Brick Production Line and Factory Setup

A brick production line is a complete industrial system designed to transform clay into finished fired bricks under controlled process conditions. The line produces common and facing bricks depending on the selected forming and firing equipment.

From an industrial perspective, brick manufacturing is important because it combines clay preparation, extrusion, drying (100–150 °C) and high-temperature firing (900–1100 °C) in a tunnel or Hoffman kiln. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary raw materials typically include clay, sand, water, optional additives and packaging materials. The core machinery set consists of crushers, clay mixers, extruders, tunnel dryers, tunnel or Hoffman kilns and packaging systems. Typical capacity ranges from 10 000 to 100 000 bricks per day.

The Industrial Department supports investors who want to establish a new brick plant as well as existing plant owners who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey brick plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The brick production line is engineered as an integrated process system covering clay extraction, crushing, mixing, extrusion, drying, firing and packaging. Design capacity is determined during the engineering phase and can typically range from 10 000–100 000 bricks per day, depending on market requirements.

Product types include common bricks, facing bricks and related clay products. The overall process flow follows a defined sequence: clay preparation, extrusion and cutting, drying in tunnel dryer, firing in tunnel or Hoffman kiln, cooling and packaging.

Main machinery groups include crushers, clay mixers, extruders, tunnel dryers (100–150 °C), tunnel or Hoffman kilns (900–1100 °C) and packaging systems. Supporting infrastructure covers electrical power (100–300 kW), gas (300–800 m³/h) and water.

Manpower requirements depend on the degree of automation. Quality control covers dimensional accuracy, compressive strength, water absorption and appearance. Finished bricks are stored under dry conditions before dispatch.

Technical Specifications

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial brick production line can manufacture common and facing bricks of various sizes and surface finishes depending on extrusion dies and kiln parameters. Packaging formats are selected according to target markets.

Raw Materials for Brick Factory

The main raw material is clay. Sand and optional additives may be used to adjust plasticity and firing behaviour. Quality of incoming clay (plasticity, mineralogy, impurities) directly influences extrusion performance and final brick quality.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by brick factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Brick
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial brick projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

1. Clay Preparation – Clay is extracted, crushed and mixed with water (and optional sand/additives) to a plastic mass.
2. Extrusion and Cutting – The plastic mass is extruded into a continuous column and cut into green bricks.
3. Drying – Green bricks are dried in a tunnel dryer at 100–150 °C to remove moisture.
4. Firing – Dried bricks are fired in a tunnel or Hoffman kiln at 900–1100 °C.
5. Cooling and Packaging – Fired bricks are cooled and packaged for dispatch.

Machinery & Equipment

• Crusher and Mixer – Prepare the clay mass. Position: first process stages. Importance: foundation of extrusion quality. Quality impact: incomplete mixing causes defects. Maintenance: hammers, blades and drives. Sahi Rasa Support: specification, installation, repair and spare parts.
• Extruder – Forms the continuous clay column and cuts green bricks. Position: core forming stage. Importance: determines brick dimensions and density. Quality impact: dimensional accuracy and surface quality. Maintenance: die, auger and cutting system. Sahi Rasa Support: design, manufacturing/procurement, installation, repair and overhaul.
• Tunnel Dryer – Removes moisture at 100–150 °C. Position: after extrusion. Quality impact: residual moisture affects firing success. Maintenance: fans, burners and conveyors. Sahi Rasa Support: design, installation, repair and automation.
• Tunnel or Hoffman Kiln – Fires bricks at 900–1100 °C. Position: core thermal stage. Importance: determines strength and durability. Quality impact: firing curve controls colour, strength and water absorption. Maintenance: refractory, burners and controls. Sahi Rasa Support: design, installation, refractory, repair, overhaul and automation.
• Packaging System – Prepares finished bricks for dispatch. Position: end of line. Quality impact: handling damage prevention. Maintenance: conveyors and strapping equipment. Sahi Rasa Support: installation, repair and spare parts.

Factory Layout & Building Requirements

Typical functional areas include clay storage, preparation, extrusion, drying, kiln, cooling, packaging, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect material flow and heat management. Exact area allocation is determined during the engineering phase according to capacity.

Utilities

• Electricity: 380 V three-phase, typically 100–300 kW
• Gas: 300–800 m³/h
• Water: 20–50 m³/day
• HVAC and environmental controls according to local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC or PMC approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing brick plants can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for extruders, dryers, kilns and packaging equipment.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn parts, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (extruder, dryer, kiln), improving packaging rate or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and humidity loops, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for brick projects.

Packaging

Palletizing, strapping, labeling and coding are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for brick projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

• Investors – planning a new brick factory or production line
• Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
• Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a brick production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Brick

FAQ

1. What is the typical cost of setting up a brick plant?
   Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
2. Which main machines are required?
   Crusher, clay mixer, extruder, tunnel dryer, tunnel or Hoffman kiln and packaging system.
3. What production capacity can be designed?
   Capacity is determined during the engineering phase according to market demand and investment criteria (typical range 10 000–100 000 bricks/day).
4. How much space is needed?
   Typical process area ranges from approximately 1000 to 3000 m², subject to final layout.
5. What are the main raw materials?
   Clay, sand, water and optional additives.
6. Can raw materials be supplied?
   Yes, via the Supply Chain Department according to project scope.
7. Is machinery manufacturing or procurement supported?
   Design, manufacturing or coordinated procurement according to the agreed scope.
8. Can existing machines be repaired?
   Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
9. Is overhaul or refurbishment possible?
   Yes – comprehensive restoration and control upgrades.
10. Can capacity of an existing line be increased?
    Often yes, by addressing bottlenecks and upgrading key equipment.
11. Are turnkey projects executed?
    Turnkey or partial turnkey scopes can be offered under defined contracts.
12. Are services available in Iraq and Kurdistan Region?
    Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
13. Are services available in Afghanistan?
    Yes, including Kabul, Herat and Mazar-e-Sharif.
14. Can raw materials be supplied from Iran for regional projects?
    Yes, coordination of material supply is part of possible supply-chain scope.
15. Is installation and commissioning included?
    They can be included according to the selected contractual package.