GREEN ENERGY SOLUTION
and help
reduce GHG emission
A concern of
Total Agro-Industrial Solution
Established in 2002 with a goal to provide State of the Art technology and full service solution for industrial development
GREEN ENERGY SOLUTION
Dedicated for Renewable Energy and Modern Energy Saving Bricks & Tiles Technology
GREEN ENERGY SOLUTION
Project Plan & Designing Turn key Project Engineering Support Spare & After Sales Service
Green
Energy
Solution
3 Steps of Bricks Production
1. Raw Bricks Making
2. Drying 3. Firing
5 Firing Technologies
Trench Kiln Zigzag Kiln
Hoffman Kiln Hybrid
Hoffman Kiln
Tunnel Kiln
Trench Kiln Production Line
Causing pollution with GHG
Zigzag Kiln Production Line
Causing pollution with GHG
Hoffman Kiln Production Line
Hybrid Hoffman Kiln (HHK)
Hybrid Hoffman Kiln (HHK)
Drying kiln of HHK
Same Hoffman Kiln without chimney
Bricks production line can be manual
or automatic
Manual/Auto Raw Bricks Production
Manual Drying & Firing
Trench Kiln System
Tunnel Kiln System
Hybrid Hoffman Kiln System
Hoffman Kiln System
Zigzag Kiln System Manual/Auto Raw Bricks Production
Manual/Auto Raw Bricks Production
Manual/Auto Raw Bricks Production
Only Automatic Bricks Production
Manual Drying & Firing
Manual Drying & Firing
Auto-dry & manual Firing
PLC Controlled full automatic
Auto-Production Line:
Can be used for any technology
Automatic Transfer to Drying Car: Mainly used in Tunnel Kiln
Same Kiln Car to Drying Kiln & Tunnel Kiln
Energy Saving Drying Kiln Energy Saving Tunnel Kiln
Modern Energy Saving Tunnel Kiln
TRENCH ZIGZAG HOFFMAN HHK TUNNEL
Production BATCH TYPE BATCH TYPE BATCH TYPE BATCH TYPE CONTINOUS
Temperature 600-700° C 700-800° C 800-900° C 800-900° C 1000-1050° C
Caloric Value per kg Coal
5600-6000 5600-6000 5600-6000 5600-6000 5600-6000
Kcal/kg 415-455Kcal 330-375Kcal 250-290Kcal 250-290Kcal 210-250Kcal
Coal Required for 100,000 b
20-22 ton 16-18 ton 12-14 ton 12-14 ton 10-12 ton
Heat & CO2 Exhaust
WITH CHIMNEY
WITH CHIMNEY WITH CHIMNEY NO CHIMNEY NO CHIMNEY
Day’s Required 25-28 DAYS 22-25 DAYS 3-4 DAYS 3-4DAYS 24 HOURS
Qualifying Rate 50-55% 55-60% 65-70% 75-80% 97%
Capacity Limited Limited Limited Limited Unlimited
Variation in 5 Technologies
Notes on Coal Consumption
• Loss of temperature because too many doors
• Qualification rate in 800~900°C temperature is lower
• If increased same temperature of Tunnel Kiln the requirement is 380~420 Kcal/kg
• One door each side ensure maximize use of heat
• Qualification rate in 1000~1050°C temperature is more
• If decreased same temperature of HHK the requirement is 180~190 Kcal/kg
Hybrid Hoffman Kiln (HHK) Energy Saving
Tunnel Kiln
Tunnel Kiln
27 persons
Hybrid Hoffman Kiln
76 persons
36 incl. Raw Bricks
setting & transfer
to Drying Car
15 incl. Raw Bricks
setting & transfer
to Kiln Car
Worker requirement : 100,000 pieces/day
10 persons incl.
transfer to Kiln
Production
Drying
Setting for firing Kiln
30 persons incl.
transfer to Kiln
30 persons incl.
