Structural Changes in Brick Industry

8/7/2019 Structural Changes in Brick Industry

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Brick industry Brick industry Structural Structural

changes changes

RATIONALISATIONENERGETIQUE

Structural brick industry changes in Europeand India

A retrospective and prospective

comparisonP. Jaboyedoff, Sorane SA, Switzerland, Lausanne, e-mail: [email protected]

Consultant to the Swiss Agency for Development andCooperation (SDC) in the Energy & Environment

Programme in India

Foundry, Glass, Brick sectors

Brick industry Brick industry Structural Structural changes changes


Structural changes in Europe

l In about 50 years timeêComplete structural transformation

l Concentration processê

From thousands to dozens of unitsl MechanisationêFrom manual to fully mechanised units

l Main trends in brick productsêFrom plain bricks to hollow products



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changes changes

RATIONALISATIONENERGETIQUETunnel kiln introduction

in Europe

0

10

20

30

40

50

60

70

80

90

100

1950 1955 1960 1965 1970 1975 1980 1985

Time (Yrs)

%

s h a r e o f t u n n e l k i l n s

Germany

France

Italy

UK


RATIONALISATIONENERGETIQUEPerforated products exampleof Belgium

Hollow bricks

Plain bricks



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changes changes


Structural change and

concentration, the case ofSwitzerland

l From hundreds of factories to less than 30ê Only 12 groups, further concentration going on

l From manual to full mechanisationê Continuous diminution of number of employee

l High investmentsê No more new unit today

l Further concentrationê Less and larger groups taking control

l Need of flexibility, innovation for smaller unitsê Only chance to survive


RATIONALISATIONENERGETIQUEMid size factory inSwitzerland

l 36’000 tons/yr (max80’000)ê (approx. equivalent to 120 lakhs

of ISI bricks)

ê Total investment of about 20Millions US$

l Many different productsê (turnover approx. 10-20 times

more than equivalent BTK)

l Continuous development ofnew products

l 18 employeesê (approx. 250-500 workers in an

equivalent BTK)



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changes changes

RATIONALISATIONENERGETIQUEBatch clay winning in deep

pits, storage for 1-2 yrs

Concession sincemore than 1 centuryand granted for thenext 50 yrs


RATIONALISATIONENERGETIQUEFrom the clay heap to thecrusher

Only one employeefor feeding



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changes changes


Crushing and refining

Only remote control,no one on site


RATIONALISATIONENERGETIQUERaw material transport byconveyor belts




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changes changes

RATIONALISATIONENERGETIQUEStoring and conveying

(about 2-3 weeks)




Conveying to the extruder




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changes changes

RATIONALISATIONENERGETIQUEDried bricks on carts and

tunnel kilns

Brickcart

Driedstackedqueing

Tunnel kiln

(partialview)


RATIONALISATIONENERGETIQUEAutomatic control of theprocess



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changes changes


Brick market in Switzerland

l Try to meetbuilding coderequirementwithout insulation



Brick market share

Clay

0

10

20

30

40

50

60

70

80

90

100

B e l g i u m

D e n m a r k

F r a n c e

G e r m a n y

G r e e c e

I t a l y

N e t h e r l a n d

U K

Belgium

Denmark

France

Germany

Greece

Italy

Netherland

UK



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changes changes


0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

1990 2000 2010 2020 2030 2040 2050

Clamp coal

Clamp bio

BTK move

BTK fix

HDK

VSBK&Tunnel

India

Baseline scenario

BTK Movable

BTK Fixed

New technologies

Tunnel, VSBK, Zig-zag, ..

Coal (biomass)

Clamps (coal)



0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1990 2000 2010 2020 2030 2040 2050

Clamp coal

Clamp bio

BTK move

BTK fix

HDK

VSBK&Tunnel

Strict enforcement of environmentalregulation, but low technical support

BTK Movable

BTK Fixed

New technologies


Clamp (biomass)

Clamps (coal)



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changes changes


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1990 2000 2010 2020 2030 2040 2050

Clamp coal

Clamp bio

BTK move

BTK fix

HDK

VSBK&Tunnel

Strict enforcement of environmental

regulation, but strong technical support

BTK Movable

BTK Fixed

New technologies


Clamp (biomass)

Clamps (coal)



Coal consumption

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

1990 2000 2010 2020 2030 2040 2050

M i o t o n s o f c o a

l

BAU

Baseline

ScenarioIII

ScenarioIV



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changes changes


Conclusions

l Structural change did take about 50 yearsto complete in Europe

l How long will it take in India ?êNobody has an answer

êGoverning factorsêEnvironmental regulations

êMarket demand for different products (hollow bricks, othermaterials)

êImprovement of labour conditions (increasing labour costand social conditions)

êIndustry has to think about it now

Structural Changes in Brick Industry

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