R&D- Research and Development in the Manufacturing of Heavy Clay Processing Machinery

Heavy Clay Processing Machinery are not manufactured by many in India. Only a few companies have the required know how to manufacture it. Most of the time we import or copy technology or machinery form European countries especially form Germany or Vienna. Now an Indian company have done a lot in this line. This is a study based on their R&D efforts.Designing a machinery for the purpose of clay processing is a complex process. Then it has to be tested. Feedback from the end user must be continuously taken, compiled and analysed. Timely modification must be brought in. All these involves a lot of efforts and resources. These slides are intended to give an insight into the efforts taken by a company in this area.

1. Vijayaprakash Industrials SINCE 1966

2. SINCE 1966 We began by building Pug Mills for the heavy clay Industry

3. We built a simple twin screw pugmill and continued to introduce modified versions almost every year

4. We kept on listening to our customers’ needs We introduced different models of Pug Mills

5. In this model One single thrust bearing, all others were bushes.

6. It was the first time in the whole our India anyone is making a Heavy Clay Pugmill

7. Along with conveyor and cutting table (Hand operated)

8. All bushes replaced with roller bearings

9. Then we came out with another modification in the shaft coupling male-female female-male

10. In 1969 Our R&D came out with the de-airing Pug mill

11. Indigenously built, another first time in India

12. First it was designed with the shredding plate in between top & bottom augers

13. A closed chamber with diagonal walls- Clogging, cut open the walls- tedious maintenance procedures

14. Introduced a model with side-window which can be opened to access the interior parts

15. No need to remove the bushes and bearing of top augers

16. We happened to see some of our traditional potters producing good quality clay potteries, clay idols , manikins and other such things from clay.

17. We kept on analysing the feedback from our customers

18. Developed the De-airing pug mill further. Slit through which the shredding plate can be pulled out without opening the window

19. Freshly hand moulded green ware in clay

20. Our customers were happy! Even then we developed it further,

21. Because on alternate days the mill interior has to be cleaned- a tedious procedure and break in productivity

22. Introduced the revolving cutter shredders- helped us to increase the size of vacuum chamber also.

23. Thus reduced the frequency of the breaks for cleaning

24. The top augers were modified to be driven by a single shaft- male female couplings interchanged

25. Helped us reduce the jerking movement, wear & Tear, and required torque

26. The sliced clay is again pounded and mixed with water and sand adequately.

27. Our customers are making a variety of clay products using this, very successfully

28. We are happy and proud to see many successful installations throughout India and in some neighbouring countries

29. We’re happy to see the oldest of our machineries sold decades back are still working

30. We’re happy to see our machineries fetch good price in the second-hand market

31. Lately we introduced a single auger machine – then the split open barrel type- enabling the easy removal of the auger segment

32. Now the shredding plates are fitted at the centre of the barrel- no moving parts exposed to the barrel- minimises the chance of air leakage to the vacuum chamber

33. Vacuum Pump

34. We also came out with water ring vacuum pumps in the early days

35. We found the piston vacuum pumps is better

36. With moving piston vacuum pumps oil drip in the crank, guide, cam etc. was a problem

37. Routine oiling was important, a delay in it can affect the life of the bearing drastically

38. We brought out a turn-around and oil immersed moving parts could solve the problem

39. Another modification was in the cylinder body. It was cast iron bodied. We introduced removable sleeves in the cylinder. On wear & tear only the sleeves needed replacement.

40. Cutting Tables

41. Hand operated two brick cutting tables first. No end waste

42. Hand operated two brick cutting tables first. No end waste- but small productivity

43. Pre-column cutting, for 10/20 bricks- fine cut- disadvantage- both end waste

44. We introduced hand cutter for pre-column cutting and final cutting motorised mechanism with manually operated switch

45. The fully automatic with moving pre-cutter- moving table along with final cutting machine

46. The fully automatic online cutter- cuts the clay column to any size in exact measures, adjustment on the chain sprocket wheel, places the cut bricks on the conveyor

47. Crushing Roller

48. The crushing surface on the rollers were grooved- straightly. Problem found scrapper blades going down-

49. Rectified by v-shaped grooves in opposing directions- improved sheering and crushing action

50. Next development- introduction of safety caps and washers- helped to avoid breaking of shafts and bearings

51. Even then it can cause breaking of washer plate; to avoid this- replaced it with bush and bolt system

52. On an eventuality no heavy load on vital parts, hence will not break, if at all the nuts will and they can be easily replaced, reducing break downs, maintenance efforts, and expenditure for maintenance

53. To keep the roller face even- automatic grinder with tools- surface leveling machines grinder tools can be used

54. High speed fine roller

55. Our high speed fine grinding rollers further mixes it and grinds the hard particles which make the water penetration easier

56. Heavy-duty spherical roller bearings ensure smooth and free rotary movement

57. The gap between the differential rpm rollers can be adjusted to a minimum of 1mm

58. High Speed Fine Grinding Roller

59. Box Feeder

60. V PI Twin Barrel Clay Mixer

61. Clay mixer has two chambers. The open chamber has beater shaped paddles which expands the clay and in the closed chamber, augers compresses the clay.

62. Clay mixer is fitted with slicers at its mouth which slices the clay into finer flakes and renders it really manageable.

63. Pan mill helps you to crush the large lumps of clay, which ensures better mixing.

64. Comparing the two process

65. Panmill Grinds the Hard particles

66. VPI Panmill

67. Panmill pushes the clay down in noodle form

68. Panmill

69. So industrial wastes if available can be utilised well in this processing method

70. Our De-airing Pug Mill removes the air column caught inside the clay and pugs it well.

71. This stage in the processing increases the elasticity of the clay to very great extent

72. So the clay is ground, mixed, watered, cured, and in the final stage using an extruder you can extrude out any product with high quality standards

73. Extrude any product

74. Made truly elastic Soft Mud Extrusion with De-airing Pugmill

75. A few more steps Forward! Some additional Mechanisation suggestions for additional quality and productivity

76. Loading

77. Pre-crushing and Curing

78. Bucket Excavator

79. Wire-cutting

80. This is not just an upgradation of technology, but it’s a bare essential processing modification every clay industry has to adopt

81. It’s our responsibility towards our coming generations ; it’s a MUST.

82. Vijayaprakash Industrials, India, can provide you the required technical help to upgrade yourself to produce the most resource efficient bricks and other clayware

83. Bricks , Hollow bricks, wall facing tiles, roofing tiles, paver blocks etc.

84. A Truly wide range of Products

85. You can now produce more number of clay products with improved quality using lesser amounts of raw materials, energy and other resources

86. Upgrade the technology. It’s the need of the hour, rather a responsibility of every entrepreneur . it’s a MUST.

87. THANK YOU http://www.vijayaprakashindustrials.com/ http://resourceefficientbricks.blogspot.in/ [email protected]