transfer to Kiln Ready bricks
out
12 persons for all
section. Same
Kiln car for drying
& firing kiln
Kiln car
enter Air
flow
Kiln car exit
Pre-heating
area Firing area Cooling
area
Smoke exhaust
Air supply Coal supply
Residual thermal
exhaust
Cooling
Heated air
Energy Saving Tunnel Kiln
Single Channel Tunnel
Double Channel Tunnel
Multi Channel Tunnel
Energy Saving Tunnel Kiln
Financial Investment
100,000 bricks/day
Basic parameter of the project:
Suitable for production of Solid & Holo Bricks
Raw materials blending/dosing system:
Automatic
Batch size : 4500 bricks per car
Car exit : 57 minutes/car
Firing temperature : 1000-1050°C
Kcal requirement per kg of Clay : 210-260 (based on firing temperature)
Total connecting Load : 550 KW for Machinery
and 124 KW for Kiln
Actual Power consumption :440 KW for Machinery
& 99.2 KW for Kiln
Investment Ratio: 60:40
Land and Building 100,000 bricks/day
Area Unit Cost/unit Total Amount BDT
Land 400 Decimal 30000 12,000,000.00
Load-unload area 137740 sft - -
Warehouse for Raw Materials 10,000 sft 400 4,000,000.00
Machinery workshop & KILN 38360 sft 400 15,344,000.00
Generator Room 200 sft 400 80,000.00
Sub-station Room 200 sft 400 80,000.00
Office & Laboratory 1500 sft 800 1,200,000.00
Sub Total: 50260 sft 32,704,000.00
Imported Machinery & Service 100,000 bricks/day
Equipment: Price/USD Quantity Unit Price/BDT Total Amount BDT
Forming Machinery 302658.06 1 Set 25.120,618.98 25,120,618.98
Automatic Setting
System 138709.67 1 11,512,902.61 11,512,902.61
KILN 1099032.25 1 Package 91219676.75 91,219,676.75
Technical Service 80,645.16 - 6,693,548.28 6,693,548.28
Sea freight 40,000 3,320,000 3,320,000.00
Sub Total: 1,661,045.14
137,866,746.62
Duty/Tax/Clearing cost
/internal transport 6,558,659.92
Installation cost
(Local cost like worker, masonry, electrical, mechanical, etc.) 6,893,337.33
Sub Total: Including installation cost 151,318,743.87
Auxiliaries: Local Items 100,000 bricks/day
Quantity Unit Price/BDT Total Amount BDT
Excavator 1 Set 4,000,000 4,000,000.00
Diesel Generator 750 KVA 1 Unit 6,500,000 6,500,000.00
Diesel Generator 200 KVA 1 Unit 2,500,000 2,500,000.00
Sub-Station, LT, HT, PFI, CTPT 1 Set 3,500,000 3,500,000.00
Power cables 1 Unit 3,000,000 3,000,000.00
Tractor + Trailer 1 Unit 1,800,000 1,800,000.00
Sub Total: 21,300,000.00
Local Supply for Kiln 100,000 bricks/day
Quantity Unit Price/BDT Total Amount BDT
Red Bricks 700,000 Pieces 7 4,900,000.00
Stones 300 MT 1,500 450,000.00
Sand 300 MT 1,200 360,000.00
Lime stone 60 MT 4,500 270,000.00
Cement 400 MT 8,000 3,200,000.00
Sub Total: 9,180,000.00
Working capital requirement 100,000 bricks/day
Quantity Unit Amount/BDT Total Amount BDT
Clay for 30 days: 9000 MT 200 1,800,000.00
Coal for 30 days 300 MT 10000 3,00,000.00
Diesel for 2 generator
(40% load moderate) 15300 Litre 60 918,000.00
Electricity bill based on 60% uses
dependable 49568 Unit 8 396,544.00
Salary & Wages As listed 400,000.00
Miscellaneous LS 500,000.00
Sub Total: 7,014,544.00
Investment 100,000 Bricks / day
Total Project Cost: Amount in BDT
Fixed Cost 207,944,083.95
Working Capital 7,014,544.00
Total Amount: 214,958,627.95
Total Fixed Cost: Amount in BDT
Land & Civil construction 32,704,000.00
