Manufacturing Process

The manufacturing process begins with Pathai — the skilled art of brick moulding. Carefully selected alluvial clay is mixed with water to the right consistency, then shaped into precise brick forms using moulds.

• High-quality alluvial clay selected from approved sources
• Clay mixed with water and tempered to ideal plasticity
• Bricks moulded using standard IS-size wooden or metal moulds
• Each brick hand-shaped or machine-pressed for uniform size
• Raw bricks sun-dried for 48–72 hours before kiln loading

Once the raw bricks (kachi bricks) are sufficiently dried, they are carefully loaded into the kiln chambers in a specific stacking pattern. Proper loading ensures even heat distribution during firing.

• Dried raw bricks inspected for cracks before loading
• Stacked in cross-pattern to allow heat circulation
• Each chamber holds 40,000–60,000 bricks
• Strategic placement ensures uniform temperature throughout
• Kiln chamber sealed before firing begins

Jalai is the most critical stage — high-temperature firing that transforms raw clay into strong, durable bricks. Our modern zigzag kilns maintain precise temperatures of 900°C–1100°C for optimal results.

• Kiln fired using coal in controlled quantities
• Temperature maintained at 900°C–1100°C for 48–72 hours
• Zigzag design ensures uniform heat distribution
• Experienced kiln operators monitor temperature 24/7
• Coal usage tracked per batch for cost and quality control

After 48–72 hours of firing, the kiln is allowed to cool gradually. Nikasi is the process of carefully unloading the fired bricks and sorting them by quality grade into first, second, and third class.

• Kiln cooled for 24 hours after firing is complete
• Bricks unloaded carefully to prevent breakage
• Quality inspection done during unloading
• Graded into First, Second, Third class, and Rodi/Tukda
• Each batch counted and recorded in the system

Before any brick leaves our facility, it goes through our quality control process. Bricks are tested for size, strength, water absorption, and visual defects. Only approved bricks are dispatched to customers.

• Compressive strength tested using hydraulic press
• Water absorption test conducted on sample bricks
• Size measurement checked against IS:1077 standards
• Visual inspection for cracks, bloating, and surface defects
• Approved bricks stacked and dispatched by our transport fleet