United Nations Development  Programme Ministry of Environment, Forest and Climate Change
TERI Ministry of Environment and Forests
Energy Efficiency Improvements in the Indian Brick Industry
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Case Studies

Kusum Brick Field

Kusum Brick FieldKusum Brick Field is located in Hapur, Distt. Ghaziabad (UP) and is owned by Mr Sanjay Dadoo, a 3rd generation brick entrepreneur. His brick kiln unit has a production capacity of about 50,000 bricks per day, with the brick production season usually extending from December to July each year.

Shift from moving chimney to fixed chimney design
Till 1997, Mr Dadoo had a moving chimney brick kiln. With environmental regulations being enforced on the brick industry by the Ministry of Environment and Forests (MoEF), he switched over to a fixed chimney kiln equipped with gravity settling chamber (pollution control system), based on the design provided by the Central Building Research Institute (CBRI), Roorkee. The switchover helped in better kiln operation, which eventually yielded fuel savings of about 10%. This motivated Mr Dadoo to explore other technology options that he could adopt to improve the market for his products.

Adoption of semi-mechanization for production of perforated bricks and hollow blocks
Kusum Brick Field was producing only solid bricks. Mr Dadoo visited a number of places like Malur (Karnataka), Baliapatam (Kerala), Morvi (Gujarat) and Vietnam to assess the technology options available in the Indian market and abroad. He acquired semi-mechanized brick moulding machinery from Gujarat, which he himself modified to suit the local conditions. From 2005, he began to produce perforated bricks in his unit (along with traditional bricks). Slowly and steadily, he increased the share in production of perforated bricks (Table 1).

Table 1 Production of perforated bricks of Kusum Bricks Field

Year Annual brick production
2005-06 8 lakh
2006-07 12 lakh
2007-08 15 lakh
2008-09 20 lakh

Some of the challenges faced by Mr Dadoo while adopting semi-mechanization include:

  • No previous experience in extruder operation and handling of perforated bricks
  • No trained operator/ labour
  • Controlled drying is required for drying of extruded products, which otherwise will lead to cracks, wastage and production losses.

Mr Dadoo has successfully solved the issues faced in technology adoption. Now, he has plans to diversify his production to include other products such as hollow blocks.