Imported machinery & installation 137,866,746.62
Duty / TAX/ Clearing Cost/ Internal
Transportation 6,558,659.92
Installation Cost 6,893,337.33
Auxiliary 21,300,000.00
Local items for kiln construction 9,180,000.00
Total Amount: 207,944,083.95
Cost of Production 100,000 Bricks / day
Items QTY Unit Price Total Amount
Clay 300 MT 200 60,000.00
Coal 10 MT 10000 100,000.00
Salary & Expenses As listed 18711 18,711.11
Utilities As listed 43,818 43,818.13
Finance cost 39189 39,188.82
Sub Total: 261,718.06
COST PER BRICK: 2.62
Factory overhead 100,000 Bricks / day
Salary & wages: Number Amount/M Total/M Total /Year BDT
Factory Manager 1 15000 15000 195,000.00
Plant Engineer 1 15000 15000 195,000.00
Accounts Officer 1 12000 12000 156,000.00
Store Officer 1 8000 8000 104,000.00
Operator 9 6000 54,000 702,000.00
Foreman 1 10000 10000 130,000.00
Technician 2 10,000 20,000 260,000.00
Skilled Worker 16 5,000 80,000 1,040,000.00
Daily Worker 10 3,500 35,000 455,000.00
Security Guard 3 4000 12,000 156,000.00
Cook/Peon 2 3,500 7,000 91,000.00
Excavator Driver 1 15,000 15,000 195,000.00
Tractor Driver 1 6,000 6,000 78,000.00
Sub Total: 49 289,000 3,757,000.00
Head Office Remuneration & Salaries 100,000 Bricks / day
Remunerations &
Salaries Number Amount/Month Total/Month Total /Year BDT
Directors
Remunerations 0 75000 0 -
General Manager 1 30000 30000 390,000.00
Manager
Sales/Marketing 1 20,000 20,000 260,000.00
Accounts Officer 1 12,000 12,000 156,000.00
Purchase Officer 1 12,000 12,000 156,000.00
Sales Officer 2 8000 16,000 208,000.00
Logistic Officer 1 7000 7,000 91,000.00
Peon/Tea Boy 2 4000 8000 104,000.00
Security 2 3000 6000 78,000.00
Sub Total: 111,000
1,443,000.00
Head Office Expenses 100,000 Bricks / day
Fixed Variable Total/Month Total /Year BDT
Head Office Rent 25,000 25,000 300,000.00
Utilities 10000 10000 120,000.00
Stationeries 2000 2000 24,000.00
Entertainment 5000 5,000 60,000.00
Conveyance &
Travelling
Allowances 50000 50,000 600,000.00
Telecommunication 15000 15,000 180,000.00
Couriers 1000 1,000 12,000.00
Miscellaneous 20000 20,000 240,000.00
Sub Total: 25,000 103000 128,000 1,536,000.00
Loss & Profit 100,000 Bricks / day
Quantity Cost/Unit Total Amount BDT
Sales of Bricks ( 97% ) 29,100,000 7.00 203,700,000.00
Cost of Production
( 100%) 30,000,000 2.62 78,515,418.37
Profit before Tax 125,184,581.63
Pay off period 1.6611
50,000 Bricks per Day
Production Analysis
Financial Investment
50,000 bricks/day
Basic parameter of the project:
Suitable for production of Solid & Holo Bricks
Raw materials blending/dosing system: Automatic
Batch size : 4500 bricks per car
Car exit : 57 minutes/car
Firing temperature : 800-900°C
Kcal requirement per kg of Clay : 210-260 (based on firing temperature)
Land and Building 50,000 Bricks / day
Area Unit Cost/unit Total Amount BDT
Land 300 Decimal 30000 9,000,000.00
Load-unload space 91680 sft 0 -
Warehouse for Raw Materials 10000 sft 400 4,000,000.00
Machinery workshop & KILN 27400 Sft 400 10,960,000.00
Generator Room 200 sft 400 80,000.00
Sub-station Room 200 sft 400 80,000.00
Office & Laboratory
1500 sft 800 1,200,000.00
sft
Sub Total: 39300 25,320,000.00
Imported Machinery & Service: 50,000 Bricks / day
Equipment: Price/USD Quantity Unit Price/BDT Total Amount BDT
