# Flyash Brick Plant Near Thermal Power Station — Case Study | Maruti Hydraulics

> A Rajasthan entrepreneur converted thermal power plant flyash waste into a profitable brick manufacturing business — achieving 8.2 MPa IS 12894 grade bricks at near-zero raw material cost.

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# 10,000 Bricks/Shift Plant Adjacent to Thermal Power Station

_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.

## Key Metrics

* **Output:** 10,000 bricks/shift
* **Strength:** 8.2 MPa
* **Time to Produce:** 30 Days
* **Raw Material Cost:** Near Zero

## The Challenge

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).

## The Maruti Solution

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.

### Equipment Supplied

* [Flyash Brick Making Machine](/products/flyash-brick-machine)

## The Result

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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