TARA BrickMek-SUPER - Knowledge Partnership Programme
Contents
1. E SAA Create uniform lixing Curing After 24 hrs of curing prepare final soil by y e Adding required quantity of pore opening After the dry mixing cure the soil mix with material like rice husk saw dust etc which addition of water by the following process is recommended e Cutting the soil vertically while ensuring all layers are being cut USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY TB VERTICAL SHAFT BRICK KILN Unload the machine from the truck safely Set up the pipe line for water supply from permanent reservoir or tanks Set up the three phase electric supply to the machine 32Amp 415V 50Hz TPN and cable 4 6mm where electric supply is exists Check and tighten all the nut bolts which might loosen during transportation and unloading Put oil and grease on the moving parts Install valve to control the supply of water Fill the water tank with clean water IET USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Connect the machine s main switch box direction of rotation is indicated on the machine Switch on the electric connection and switch on the 7 5HP electric motor Check the direction of rotation if OK then go to next step but tf not OK then call an electrician and change the electric connection Similarly Switch on the 1HP Pump and check the water circulation If OK otherwise check the connection by the electrician Whereas for TARA BrickMek Super no n2. soil In the normal practice the transportation of the dry green bricks and the soil is done through tractor trolley So during the development of the production yard the path of the movement of the tractor is determined to avoid damage to the surface of the green brick demoulding yard Water and Electricity during the layout of the production yard the water and electrical services are laid in a manner which avoids cross over of the service lines Manpower movement amp management To achieve the productivity of the green bricks the movement of the manpower involved in the production plays a vital role Their movement and management are explained in Production Management Page 26 Safety For the continuous production of the green bricks the Production yard needs to be organized without hazards and encumbrances to ensure safety of workmen e E y gt Ta A Sae i Saa e CN AG Es 8 O 9 Drainage of Waste Water from the Machine To achieve the smooth surface of the demoulding yard the ground needs to be prepared as follows Cut level the Remove grass roots Ready to use ground Spray water Broom the ground Scrape with Circular and Spray sand Metallic Ring INEA USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY X TARA Based on the soil report the specified soil needs to be dumped at the desired area and the process shown below for soil preparation should be followed
3. Diesel engine the Worm Shaft Augur is not rotating PASS Check the tightness of chain If sound shrill is 9 9 loosen then tighten the chain by emerging or not shifting the Idler sprocket Check the tightness of all the Check if the worm fasteners of pulleys sprockets During this process Shaft is rotating gears One person needs to keep need to check the properly i e the finger on the stop button alignment of every driving assembly if any thing goes wrong then rotating parts like is aligned properly motor needs to be switched off gears chain etc immediately The Worm Shaft Check if any sound Switch off the motor amp MCB will rotate freely occurs inside adjust the arm shoes of the and the machine the barrel worm shaft can be operated for production IED user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Freguent breakage of safety bolts Bricks are not shaping properly Moulds are not cleaning properly Check if hard materials like Need to change the soil or to stone are available sieve the soil to remove stones in the soil Check if hard materials like dry soil lumps are available in the soil Check if the moulds are obstructed by the scrapper Check If the moulds are obstructed on the Sliding platform Check the water percentage of the soil in the barrel Check the proper ageing of the soil Check the pressure of the water jet at the cleaning chamber Need to age
4. Size 30 X 20 11 Green Brick Demoulding Yard Green Brick Demoulding Yard 11 Size 30 X 20 Size 30 X 20 Soil Stacking Area Size 15 X10 X2 Soil Stacking Area Size 15 X10 X2 Soil Stacking Area Size 15 X10 X2 USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY EMS VERTICAL SHAFT BRICK KILN Production yard plays a major role in the production of quality green bricks using TARA BrickMek For development of the production yard the essential requirements are as follows 1 Location for the movement of TBMM soil stacking area green brick demoulding yard stacking area Based on the normal practice the above layout is recommended the layout may vary depending on the site and requirements of each entrepreneur 2 Surface of the green brick demoulding yard The surface finish of every brick depends upon the surface of the green brick laying platform To achieve a uniform surface the ground preparation is followed by few processes given in the following page 15 3 Drainage of the waste water from the machine After the end of the every working day the bottom tank needs to be cleaned The drained waste water is channelized to asump to prevent damage to the dry surface of the demoulding yard i pi ru e A y a MA AE 1 kd Y He A A w A i A Uniform Surface of the Green Brick Laying Platform Ground Preparation 5 Transportation of the dry green bricks and the