Forming Machinery 278,464.51
1
Set
23,112,554.33 23,112,554.33
Automatic Setting
System 138709.00 1
11,512,847.00 11,512,847.00
KILN 751,612.90 1 Package
62,383,870.70 62,383,870.70
Sea freight 32000
2,656,000.00 2,656,000.00
Technical Service 70645.00
5863535.00
5,863,535.00
Sub Total: 1,271,431.41
105,528,807.03
Duty/Tax/Clearing cost
4,983,263.60
Installation cost (Local cost like worker, masonry, electrical,
mechanical, etc.) 5276440.35
Sub Total: Including installation cost 115,788,510.98
Auxiliaries: Local Items 50,000 Bricks / day
Quantity Unit Price/BDT Total Amount BDT
Excavator
1
Set
4,000,000
4,000,000.00
Diesel Generator 600 KVA
1
Unit
5,500,000
5,500,000.00
Diesel Generator 200 KVA
1
Unit
2,500,000
2,500,000
Sub-Station, LT, HT, PFI
1
Set
3,000,000
3,000,000.00
Power cables
1
Unit
3,000,000
3,000,000.00
Tractor & Trailers
1
Set
1,800,000.00
1,800,000.00
Sub Total: 19,800,000.00
Construction items need to buy locally 50,000 Bricks / day
Quantity Unit Price/BDT Total Amount BDT
Red Bricks 420000 Pieces 7 2,940,000.00
Stones 132 MT 1,500 198,000.00
Sand 180 MT 1,200 216,000.00
Lime stone 180 MT 4,500 810,000.00
Cement 240 MT 8,000 1,920,000.00
Sub Total: 6,084,000.00
Working capital requirement 50,000 Bricks / day
Quantity Unit Amount/BDT Total Amount BDT
Clay for 30 days: 4050 MT 200 810,000.00
Coal for 30 days 150 MT 10000 1,500,000.00
Diesel fpr generator (40% load) 13500 Litre 60 810,000.00
Electricity bill based on 60%
uses 43008 Unit 8 344,064.00
Salary & Wages As listed 400,000.00
Miscellaneous LS 500,000.00
Sub Total: 4,364,064.00
Investment 50,000 Bricks / day
Total Project Cost: Amount in BDT
Fixed Cost 162,009,247.38
Working Capital 4,364,064.00
Total Amount: 166,373,311.38
Total Fixed Cost: Amount in BDT
Land & civil construction 25,320,000.00
Imported machinery & installation 115,788,510.98
Local machinery 19,800,000.00
Local items for kiln construction 6,084,000.00
Total Amount: 162,009,247.38
Cost of Production 50,000 Bricks / day
QTY Unit Price Total Amount
Clay 150 200 30,000.00
Coal 5 10000 50,000.00
Salary & Expenses As listed 18711 18,711.11
Utilities As listed 38469 38,468.80
Finance cost 30602 30,601,85
Sub Total: 167,781.76
COST PER BRICK: 3.36
Loss & Profit 50,000 Bricks / day
Quantity Cost/Unit Total Amount BDT
Sales of Bricks( 97%) 14550000 7.00 101,850,000.00
Cost of Production
( 100%) 15,000,000 3.36 50,334,528.18
Profit before Tax 51,515,471.82
Pay off period 3.1449
Factory overhead 50,000 Bricks / day
Salary & wages: Number Amount/M Total/M Total /Year BDT
Factory Manager 1 15000 15000 195,000.00
Plant Engineer 1 15000 15000 195,000.00
Accounts Officer 1 12000 12000 156,000.00
Store Officer 1 8000 8000 104,000.00
Operator 9 6000 54000 702,000.00
Technician 2 10000 20000 260,000.00
Foreman 1 10000 10000 130,000.00
Skilled Worker 16 5000 80000 1,040,000.00
Daily Worker 10 3500 35000 455,000.00
Security Guard 3 4000 12000 156,000.00
Cook/Peon 2 3500 7000 91,000.00
Excavator Driver 01 15000 15000 195,000.00
Tractor Driver 1 6000 6000 78,000.00
Sub Total: 49 289,000 3,757,000.00
Head Office Remuneration & Salaries 50,000 Bricks / day
Remunerations &
Salaries Number Amount/Month Total/Month Total /Year BDT
Directors
Remunerations 0 75000 0 -
