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Converting Industrial Flyash Waste to Construction Revenue
Location: Rajasthan, India | Capacity: 10,000 bricks/shift | Plant Type: Flyash Brick Machine | Year: 2019
A Rajasthan entrepreneur established a high-output flyash brick unit adjacent to a thermal power station, using free flyash waste as raw material. Maruti delivered a fully hydraulic brick machine producing 10,000 IS 12894-compliant bricks per shift.
The site was located 2 km from a thermal power plant generating surplus flyash that was being landfilled. The opportunity: monetise this waste stream as the primary raw material for flyash bricks. The challenge was achieving IS 12894 Grade FPS B compressive strength (>7.5 MPa) using variable-quality pond ash from the power plant, while keeping the plant footprint compact and the team small (6 operators).
Maruti Hydraulics supplied a fully automatic hydraulic flyash brick machine with a weigh-batching mixing system that could handle pond ash variability by adjusting the lime-gypsum proportion per batch. The press force was sized for 10,000 bricks per 8-hour shift with two-cavity mould tooling. Mix design trials were conducted at the Nashik plant using sample ash from the site before machine delivery. A belt conveyor system automated raw material feeding to eliminate manual handling.
The plant achieved full commercial production within 30 days of commissioning. Bricks tested at 8.2 MPa average compressive strength — exceeding IS 12894 Grade FPS B requirement. Raw material cost is near-zero (flyash collected free from the power plant), producing a high-margin product from what was previously a waste disposal cost.
Tags: Flyash Bricks · Waste Utilisation · Thermal Power · Rajasthan
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