Jun 22, 2018
Hello Zidisha community.
I want to share my experience in running a brick business, in this case is the process of making bricks. the purpose I write it is so that we can share knowledge and experience, especially those who have similar business so that can find the right formula to get the best bricks, and hopefully can be an idea of effort for other members.
brick making process that I do is as follows:
Translated by Google
Laurie, Julie, Gideon Kiprotich and Joost like this.
Jun 23, 2018
1. prepare raw materials ie: soil, sand and ash with a ratio of 2: 1: 1
This composition must be precise because if it does not match it will produce ugly bricks (easily broken etc.).
the above raw materials may differ in other areas depending on the type of soil used. in other areas I have seen the process of making bricks that only use the soil and sand because in that area there hsanya calcareous soil can still produce a strong brick despite not adding ash in the production process, but the resulting impact of bricks is less attractive because it is not perfect red color after burning.
Laurie, Gideon Kiprotich, Joost and Yna Lua like this.
2. the three raw materials are mixed with the hoe manually in order to produce perfectly mixed dough with a little water added. this process takes up to half a work day and is run by 2 people (depending on the amount of raw material).
after which the dough is inserted into the grinding machine and cutter to produce raw bricks are still wet and stacked near the cutting machine, the cutting process is done by 3 to 4 people (1 person duty to put the dough into the cutter, 1 person in charge of cutting the dough, and 2 people are in charge of picking up raw bricks from the machine), this process also takes up to half a working day.
Dorcas Nene, Laurie, Charles Manyange, Gideon Kiprotich and Joost like this.
Nov 19, 2018
You are doing a wonderful job brother.
I need this Machine.
3. a pile of raw rocks that are still wet is then transported out of the room and stacked in rows to dry naturally by the sun to dry completely. this drying process takes 3 days when the weather is nice and can be longer when the rainy season.
Laurie, Joost and Yna Lua like this.
4. dried bricks are then transported back into the room to be stacked in 1 area so that it is ready to be burned.
Laurie, Gideon Kiprotich and Joost like this.
5. bricks that have been prepared ready to burn until cooked, this burning process takes 24 hours non stop and done by 2 people in turn. this process is very important because the fire condition must be maintained properly, if the fire is too small it will produce an immature brick (either partially or black) and if the fire is too large will result in a cracked brick and the size is smaller.
6. after the combustion process is completed then the pile is laid down between 1-2 days for the temperature becomes cold and ready dismantled and distributed to the consumer.
a good mixing process of raw materials, drying and combustion will produce a perfect brick with the characteristics: reddish, non-breakable, non-shrinking, no cracks like the picture example below:
Laurie, Willy Ambani, Gideon Kiprotich and Joost like this.
I am asking for ideas and suggestions to produce better bricks (more efficient in terms of time, cost and effort), for other members who have similar business may be able to share their experience and knowledge as well.
I would also like to thank the lenders who have lent me and to Zidisha who have given me the opportunity to be part of the Zidisha community for a better future.
Jun 23, 2018
Thanks a LOT for sharing details of brick making process! Very interesting. And as for our earlier discussion about weather resistant plastic for #3, now I get it - you are not just storing them. Every day you want to expose them to daylight/sun so they dry out. But at the same time, during night and if there is any rain during day, you want to quickly cover them up.
Here is another thought. I see that you have one brick thick piles, 7 bricks high. The distance between rows is about 6 inches in #3 pictures but almost 1.5 feet in first #4 picture. Considering that you want to dry out the bricks, few things come to mind;
1. If you are placing them with shorter distance between rows as in #3 pictures, can you increase it? Or is the first picture in #4 more representative? The greater distance will assist air movement and help drying process.
2. The piles are 7 brick high. This means that except for bricks in outermost layer, all other bricks have only their side edges exposed to air. Can you leave little distance between brick blocks? What I mean is that you currently have 7 bricks high wall that is, say, 100 bricks long. So it is 7X100 brick wall. Instead have 7X2 brick wall, then leave 6 inch space and then next 7X2 brick wall, again leave 6 inches and third 7X2 brick wall and so on. Of course this will take more space and more effort. You can best judge if it is feasible. But this increases exposed surface area of each brick so that it should dry faster. You can probably should try this on 60-80 bricks or so - make single wall as well as 'separated wall' (on same day, using bricks from same batch so that only drying conditions vary) and see if it makes any difference in drying time.