General Manager 1 30000 30000 390,000.00
Manager
Sales/Marketing 1 20000 20000 260,000.00
Accounts Officer 1 12000 12000 156,000.00
Purchase Officer 1 12000 12000 156,000.00
Sales Officer 2 8000 16000 208,000.00
Logistic Officer 1 7000 7000 91,000.00
Peon/Tea Boy 2 4000 8000 104,000.00
Security 2 3000 6000 78,000.00
Sub Total: 11 111,000 1,443,000.00
Head Office Expenses 50,000 Bricks / day
Fixed Variable Total/Month Total /Year BDT
Head Office Rent 25000 25000 300,000.00
Utilities 10000 10000 120,000.00
Stationeries 2000 2000 24,000.00
Entertainment 5000 5000 60,000.00
Conveyance &
Travelling
Allowances 50000 50000 600,000.00
Telecommunication 15000 15000 180,000.00
Couriers 1000 1000 12,000.00
Miscellaneous 20000 20000 240,000.00
Sub Total: 25000 103000 128,000 1,536,000.00
Hybrid Hoffman Kiln (HHK)
50,000 Bricks per Day
Production Analysis
Financial Investment
HHK 50,000 bricks/day
Basic parameter of the project:
Suitable for production of Solid & Holo Bricks
Raw materials blending/dosing system: Automatic
Number of Drying Channel : 4
Firing temperature : 800 -900°C
Kcal requirement per kg of Clay : 250-290 (based on firing temperature)
Land and Building 50,000 Bricks / day
Area Unit Cost/unit Total Amount BDT
Land 400 Decimal 40000 12,000,000.00
Load-unload space 156740 sft 0 -
Warehouse for Raw Materials 10000 sft 400 4,000,000.00
Machinery workshop & KILN 5500 sft 1500 2,200,000.00
Generator Room 200 sft 400 80,000.00
Sub-station Room 200 sft 400 80,000.00
Office
1500 sft 800 1,200,000.00
Laboratory 500 sft 1000 500,000.00
Sub Total: 17900 sft 20,060,000.00
Imported Machinery & Service: 50,000 Bricks / day
Equipment: Price/USD
Quantity
Unit
Price/BDT
Total Amount BDT
Forming Machinery 166,206.45
1
Set
13,795,135.48 13,795,135.48
Automatic Setting
System - - - - -
KILN 371451.61 1 Package
30,330,483.87 30,330,483.87
Sea freight 18000 1494000 1,494,000.00
Sub Total: 537658.0645
46,119,619.35
Duty/Tax/Clearing cost 2,305,980.97
Installation cost (Local cost like worker, masonry, electrical,
mechanical, etc.) 3,689,569.55
Sub Total: Including installation cost 52,115,169.87
Auxiliaries: Local Items 50,000 Bricks / day
Quantity Unit Price/BDT Total Amount BDT
Excavator 1 Set 4,000,000 4,000,000.00
Diesel Generator 750 KVA 1 Unit 6,500,000 3,500,000.00
Sub-Station, LT, HT, PFI 1 Set 3,000,000 2,500,000.00
Power cables 1 Unit 2,000,000 2,000,000.00
Tractor 2 Set 1,800,000.00 3,600,000.00
Sub Total: 15,600,000.00
Construction items need to buy locally 50,000 Bricks / day
Quantity Unit Price/BDT Total Amount BDT
Red Bricks 1000000 Pieces 7 7,000,000.00
Stones 220 MT 1,500 330,000.00
Sand 400 MT 1,200 480,000.00
Lime stone 60 MT 4,500 270,000.00
Cement 300 MT 8,000 2,400,000.00
Sub Total: 10,480,000.00
Working capital requirement 50,000 Bricks / day
Quantity Unit Amount/BDT Total Amount BDT
Clay for 30 days: 4860 MT 200 972,000.00
Coal for 30 days 168 MT 10000 1,680,000.00
Diesel fpr generator (40% load) 10890 Litre 60 653,400.00
Electricity bill based on 60%
uses 43008 Unit 8 344,064.00
Salary & Wages As listed 575,000.00
Miscellaneous LS 500,000.00
Sub Total: 4,724,464.00
Investment 50,000 Bricks / day
Total Project Cost: Amount in BDT
Fixed Cost 98,255,169.87
Working Capital 4,724,464.00