5. and Opening Functions Single cylinder engine is used to drive the worm shaft assembly the mould pushing arm and the water pump It works only when induction motor is OFF The motor is used to drive the worm shaft assembly the mould pushing arm and the water pump It works only when diesel engine is OFF By lifting both handles at a time the three green bricks are demoulded from the mould box To run the 10HP Engine diesel needs to be filled in the 10L capacity tank assembled with the engine Two outlets for draining out the waste water Stainless steel fabricated moulds fitted with frogs are used for shaping the green bricks After demoulding of bricks the moulds get cleaned while passing through the chamber To push the mould towards the mould filling mouth and after filling slide outside for de moulding For easy demoulding parting sand is sprayed manually on the water cleaned mould USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY EE VERTICAL SHAFT BRICK KILN S No Items Functions 10 Rubber Tyres To enable movement of the machine in the production yard Two safety nuts with bolts are used to avoid excess load on the mould pushing arm Safety nuts Scrapping Tool To scrapethe excess soil from the top ofthe mould The roller assembly slides the filled moulds ready for carrying to the demoulding yard Sliding Platform Sliding Platform Adjustor The bolts atthe four end ofthe sliding platf
6. placed adjustable blades for mixing and pushing the soil mix to the mould MID user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY TARA Soil Feeding Hopper Water Tank Water Sewage Pump Mould Pushing Arm to pushthe moulds for filling and finally to the sliding platform after being scrapped the excess soil i cl Zz i a Fu 57 i o Tse i Switch Box Components of TARA BrickMek Super Parting Sand Stacking Chamber and Opening Mould cleaning chamber for cleaning the moulds after the bricks get de moulded 7 5HP Induction Motor LOHP Diesel Engine Diesel Tank Mould assembly Brick Demoulding Handle e Parting sand box Outlet of parting sand USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY VERTICAL SHAFT BRICK KILN Components of TARA BrickMek Super Drainage Screw 10 Scrapping Tool Safety Bolts 11 Sliding Platform Tow 13 Sliding Platform Adjustor Sliding Platform Releasing 14 Mould Cleaning Chamber Handle 18 Tool Box Empty mould with sprayed parting sand Mould cleaning chamber for cleaning the moulds after the bricks get de moulded Filled and scrapped mould with soil MEID user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Function of Machine Components S No Items 10 HP Diesel Engine 7 5HP 3Phase Induction Motor Brick demoulding handle Diesel Tank Drainage Screw Mould assembly Mould Cleaning Chamber Mould Pushing Arm Parting Sand Stacking Chamber
7. the soil properly minimum 36 hours as instructed during training period Switch off the machine and adjust the springs of the scrapper If the elasticity of the spring is reduced then change the spring Check the quality of every mould If any deformation occurred then rectify it at a local workshop who has the skill and tools for Stainless Steel work also check the Rubber liner on the side guiding system if required change the rubber Check the cleanliness of the rollers Platform Clean by water check the movement and position the platform at its original position Check the linearity of the mould side guiding frame with rubber liner If it is not then adjust it by the loosening the bolts and tighten after setting it right If excess water then stop feeding water and feed dry soil till the mix comes upto the mark To get conditioned soil every soil needs to be aged properly for minimum 36 hrs Open the stopper at the end of the pipe in the cleaning chamber and clean the pipe After cleaning if the water pressure is not upto the mark then open the stop valve at the top of the water tank If then the water pressure is not upto the mark then open the stopper and clean the 4 diameter pipe at the bottom of the top water tank USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY PIM Adjust the bolts at the 4 corners of the Sliding platform to set the gap so that the moulds can move freely but check cla
8. Do not put hands or metallic body inside the worm during running condition Do not put hands or tamper with the scrapping blades during running condition Do not put hands or tools inside the chain and sprocket during running condition Do not put hands or metallic parts inside the Gear assembly during running condition Do not put soil with grass roots unseived stone dust lump of hard soil or stone particle high plastic soil sandy soil and excess water DO NOT RUN THE PUMP DRY USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY ET VERTICAL SHAFT BRICK KILN Trouble Shooting Common Problems Faced Problem Faced Step Observation Suggestive Solutions Remarks Before doing this activity the soil inside the barrel need to be softened by adding water Check if humming sound is coming from the electric motor Switch off the starter and MCB loosen the V belts from the pulleys and then switch on the MCB amp starter Check if the motor diesel engine is not rotating Check the tightness of the V Belt E If loosen then tighten by shifting During this process 3 sees liine the position of motor Then need to check any Call an electrician or engine Check the Kirloskar mechanics and check the Engine Guide for any electrical connection or Engine other trouble After switching on the MCB and Starter or engaging the lever for transmitting motion from