3. Actually, the very last picture would be ideal - remove top brick and see how the four bricks are arranged. You can probably assemble four more on top. But it will be very labor intensive. And also, I dont know how strong raw bricks are. If you cannot have at least 4 brick high structure using this pattern, it will end up taking too much space as well. But that really exposes 80% of areas of brick and should certainly dry faster.
By the way, once again, I am just making suggestions based on what I see in pictures. They might be worthless!
Gideon Kiprotich and Wahyu Setiawan like this.
Jun 24, 2018
First of all I would like to thank you for your loan support, I would also like to thank you for your suggestions.
You are right that every day I have to open and close this plastic cover because this drying process is one of the most important parts in the brick making process, I can not continue to cover the bricks every day because it will greatly affect the drying process of this brick.
the longer of drying process will affect the combustion process and ultimately affect the delivery schedule of bricks to the consumers, if I am too forced to burn bricks that have not dried perfect it will produce bricks that easily broken when distributed to consumers and will make consumers disappointed .
I want to add a bit of picture information above, picture # 3 is a pile of wet bricks that just came out of cutting machine, this cutting process is done by 3 to 4 people with the task:
1 person puts mixed dough (soil, sand and ash) into this brick / cutter machine.
1 person is in charge of running the wet cobblestone cutter that comes out of the brick / cutter tool, 1 time the cutting tool is executed will produce 3 pcs of wet bricks
1 or 2 persons are in charge of picking up the wet bricks that have been cut to stack them in the nearest area (picture # 3)
The process of stacking is done randomly without giving a gap between the bricks or paying attention to the distance between rows because the cutting process is done quickly, the pile of wet bricks is then taken out of the room (open area) and stacked back per row (figure # 4) , this is where the stacking process is done neatly per line. the function of the distance between the rows here is that the raw brick transporting device can enter easily so that the required distance between lines is sufficient, in addition to it so easy when transporting back the bricks that have been dried to be brought back into the room for the combustion process, another reason for the bricks are quick to dry because the sun can shine down to the lowest layer of the pile of bricks.
One more thing I need to add, there is 1 more routine work to do after wet bricks are transported out of the room that is separating or rearranging the sequence so that there is a distance between one brick with another brick so that the drying process will be faster because the sun and wind reach all sides of the brick (as shown below).
About the height of the pile of bricks it seems that it is also random (not all rows have the same pile) because we transport the bricks that have dried gradually from the top of the pile (drier faster because it is directly exposed to the sun), the next day the next pile of transport so each row do not have the same height because dry bricks are not always the same every line. our standard for each row has a height of 5 to 7 piles of bricks, if it is too high then the pile will collapse because the bricks are still wet so that the bottom layer will not strongly support the pile above it.
Actually, the very last picture would be ideal - remove top brick and see how the four bricks are arranged. --- >> the pile of bricks being dried does have that space but I can not possibly craft the crude bricks crossed like the picture above because the wet brick conditions will not be strong to support the pile that is too high, otherwise it will take some time longer, I still pile up the bricks in parallel, just give space between bricks only.
by the way, there is no science that is "worthless" when we want to share it with others, I really appreciate your suggestions.
once again thank you for your support!
Description of pictures below:
Picture 1 is a pile of wet bricks that just came out of the cutting machine, stacked at random, no spacing between bricks and no spacing between rows / piles of bricks.
Picture 2 is a pile of wet bricks outside the room that has been reorganized by providing space between bricks and between lines / piles of bricks so that the drying process will be more effective.
Picture 3 is brick-bearing devices, inter-row spaces / piles of bricks are required to make it easy to get in and out to transport wet or dry bricks.
Noord Brabant, Netherlands
Jun 23, 2018
Thank you for sharing. It’s a very interesting and well documented process.
I wish I could give you some tips but I can’t. (I am a software developer for a living.)
Wahyu Setiawan likes this.
I understand that everyone of course has their own expertise, the support and the loans you give have been very helpful to my efforts.
Thank you very much!
Joost likes this.
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