kiln refractories and bricks
 Control room / wiring / air conditioning
 Local manpower – during project and training for
operations

29. Kannan V K
Approvals
 Local Licenses
 Approvals
 Pollution certificate
 Factory license
 Labor license

30. Kannan V K
HTC
 Solution Partner to the clay brick industry
 Helping brick makers make responsibly
 Assisting brick makers move forward.
 Assist at all levels
 Solutions tailor made

31. Kannan V K
Heavy Clay Technologies
Assist brick makers to
make responsibility
Future
ready
Project assists
Low
CAPEX
LOW
OPEX
Sourcing best
OEM
Working within defined budgets
Move
forward
Tailor made solutions /
options
We are there at all stages to assist and make
responsibly
Solution Partner to the
clay brick industry
Low Emissions

32. Kannan V K
Change = K
The future
belongs to
those who
prepare for it
TODAY !!

33. Kannan V K
Contact us
https://kannanvk123.wixsite
.com/heavyclaytech
website
Email / Whatsapp
kannan.vk123@gmail.com
0091 99801 53669

34. Kannan V K
Thank you for
Your
attention
Kannan V K
Lets Pledge to
Make Responsibly