VSBK 11, Morena, owned by Mr. Kaushal Singhal was ignited on 23rd. of February, 2002 and saleable bricks rolled out from 25th. of February. Presently entrepreneur is running one shaft only for shortage of green bricks. Additional moulders has already been deployed from 25th. of March to scale up the production as per requirement of the two shafts. Financial viability works out on two stably operated shafts based on 4 labour requirement for loading and unloading per shift.

Till date he is unloading around 14 to 15 batches per day containing 308 bricks per batch. Coal consumption has been stabilized at 13.5 kg per layer, approximately 13 T per lakh. It is also necessary to mention here that he is presently firing bricks without any internal fuel and is satisfied about the product quality. Fuel consumption in his previous movable chimney started with 22 T per lakh and stabilized at 18 T per lakh. Compared to movable chimney, VSBK has a direct saving of 28% external fuel with identical green brick composition. Although it had been committed by the entrepreneurs to fire internal fuel bricks in VSBK to obtain required quality, he had some stock of green bricks for intended movable chimney operation. Also there would have been a substantial learning for the Project for firing of non-internal fuel bricks.

During the last one month of operation there was a substantial breakage (10%) during unloading. This was verified to be of wrong specification of girder rail beam and uneven unloading wooden support bars. After changing the specification of the above materials and checking their dimensions fired breakage reduced to 3%.

Still around 1.5 % of the breakage was attributed due to presence of shrinkage cracks in the green bricks which was pointed out to the entrepreneur and asked to rectify. Although the colour was acceptable to the entrepreneur, still for achieving higher colour it was found necessary to construct a cooling chamber out of mud masonry and GI roof. This would decrease the cooling rate thereby enhancing the fired colour. A 14 ft. by 18 ft with 8.5 ft. height cooling chamber on both the sides of the shaft with two 3 ft. wide doors on both sides were advised to be constructed.

Entrepreneur was also instructed to mould internal fuel bricks with 2% and 3% coal dust which he has already procured in fine (< 3 mm) form. After firing in VSBK and judging the colour we would decide on the optimum content. However he has been instructed to start moulding with 3% internal fuel bricks which will possibly bring down the coal consumption to around 6 tonnes per lakh.

Entrepreneur has also fabricated a coal crusher of the disintegrator model and was found to be more robust than those usually supplied from Gorakhpur. It ha s a capacity to disintegrate around 2 tonnes per hour with a very high feed size weighing around 10 to 15 kg. At present his production cost is identical as movable chimney since the savings on coal is offsetted by increased labour i.e. 4 labours firing 1 shaft. When he operates 2 shafts production will increase without increasing firing labour cost. Use of internal fuel will still decrease the production cost. Based on the above entrepreneur envisages a profit of Rs. 100 more compared to movable chimney operation (production cost Rs. 900 / 1000). Overall profit is perceived to increase to Rs. 300 per 1000 bricks since his selling price is Rs. 1100 ex. site.