Total Amount: 102,979,633.87
Total Fixed Cost: Amount in BDT
Land & civil construction 20,060,000.00
Imported machinery & installation 52,115,169.87
Local machinery 15,600,000.00
Local items for kiln construction 10,480,000.00
Total Amount: 98,255,169.87
Cost of Production 50,000 Bricks / day
QTY Unit Price Total Amount
Clay 162 200 32,400.00
Coal 9 10000 90,000.00
Salary & Expenses As listed 25031 25,030.56
Utilities As listed 33249 33,248.80
Finance cost 17251 17251.03
Sub Total: 197,930.39
COST PER BRICK: 3.96
Loss & Profit 50,000 Bricks / day
Quantity Cost/Unit Total Amount BDT
Sales of Bricks
Grade : A ( 80%)
12000000 7.00 84,000,000.00
Grade : B &C (Average)
2500000 5.00 12,500,000.00
Cost of Production
100% 15000000 3.96 59,379,116.86
Profit before Tax 37,120,883.14
Pay off period 2.6469
Factory overhead 50,000 Bricks / day
Salary & wages: Number Amount/M Total/M Total /Year BDT
Factory Manager 1 15000 15000 195,000.00
Plant Engineer 1 15000 15000 195,000.00
Accounts Officer 1 12000 12000 156,000.00
Store Officer 1 8000 8000 104,000.00
Operator 9 6000 54000 702,000.00
Technician 2 10000 20000 260,000.00
Foreman 1 10000 10000 130,000.00
Skilled Worker 16 5000 80000 1,040,000.00
Daily Worker 60 3500 210000 2,730,000.00
Security Guard 3 4000 12000 156,000.00
Cook/Peon 2 3500 7000 91,000.00
Excavator Driver 01 15000 15000 195,000.00
Tractor Driver 1 6000 6000 78,000.00
Sub Total: 99 464000 6,032,000.00
Head Office Remuneration & Salaries 50,000 Bricks / day
Remunerations &
Salaries Number Amount/Month Total/Month Total /Year BDT
Directors
Remunerations 0 75000 0 -
General Manager 1 30000 30000 390,000.00
Manager
Sales/Marketing 1 20000 20000 260,000.00
Accounts Officer 1 12000 12000 156,000.00
Purchase Officer 1 12000 12000 156,000.00
Sales Officer 2 8000 16000 208,000.00
Logistic Officer 1 7000 7000 91,000.00
Peon/Tea Boy 2 4000 8000 104,000.00
Security 2 3000 6000 78,000.00
Sub Total: 11 111000 1,443,000.00
Head Office Expenses 50,000 Bricks / day
Fixed Variable Total/Month Total /Year BDT
Head Office Rent 25000 25000 300,000.00
Utilities 10000 10000 120,000.00
Stationeries 2000 2000 24,000.00
Entertainment 5000 5000 60,000.00
Conveyance &
Travelling
Allowances 50000 50000 600,000.00
Telecommunication 15000 15000 180,000.00
Couriers 1000 1000 12,000.00
Miscellaneous 20000 20000 240,000.00
Sub Total: 25000 103000 128000 1,536,000.00
Comparison on basic cost calculation Based on 50,000 bricks / Day (Approx)
TUNNEL KILN TECHNOLOGY HYBRID HOFFMAN KILN TECHNOLOGY
Item QTY Unit Price Total Amount QTY Unit Price Total Amount
Clay 150 MT 200 30,000.00 162 MT 200 32,400.00
Coal ( 6000KCal/kg) 5 MT 10,000 50,000.00 9 10000 90,000.00
Salary & Expenses 10 18711 18,711.11 As listed 25031 25,030.56
Utilities As listed
38469 38,468.80 As listed 33,249 33,248.80
Finance cost As listed 30602 30601.76 17251 17251.033
Sub Total: 167,781.76 197,930.393
Cost per Bricks
BDT 3.36 3.96
Profit Before TAX 51,515,471.82 37,120,883.14
Pay Off Period Year 3.1449 2.6469
Performance Ratio 97%
80%
Thank you very much
Let us try to choose the best for our development…
Let us save our limited energy and keep a bright future for our next generation…
Let us find the best value of our investment…