9. TARA BnckMek SUPER USER MANUAL Ky GLOBAL Soft Mud Moulding Technology Knowledge Partnership Programme Expanding Horizons Enriching Te Contact Details Technology and Action for Rural Advancement B 32 TARA Crescent Qutub Institutional Area New Delhi 110016 Phone Number 011 26544100 Email smaity devalt org knagrath devalt org All the content or information present here is the exclusive property of Technology and Action for Rural Advancement TARA The content information contained here is correct at the time of publishing The views expressed in this catalogue do not necessarily reflect the views of any organisation s associated with Technology and Action for Rural Advancement No material from here may be copied modified reproduced republished uploaded transmitted posted or distributed in any form without prior written permission from TARA Unauthorised use of the content information appearing here may violate copyright trademark amp other applicable laws amp could result is criminal or civil penalties Technology and Action for Rural Advancement 2014 This user manual has been developed in response to the interest in Malawi in understanding the process of production of green bricks It aims to describe the methods of production of green bricks through the TARA BrickMek Super The manual also explains in detail the methods of management of manpower trouble shooting and maintenance of the machine Th
10. ain sprockets belt pulley wheel of the stroke arm mould Sliding rollers Clean the residue of clay from the 4 diameter pipe at the top of the machine Check the rubber liner on the mould guiding system a s a mia 4 E a Ea 4 E be ari A oe ye USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY FEE VERTICAL SHAFT BRICK KILN Production Management Production Management Based on the operational seguence in the TARA BrickMek the involvement of manpower is detailed in the chart below Green Brick Demoulding Yard TARA CA Brick Position of the Operating Manpower S No Operation Persons Activity Soil Filling in gt Persons involve in soil preparation and afterward filling Container soil in the pan Soil Carrying for 3 4 Persons carry the pan with soil from the Soil stacking area feeding to TBMM and feed into the hopper of the machine Person needs to pull the cleaned empty mould from the cleaning chamber then spray parting sand and position that before the pushing arm He she needs to synchronies with the timing of the pushing arm Mould Positioner De moulding from 1 Person needs to shift the filled mould that slides on the the Sliding table sliding table to the transfer trolley Persons need to carry the filled moulds on the transfer Mould transferring trolley to the demoulding yard for demoulding the green E and ejection of green 4 5 bricks After demoulding persons need to carry the em
11. and main switch e Donotuse any other external power Diesel Petrol Engine or Tractor for transmission of power Only use the designated motors or Diesel Engine e Donot attempt to disassemble or alter any part of the equipment that is not expressly described in this manual USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY VERTICAL SHAFT BRICK KILN SET USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY of OP a PA AN i USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY FE VERTICAL SHAFT BRICK KILN Action likely to run the machine Mix the dry soil and industrial waste uniformly Age the soil mix for 36hours Water to be added about 12 15 for non plastic soil 15 20 for semi plastic soil and 20 25 for plastic soil Spraying water during every feeding of soil at the hopper to run the machine with constant load Spray parting sand on the mould after washing in the cleaning chamber Uniform spray of parting sand results in better guality bricks Lockall the safety doors during running of machine Replace and tighten both the 3 8 BSW safety bolts in their holes by check nuts Switch off the main switch during cleaning servicing and trouble shooting MITE user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Action likely to damage the machine Do not feed excess soil Excess soil will cause severe breakdown of the machine by damaging the different parts like gears bearings keys moving blades etc
