Zig-zag kilns offer a 15-20% reduction in Specific Energy Consumption (SEC) and up to 75% reduction in SPM emissions over FC-BTK. A higher percentage of Class I bricks are produced as compared to FC-BTK (80-85% Class I bricks as compared to 55-60% in FC-BTK). There is an option for easy retrofit of FC-BTK to natural draught Zig-zag kiln. Savings from reduced fuel consumption and increase in revenue due to the higher percentage of Class I bricks. The capital cost of retrofitting of existing FC-BTKs ranges from INR 10-25 lakhs and pays back in 3 months-2 years. However, for new construction, the capital cost ranges from INR 35-45 lakhs natural draught kiln and INR 40-45 lakh for a high draught kiln. The payback period for the new construction of the Zig-zag kiln is 2-3 years.
Zig-zag kiln required skilled manpower for its operation. However, the same workforce working in FC-BTK can be easily trained for operating Zig-zag kilns. 4 persons are required for firing at a 6-hour shift.
• Production Capacity: 20,000 – 60,000 Bricks per day.
• Up to 25% less fuel consumption compared to FCBTK.
• Product Quality:
– Class-I bricks: 80% – 90%
– Underfired, over-fired, or breakages: 10-20%
• Capital Investment (excluding land cost): Capital Investment (excluding land cost): Rs 30-50 lakh 50 lakh
• Emits 70-80% lower PM as compared to FCBTKs.
. Capital cost making zig-zag Bhatta approximate 40 to 50 lakh.
. zig zag Bhatta price depends on the capacity of Bhatta.
Zig Zag Kiln Working
• Fire moves in closed
through the brick
stacked in the trench.
• Operates under
natural or induced
• Three zones:
• Firing zone
• Pre-heating zone
• Cooling zone
• Solid fuel fed from
the top continuously.
• Chamber type brick
• Improved version of FCBTK.
• Central Building Research Institute (CBRI) first introduced the zigzag firing
technology-based during the early 1970s.
• 3,000 – 4,000 kilns in India