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GREEN ENERGY SOLUTION

and help
reduce GHG emission

GREEN ENERGY SOLUTION

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

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)

Hybrid Hoffman Kiln (HHK)

Drying kiln of HHK


Same Hoffman Kiln
without chimney

Bricks production line can be manual


or automatic
Trench Kiln
System

Manual/Auto Raw
Bricks Production

Manual Drying &


Firing

Zigzag Kiln System

Manual/Auto Raw
Bricks Production

Manual Drying &


Firing

Hoffman Kiln
System

Manual/Auto Raw
Bricks Production

Manual Drying &


Firing

Hybrid Hoffman
Kiln System

Manual/Auto Raw
Bricks Production

Auto-dry &
manual Firing

Tunnel Kiln
System

Only Automatic
Bricks Production

PLC Controlled full


automatic

Auto-Production Line:
Can be used for any technology

Automatic Transfer to Drying Car:


Mainly used in Tunnel Kiln

Modern Energy Saving Tunnel Kiln

Same Kiln Car to Drying Kiln & Tunnel Kiln

Energy Saving Drying Kiln

Energy Saving Tunnel Kiln

Variation in 5 Technologies
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

Days 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

Notes on Coal Consumption


Hybrid Hoffman Kiln (HHK)

Energy Saving
Tunnel Kiln

Loss of temperature
because too many doors

One door each side ensure


maximize use of heat

Qualification rate in
800~900C temperature is
lower

Qualification rate in
1000~1050C temperature
is more

If increased same
temperature of Tunnel Kiln
the requirement is 380~420
Kcal/kg

If decreased same
temperature of HHK the
requirement is 180~190
Kcal/kg

Worker requirement : 100,000 pieces/day


Hybrid Hoffman Kiln
76 persons

Tunnel Kiln
27 persons

Production

36 incl. Raw Bricks


setting & transfer
to Drying Car

15 incl. Raw Bricks


setting & transfer
to Kiln Car

Drying

10 persons incl.
transfer to Kiln

Setting for
firing Kiln

30 persons incl.
transfer to Kiln

Ready bricks
out

30 persons incl.
transfer to Kiln

12 persons for all


section. Same
Kiln car for drying
& firing kiln

Energy Saving Tunnel Kiln


Pre-heating
area

Firing area

Kiln car
enter

Cooling
area

Heated air

Smoke exhaust
Air supply

Coal supply

Air
flow

Kiln car exit

Cooling
Residual thermal
exhaust

Energy Saving Tunnel Kiln


Single Channel Tunnel

Double Channel Tunnel

Multi Channel Tunnel

Financial Investment
100,000 bricks/day
Basic parameter of the project:
Suitable for production of

Solid & Holo Bricks

Raw materials blending/dosing system:


Batch size

: 4500 bricks per car

Car exit

: 57 minutes/car

Firing temperature
Kcal requirement per kg of Clay

: 1000-1050C
: 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

Automatic

Land and Building


100,000 bricks/day
Area

Unit

400

Decimal

Load-unload area

137740

Warehouse for Raw Materials


Machinery workshop & KILN

Land

Cost/unit

Total Amount BDT

30000

12,000,000.00

sft

10,000

sft

400

4,000,000.00

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

50260

sft

Sub Total:

32,704,000.00

Imported Machinery & Service


100,000 bricks/day
Equipment:
Forming Machinery
Automatic Setting
System
KILN
Technical Service
Sea freight
Sub Total:

Price/USD

Quantity

Unit

Price/BDT

302658.06

Set

25.120,618.98

25,120,618.98

138709.67

11,512,902.61

11,512,902.61

1099032.25

Package

91219676.75

91,219,676.75

6,693,548.28

6,693,548.28

3,320,000

3,320,000.00

80,645.16
40,000

Total Amount BDT

137,866,746.62

1,661,045.14

Duty/Tax/Clearing cost
/internal transport
Installation cost
(Local cost like worker, masonry, electrical, mechanical, etc.)
Sub Total: Including installation cost

6,558,659.92
6,893,337.33

151,318,743.87

Auxiliaries: Local Items


100,000 bricks/day
Quantity

Unit

Excavator

Set

4,000,000

4,000,000.00

Diesel Generator 750 KVA

Unit

6,500,000

6,500,000.00

Diesel Generator 200 KVA

Unit

2,500,000

2,500,000.00

Sub-Station, LT, HT, PFI, CTPT

Set

3,500,000

3,500,000.00

Power cables

Unit

3,000,000

3,000,000.00

Tractor + Trailer

Unit

1,800,000

1,800,000.00

Sub Total:

Price/BDT

Total Amount BDT

21,300,000.00

Local Supply for Kiln


100,000 bricks/day
Quantity

Unit

700,000

Pieces

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

Red Bricks

Sub Total:

Price/BDT
7

Total Amount BDT


4,900,000.00

9,180,000.00

Working capital requirement


100,000 bricks/day
Quantity

Unit

Clay for 30 days:

9000

MT

200

1,800,000.00

Coal for 30 days

300

MT

10000

3,00,000.00

15300

Litre

60

918,000.00

49568

Unit

396,544.00

Diesel for 2 generator


(40% load moderate)
Electricity bill based on 60% uses
dependable
Salary & Wages
Miscellaneous
Sub Total:

Amount/BDT Total Amount BDT

As listed

400,000.00

LS

500,000.00
7,014,544.00

Investment
100,000 Bricks / day
Total Fixed Cost:
Land & Civil construction
Imported machinery & installation
Duty / TAX/ Clearing Cost/ Internal
Transportation
Installation Cost
Auxiliary
Local items for kiln construction
Total Amount:
Total Project Cost:
Fixed Cost
Working Capital
Total Amount:

Amount in BDT
32,704,000.00
137,866,746.62
6,558,659.92
6,893,337.33
21,300,000.00
9,180,000.00
207,944,083.95
Amount in BDT
207,944,083.95
7,014,544.00

214,958,627.95

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

39189

39,188.82

Finance cost
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

15000

15000

195,000.00

Plant Engineer

15000

15000

195,000.00

Accounts Officer

12000

12000

156,000.00

Store Officer

8000

8000

104,000.00

Operator

6000

54,000

702,000.00

Foreman

10000

10000

130,000.00

Technician

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

4000

12,000

156,000.00

Cook/Peon

3,500

7,000

91,000.00

Excavator Driver

15,000

15,000

195,000.00

Tractor Driver

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
Directors
Remunerations

Number

Amount/Month

Total/Month

Total /Year BDT

75000

General Manager

30000

30000

390,000.00

Manager
Sales/Marketing

20,000

20,000

260,000.00

Accounts Officer

12,000

12,000

156,000.00

Purchase Officer

12,000

12,000

156,000.00

Sales Officer

8000

16,000

208,000.00

Logistic Officer

7000

7,000

91,000.00

Peon/Tea Boy

4000

8000

104,000.00

Security

3000

6000

78,000.00

Sub Total:

111,000

1,443,000.00

Head Office Expenses


100,000 Bricks / day
Fixed
Head Office Rent

Variable

Total/Month

25,000

Total /Year BDT

25,000

300,000.00

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

1000

1,000

12,000.00

20000

20,000

240,000.00

103000

128,000

1,536,000.00

Utilities

Couriers
Miscellaneous
Sub Total:

25,000

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

Pay off period

125,184,581.63

1.6611

50,000 Bricks per Day


Production Analysis

Financial Investment

50,000 bricks/day

Basic parameter of the project:


Suitable for production of
Raw materials blending/dosing system:
Batch size
: 4500 bricks per car
Car exit
: 57 minutes/car
Firing temperature
: 800-900C
Kcal requirement per kg of Clay
(based on firing temperature)

: 210-260

Solid & Holo Bricks


Automatic

Land and Building


50,000 Bricks / day

Area

Unit

300

Decimal

Load-unload space

91680

Warehouse for Raw Materials


Machinery workshop & KILN

Land

Cost/unit

Total Amount BDT

30000

9,000,000.00

sft

10000

sft

400

4,000,000.00

27400

Sft

400

10,960,000.00

Generator Room

200

sft

400

80,000.00

Sub-station Room

200

sft

400

80,000.00

1500

sft

800

1,200,000.00

Office & Laboratory

sft
Sub Total:

39300

25,320,000.00

Imported Machinery & Service:


50,000 Bricks / day
Equipment:

Price/USD

Quantity

Forming Machinery

278,464.51

Automatic Setting
System

138709.00

KILN

751,612.90

Sea freight
Technical Service
Sub Total:

Unit

Price/BDT

Total Amount BDT

23,112,554.33

23,112,554.33

11,512,847.00

11,512,847.00

62,383,870.70

62,383,870.70

32000

2,656,000.00

2,656,000.00

70645.00

5863535.00

5,863,535.00

Set

Package

1,271,431.41

Duty/Tax/Clearing cost

Installation cost (Local cost like worker, masonry, electrical,


mechanical, etc.)