12. eed to check asthe pump is coupled with the 7 5HP Electric Motor e Open the back cover and manually start the engine by rotating handle 1 and then engaging the diesel supply valve 2 e Engage the V Belts by operating the hand lever 3 to drive the Worm Shaft Moulding Pushing system and Water pump e Check for any metallic sound or chatter If YES then find out area from where the metallic sound appears Adjust the parts e Position the Metallic mould before the pushing arm and check the movement on the sliding table If required adjust the height 4 and also the arm movement length 5 e Check the pressure of water jet at the cleaning chamber e Check the movement of machine e Position the machine at the production yard near the soil source e Feed soil gradually with required amount of water at the hopper Do not feed more soil and water at the initial stage e Check the moulding mechanism is working properly initially put mould after second or third e Check the green brick quality if OK then go to the next step but if not OK check the soil water ratio e Position the manpower at their location described in Production Management Page 26 e Start producing brick with an target of 500 700 brick hr e Continue it for 2 3 days till the team is able to Metallic Mould cope up with the mechanism and process e Do not connect the electric motor directly from the main Supply without the MCB starter
13. el the Mixed soil is ready to be formed into bricks 2 EJECTION Mixed soil from the barrel Is pressed into the mould assembly through the eccentric mechanism of the worm shaft Moulding Process 1 Moulds are fed into the machine where they are washed in the cleaning chamber parting sand is sprayed and sanded moulds are fed into the stroke of the mould pushing arm 2 Mould assembly is slid over the sliding platform for filling Demoulding Process 1 Soil filled mould assembly ts lifted manually and carried to the de moulding yard 2 After positioning the mould at the de moulding yard the mould assembly is flipped up side down 3 The operator lifts the mould while pressing the lever mechanism the shaped green bricks are de moulded on to the level ground surface Drying Process 1 The green bricks are laid on the de moulding yard for drying to leather hard condition 2 The bricks are stacked into stacks with a pattern such that air can easily pass through every bricks resulting in uniform drying of the bricks 3 The dried brick are then transferred for firing in the kiln NET user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Installation Layout 45H Transportation of Green Bricks for Firing__ gt 5 Green Brick Stacking Area 1 Green Brick Stacking Area Size 30 X 10 Size 30 X 10 Green Brick Stacking Area Size 30 X 10 Green Brick Demoulding Yard
14. is user manual is expected to serve as a basic tool for the workers and supervisors in a kiln to delineate the essential parameters of operating the TARA BrickMek Super and producing green bricks This manual doesn t claim to be complete or perfect It is in the hands of users to utilise it fully by using it as a reference guide for further improvement The authors would appreciate if you could share your ideas and work experiences to further improve this user manual Society for Technology and Action for Rural Advancement India During the course of developing this manual every effort was made to include the existing knowledge base along with interactions between personnel associated with the technology We would like to acknowledge the support of various organizations TARA Machines and Tech Services Pvt Ltd India Centre for Community Organization and Development CCODE Lilongwe Malawi Eco bricks Y Limited Lilongwe Malawi and IPE Global New Delhi who have whole heartedly contributed towards developing the same Our sincere thanks TA to various individuals whose views have been accessed personally 4 through one to one interactions the internet and printed documents The research efforts captured in this manual would not have been possible without the institutional support given to the project organisations by Deutsche Gesellschalt fur Internationale Zusammenarbeit GIZ GmbH and the Knowledge Partnership Program
15. me KPP of the Department of International Development DFID India Managed and Supported by IPE Global the KPP aims to step up collaboration around ideas knowledge evidence accountability technology and innovation impacting the delivery of global public goods and services and leverage Indian experiences to reduce poverty in LDCs Society for Technology amp Action for Rural Advancement India Contents Sore MuUGIMOUlaIGIFeChNOlOGV acc A 1 Macanal eS aA a a E A a aaa a 6 Function of Machine Components csssseeceeeeccsessssseeeesessesssseeeeeees 9 Machine ame O 11 AAA EN A o 12 kaksus kei djela ea t Teri tet 13 Settingiupthe Macia A testi ai 16 PRO RROGCSSer Ea 18 MODEST 22 Ma co am a a n ea 24 Produccion NANO tt 900 26 VERTICAL SHAFT BRICK KILN Machine Features TARA BrickMek is a green clay brick moulding machine powered by either 7 5HP 3 Phase induction electric motor or 10HP diesel engine A sewage pump is fitted for watering of soil amp also cleaning the stainless Steel fabricated moulds The four wheeled machine can be towed at the moulding site The TARA BrickMek has been designed to mix easily soil industrial waste flyash coal dust etc and water into a homogeneous mix produce to produce consistent quality of green bricks with frogs The machine has a rated capacity of 1440 or 1620 bricks per hour Worm blade Worm shaft Worm blade A E E la 3 Worm shaft with angular
