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Recommended Machinery, equipment and supplies and
materials for small scale ceramic Filter Production ( 800-1000 filters a month )
to be installed in an existing pottery with trained potters Manual hydraulic press.
We recommend the
initial press be purchased in Nicaragua, Holland
or Cambodia. Once the press is in place (an
material prepared) the production of prototypes
can begin immediately.
More presses can be copied and improved on
once the filter factory is generating income. Up
grades to electric/Hydraulic is the next step. An
electric hydraulic press can be purchased in
Cambodia for about US 2,100.00 plus shipping.
Or PFP can supply RDI plans for construction
At least 50 round flat sheet metal plates are
required to be placed on the bottom of the female old (see production video)
A 15-20 ton Manual hydraulic truck jack is
required and can usually be bought locally. A
spare jack, hydraulic fluid and oil for lubrication
should be handy at all times.
The press will work 6-8 hours a day
Small Hammer Mill
with interchangeable sieves Powered by a 2-3 hp or more electric motor
(electric motor makes allot less noise than a
internal combustion motor) .
You will not use the hammer mill daily.
A Motor mixer
like the one in the Picture should
be acquired with an electric motor. The RPM’s
that the mortar mixer normally runs at for cement
mixes is too fast for our purposes (because mortar
is more liquid) and must be changed to work at
40-50 RPMs for the filter mix which is much
more dense and “sticky”.
The mixer will work from 6-8 hours a day.
If these cannot be found in the local market we
can provide plans for its construction (from the
RDI filter Project)
A large enough Kiln. Most all of the kilns used for the
filter production world wide are Mani
kilns which usually can load 40-60 filters at a time.
Most kilns are fired with wood but some have
been fired with oil (Thailand) and sawdust
(Ghana) The kiln will be used about 4 times a week for 8- 12 hours and requires
about 1500 bricks to
construct. Smaller kiln sizes can be use for prototypes but will increase the
costs of the filter.
Pyro metric cones
are required to help assure that the correct temperature is attained.
In some cases these cones must be either
imported or brought in by the sponsoring
organization. Three batteries of 3 cones each are placed in the kiln at
different heights. These will be used in all firings and a kiln firing chart
should be prepared. Thermo couples form part of
the pyro-meters that
should be used to control the rise of temperature
in the kiln. When purchases get two with their protective sieves. Both are used
in all the firings.
Pyro meter
is used to help manage the rise of
temperature in the kiln . When purchasing one
get one with two terminals and of the better brand
like FLUKE (it will last much longer) .
The pyrometer will be used in all the firings for
8-12 hours.
Enough shelf space to store 1000 filters which the
workshop will need in less than a month.
If budget permits steel shelving is preferred; make
sure that the placement and removal of the soft,
damp and freshly pressed filter can be carried out
with much care in a comfortable manner.
Used daily
Soaking tank and be a very large plastic tank or
one made from cement.
Large enough to place 30 to 50 filters in for a
period on no shorter than 4 hours for the
pre- filtration rate tests.
Carried out daily
Plastic faucets (spigots) as the one in the picture
last longer than the spring type. The threaded
part must be long enough to use 2 washers and a
placement nut .
Buying in bulk will reduce the price by more than
50%. Some countries have a local production of
faucets.
Five gallon Plastic Receptacles with silk screened
instructions on the front so they can be read easily
by all..
Note… the “normal” tops made for the 5 gallon
plastic receptacle will not fit once the filter is in
place. When buying plastic receptacles by bulk
assure that you can also get a top (usually form
another model) that will cover the filtering
element once installed.
Check to see if there is local production of this
product if not we are presently sourcing Chinese
made plastic receptacles and faucets..
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