Sub Total: Including installation cost

105,528,807.03
4,983,263.60
5276440.35

115,788,510.98

Auxiliaries: Local Items


50,000 Bricks / day
Quantity

Unit

Price/BDT

Total Amount BDT

Excavator

Set

4,000,000

4,000,000.00

Diesel Generator 600 KVA

Unit

5,500,000

5,500,000.00

Diesel Generator 200 KVA

Unit

2,500,000

2,500,000

Sub-Station, LT, HT, PFI

Set

3,000,000

3,000,000.00

Power cables

Unit

3,000,000
3,000,000.00

Tractor & Trailers


Sub Total:

Set

1,800,000.00

1,800,000.00
19,800,000.00

Construction items need to buy locally


50,000 Bricks / day
Quantity

Unit

420000

Pieces

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

Red Bricks

Sub Total:

Price/BDT
7

Total Amount BDT


2,940,000.00

6,084,000.00

Working capital requirement


50,000 Bricks / day
Quantity

Unit

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

344,064.00

Salary & Wages


Miscellaneous
Sub Total:

Amount/BDT Total Amount BDT

As listed

400,000.00

LS

500,000.00
4,364,064.00

Investment
50,000 Bricks / day
Total Fixed Cost:
Land & civil construction
Imported machinery & installation
Local machinery

Local items for kiln construction


Total Amount:

Total Project Cost:


Fixed Cost

Amount in BDT
25,320,000.00
115,788,510.98
19,800,000.00
6,084,000.00
162,009,247.38

Amount in BDT

Working Capital

162,009,247.38
4,364,064.00

Total Amount:

166,373,311.38

Cost of Production
50,000 Bricks / day
QTY

Unit Price

Total Amount

200

30,000.00

10000

50,000.00

Salary & Expenses

As listed

18711

18,711.11

Utilities

As listed

38469

38,468.80

30602

30,601,85

Clay

150

Coal

Finance cost

167,781.76

Sub Total:

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

Pay off period

51,515,471.82

3.1449

Factory overhead
50,000 Bricks / day
Salary & wages:

Number

Amount/M

Total/M

Total /Year BDT

Factory Manager

15000

15000

195,000.00

Plant Engineer

15000

15000

195,000.00

Accounts Officer

12000

12000

156,000.00

Store Officer

8000

8000

104,000.00

Operator

6000

54000

702,000.00

Technician

10000

20000

260,000.00

Foreman

10000

10000

130,000.00

Skilled Worker

16

5000

80000

1,040,000.00

Daily Worker

10

3500

35000

455,000.00

Security Guard

4000

12000

156,000.00

Cook/Peon

3500

7000

91,000.00

Excavator Driver

01

15000

15000

195,000.00

Tractor Driver

6000

6000

78,000.00

Sub Total:

49

289,000

3,757,000.00

Head Office Remuneration & Salaries


50,000 Bricks / day
Remunerations &
Salaries
Directors
Remunerations

Number

Amount/Month

Total/Month

Total /Year BDT

75000

General Manager

30000

30000

390,000.00

Manager
Sales/Marketing

20000

20000

260,000.00

Accounts Officer

12000

12000

156,000.00

Purchase Officer

12000

12000

156,000.00

Sales Officer

8000

16000

208,000.00

Logistic Officer

7000

7000

91,000.00

Peon/Tea Boy

4000

8000

104,000.00

Security

3000

6000

78,000.00

Sub Total:

11

111,000

1,443,000.00

Head Office Expenses


50,000 Bricks / day
Fixed
Head Office Rent

Variable

Total/Month

25000

Total /Year BDT

25000

300,000.00

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

1000

1000

12,000.00

20000

20000

240,000.00

103000

128,000

1,536,000.00

Utilities

Couriers
Miscellaneous
Sub Total:

25000

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
Raw materials blending/dosing system:
Number of Drying Channel
:4
Firing temperature

: 800 -900C

Kcal requirement per kg of Clay

: 250-290

(based on firing temperature)

Solid & Holo Bricks


Automatic

Land and Building


50,000 Bricks / day

Area

Unit

400

Decimal

Load-unload space

156740

Warehouse for Raw Materials

Land

Cost/unit

Total Amount BDT

40000

12,000,000.00

sft

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

1500

sft

800

1,200,000.00

Laboratory

500

sft

1000

500,000.00

Sub Total:

17900

sft

Office

20,060,000.00

Imported Machinery & Service:


50,000 Bricks / day
Equipment:
Forming Machinery

Price/USD

Unit

166,206.45

Set

371451.61

Package

Automatic Setting
System
KILN

Quantity

Sea freight

18000

Sub Total:

537658.0645

Price/BDT

Total Amount BDT

13,795,135.48

13,795,135.48

30,330,483.87

30,330,483.87

1494000

1,494,000.00
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

Excavator

Set

4,000,000

4,000,000.00

Diesel Generator 750 KVA

Unit

6,500,000

3,500,000.00

Sub-Station, LT, HT, PFI

Set

3,000,000

2,500,000.00

Power cables

Unit

2,000,000

2,000,000.00

Tractor

Set

1,800,000.00

3,600,000.00

Sub Total:

Price/BDT

Total Amount BDT

15,600,000.00

Construction items need to buy locally


50,000 Bricks / day
Quantity

Unit

1000000

Pieces

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

Red Bricks

Sub Total:

Price/BDT
7

Total Amount BDT


7,000,000.00

10,480,000.00

Working capital requirement


50,000 Bricks / day
Quantity

Unit

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

344,064.00

Salary & Wages


Miscellaneous
Sub Total:

Amount/BDT Total Amount BDT

As listed

575,000.00

LS

500,000.00
4,724,464.00

Investment
50,000 Bricks / day
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

Total Project Cost:


Fixed Cost

Amount in BDT

Working Capital

98,255,169.87
4,724,464.00

Total Amount:

102,979,633.87

Cost of Production
50,000 Bricks / day
QTY

Unit Price

Total Amount

200

32,400.00

10000

90,000.00

Salary & Expenses

As listed

25031

25,030.56

Utilities

As listed

33249

33,248.80

17251

17251.03

Clay

162

Coal

Finance cost

197,930.39

Sub Total:

COST PER BRICK:

3.96

Loss & Profit


50,000 Bricks / day
Quantity

Cost/Unit

Total Amount BDT

12000000

7.00

84,000,000.00

2500000

5.00

12,500,000.00

15000000

3.96

59,379,116.86

Sales of Bricks
Grade : A ( 80%)
Grade : B &C (Average)
Cost of Production
100%

Profit before Tax

Pay off period

37,120,883.14

2.6469

Factory overhead
50,000 Bricks / day
Salary & wages:

Number

Amount/M

Total/M

Total /Year BDT

Factory Manager

15000

15000

195,000.00

Plant Engineer

15000

15000

195,000.00

Accounts Officer

12000

12000

156,000.00

Store Officer

8000

8000

104,000.00

Operator

6000

54000

702,000.00

Technician

10000

20000

260,000.00

Foreman

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

4000

12000

156,000.00

Cook/Peon

3500

7000

91,000.00

Excavator Driver

01

15000

15000

195,000.00

Tractor Driver

6000

6000

78,000.00

Sub Total:

99

464000

6,032,000.00

Head Office Remuneration & Salaries


50,000 Bricks / day
Remunerations &
Salaries
Directors
Remunerations

Number

Amount/Month

Total/Month

Total /Year BDT

75000

General Manager

30000

30000

390,000.00

Manager
Sales/Marketing

20000

20000

260,000.00

Accounts Officer

12000

12000

156,000.00

Purchase Officer

12000

12000

156,000.00

Sales Officer

8000

16000

208,000.00

Logistic Officer

7000

7000

91,000.00

Peon/Tea Boy

4000

8000

104,000.00

Security

3000

6000

78,000.00

Sub Total:

11

111000

1,443,000.00

Head Office Expenses


50,000 Bricks / day
Fixed
Head Office Rent

Variable

Total/Month

25000

Total /Year BDT

25000

300,000.00

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

1000

1000

12,000.00

20000

20000

240,000.00

103000

128000

1,536,000.00

Utilities

Couriers
Miscellaneous
Sub Total:

25000

Comparison on basic cost calculation


Based on 50,000 bricks / Day (Approx)
TUNNEL KILN TECHNOLOGY
Item
Clay

QTY

Unit Price

150 MT

Total Amount

HYBRID HOFFMAN KILN TECHNOLOGY


QTY

200

30,000.00

162 MT

Unit Price

Total Amount

200

32,400.00

Coal ( 6000KCal/kg)

5 MT

10,000

50,000.00

10000

90,000.00

Salary & Expenses

10

18711

18,711.11

As listed

25031

25,030.56

38,468.80

As listed

33,249

33,248.80

17251

17251.033

Utilities

As listed

Finance cost

As listed

38469
30602

Sub Total:

Cost per Bricks

167,781.76
BDT

Profit Before TAX


Pay Off Period
Performance Ratio

30601.76

3.36
51,515,471.82

Year

197,930.393

3.96
37,120,883.14

3.1449

2.6469

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