16. orm For removing mould during non working period power failure the sliding platform can be lowered by operatingthe releasing handle Sliding Platform Releasing handle Soil Feeding Hopper To feed the soil mix into the barrel of the machine Electric switches are enclosed in the box Tool Box The box for keeping the important tools like spanner screw driver hammer nut bolts oil can etc To directthe movement of the TARA BrickMek Machine at site Pumps the water from the water tank to distribution pipe Water Sewage Pump cleaning chamber and barrel To store water that circulates to the distribution pipe and Water Tank the cleaning chamber through pump Weiss To mix the soil with the industrial waste and water and push it to the outlet for filling the mould IET user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Machine Parameters Machine Parameter The TARA BrickMek is a versatile machine designed to produce consistent superior quality soft clay bricks with frogs The TARA BrickMek is a game changer for overcoming drudgery of workers engaged in traditional manual operations involving mixing pugging and moulding of clay The TARA BrickMek is easy to operate with one skilled machine operator assisted by local manpower men amp women The TARA BrickMek increases the Skills productivity and earning capacity of women engaged in brick making Advantage e Robust machine for soft moulding of bricks b
17. pty bricks mould to the cleaning chamber and manually keep them on the floor Mould in Cleaning 1 Person needs to put the empty mould in the cleaning chamber chamber for washing To supervise the complete production system a SUPERVISOR needs to be appointed to monitor all the activities that can match the timing of the machine operation He also monitors the soil and water in the barrel in the machine He needs to stand on the top of the machine to monitor all the operational activities IIED user MANUAL FOR SOFT MUD MOULDING TECHNOLOGY X TARA Registered Office B 32 TARA Crescent Qutab Institutional Area New Delhi 110 016 India KNOWLEDGE PARTNERSHIP PROGRAMME K VI JA Knowledge Partnership Programme South South Technology Transfer Low Carbon Building Technologies User Manual Technology and Action For Rural Advancement New Delhi Submitted to AY LI AN ukaid from the British people Department for International Development DFID 33 GLOBAK Expanding Horizons Enriching Lives IPE Global P Ltd November 2014
18. uilt up with a simple mechanism that ensures Specifications Specifications Mould Sizes TARA BrickMek Super homogeneous mixing of clay with different industrial waste additivies like coal flyash Sponge iron waste High product quality uniform size and shape with better surface finish amp sharp edges Customized sizes of bricks with desired frog Decentralized production allows to operate at any moulding location with or without availability of 3phase electric power Ease of Operation the machine is easily operated by local manpower simple changeover from diesel engine driven to motor driven mode is possible TARA BrickMek Stainless Steel 55 304 moulds are manufactured as pe customer s requirement Mould quantity Powered by Weight Production capacity Manpower Mould Transfer Trolley Bricks per stroke 3phase 8 5HP 7 5 1 with 10 HP Diesel engine induction motor USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY ET VERTICAL SHAFT BRICK KILN Machine Functions Narrative of the machine operation Soil Feeding Soil with industrial waste is fed through the soil feeding hopper to the barrel of the machine Soil Mixing Soil mixing is done by addition of controlled quantity of water in the barrel 1 HOMOGENISATION In the barrel the angular blades assembly of the worm shaft allows easy and uniform mixing of the soil with water while pushing it towards the mould Within the barr
19. y is not leaking out over the moulds Check the mould place rightly and sliding along the guiding liner The Machine can be operated for Production Assume soils are being tested at Lab The Machine can be operated for Production Assume every day water in the bottom tank is drained out and thus clean the bottom and top water tanks properly The header needs to be cleaned on every week The Machine can be operated for Production VERTICAL SHAFT BRICK KILN Maintenance Maintenance Schedule Daily Clean and drain out the dirty water by unscrew the outlet of the water tank at the bottom of the machine as shown in 1 2 amp 3 Chronologically Clean the soil from the different working zones like soil scrapper assembly moulds etc The mould Sliding track needs to clean by water and with a piece of cloth Refer to 4 5 6 Method of Cleaning the Machine Check the tightness of all nuts and bolts WED USER MANUAL FOR SOFT MUD MOULDING TECHNOLOGY Oiling on the bearing Greasing on the gears and chain sprocket Clean the barrel and every joints of worm assembly Clean the residue of clay from the water pipes Check the alignment of the gears chain sprocket bearings keys etc Check the seal and joints of the water pipeline Check the moulds assembly Checkthe air pressure ofthe rubber tyres Tighten the flange ofthe seal to preventthe leakage of soil Check the gear tooth ch
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