Eco-Friendly Brick Making Unit (Fly Ash Bricks) basic information of project report

Project Report: Eco-Friendly Fly Ash Brick Manufacturing Unit
1. Introduction
Fly ash bricks are an eco-friendly alternative to traditional clay bricks. They are made from the byproducts of thermal power plants—mainly fly ash, along with sand, cement, and sometimes lime or gypsum. This project contributes to sustainable development by utilizing waste materials and reducing dependence on topsoil.

2. Objectives
To produce high-quality, eco-friendly bricks.

To reduce environmental degradation by utilizing industrial waste.

To create employment and entrepreneurial opportunities.

3. Product Description
Product: Fly Ash Bricks

Size: Standard – 230mm x 110mm x 75mm (custom sizes possible)

Characteristics: Lightweight, high strength, thermal insulation, sound insulation, low water absorption.

4. Market Potential
Rapid urbanization increases demand for affordable building materials.

Government incentives for eco-friendly construction.

Preferred in green buildings and government projects (e.g., PMAY).

5. Raw Materials
Fly Ash: 60% (from nearby thermal power plants)

Sand/Stone Dust: 30%

Cement: 10%

Water: As required

6. Manufacturing Process
Mixing: Fly ash, sand, and cement mixed in proper ratio.

Moulding: Using hydraulic/manual press machines to shape bricks.

Curing: Bricks kept under moist conditions for 7–14 days.

Drying & Packing: After curing, bricks are dried and packed.

7. Machinery and Equipment
Pan Mixer (250–500 kg capacity)

Brick Press Machine (Manual/Semi-Automatic/Hydraulic)

Conveyor Belt

Pallets

Curing Trolley

Estimated Cost of Machinery: ₹5–15 Lakhs (Depending on capacity and automation level)

8. Project Cost Estimate (Example for Small Unit)
Item Amount (₹)
Land (Rent/Lease) 1,00,000
Building/Shed 3,00,000
Machinery & Tools 10,00,000
Raw Materials 1,00,000
Working Capital (3 months) 2,00,000
Total ₹17,00,000

9. Financials (Sample Projections)
Production Capacity: 10,000 bricks/day

Sales Price: ₹5–₹6 per brick

Monthly Revenue: ₹12–₹15 Lakhs

Monthly Expenses: ₹8–₹10 Lakhs

Net Profit: ₹3–₹5 Lakhs/month (after breakeven)

10. Licenses and Approvals
Udyam Registration (MSME)

Factory License

Pollution Control Board NOC

GST Registration

BIS Certification (IS 12894:2002 for fly ash bricks)

11. SWOT Analysis
Strengths:

Low production cost

Government support

Environment-friendly

Weaknesses:

Initial awareness and acceptance

Dependence on power plant waste

Opportunities:

Expansion into prefab construction

Export potential

Threats:

Competition from traditional bricks

Inconsistent fly ash supply

12. Conclusion
The Fly Ash Brick Manufacturing Unit is a profitable and sustainable business opportunity. With the support of government schemes and growing demand for green construction materials, it offers long-term viability.