Fly Ash Bricks Making Machine at Nishat Power Ltd Lahore – Turning 35 Ton Daily Waste into 10,000 Bricks per Day (SSM 15 Plant)

Introduction – The Environmental Challenge at Nishat Power Ltd

Nishat Power Limited, a subsidiary of Nishat Group – one of Pakistan’s largest industrial conglomerates – operates a coal‑fired power plant in Lahore. Like all coal‑based thermal plants, it produces a massive amount of fly ash as a byproduct. Every single day, the plant generated 35 tons of fly ash – a fine, powdery waste that posed a serious environmental threat.

Dumping fly ash in open land contaminates soil and groundwater. Airborne fly ash particles cause respiratory diseases. The Environmental Protection Agency (EPA) repeatedly warned Nishat Power about fines and potential shutdowns. The company needed a sustainable, profitable solution – urgently.

That’s when they turned to Silver Steel Mills.

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The Problem – 35 Tons of Fly Ash Daily: A Waste or a Resource?

Before 2017, Nishat Power Ltd spent significant resources on fly ash disposal:

• Landfill costs – Hiring trucks to haul ash to designated dumping sites.

• EPA fines – Regular penalties for exceeding allowable emission/disposal limits.

• Negative public image – Local communities complained about dust and health hazards.

But fly ash is not just waste. It contains silica, alumina, and calcium – exactly the same minerals found in cement. When mixed with cement and sand, it can produce high‑strength bricks, pavers, and blocks. The challenge was to find a technology that could convert this waste into a valuable product at scale.

 

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The Solution – Silver Steel Mills Steps In

Nishat Group’s engineering team approached Silver Steel Mills in early 2017. After detailed discussions, site visits, and raw material analysis, Silver Steel Mills proposed:

• Install an SSM 15 block making plant – configured specifically for fly ash bricks.

• Run trials to optimise the mix design (fly ash : cement : sand ratio).

• Target a minimum compressive strength of 2000 PSI – suitable for non‑load‑bearing walls and partition walls.

• Achieve daily production of 10,000 fly ash bricks (plus 15,000 tuff tiles if needed).

The goal was not just waste disposal, but waste‑to‑wealth – turning an environmental liability into a profit centre.

 

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The Trials – Finding the Perfect Mix

Silver Steel Mills’ technical team conducted over 50 trial batches at our in‑house lab and later on‑site at Nishat Power. Variables tested included:

• Fly ash to cement ratio (from 70:30 to 40:60)

• Sand/fly ash proportion

• Water content

• Curing time (7, 14, 21 days)

Final optimised mix (for 2000+ PSI bricks):

After 14 days of curing, the bricks consistently achieved 2200–2500 PSI – exceeding the target.

 

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The Machine – SSM 15 Fly Ash Brick Plant (Installed at Nishat Power Ltd, Lahore)

The plant installed at Nishat Power Ltd in 2018 is an SSM 15 single‑portion block machine, specifically configured for fly ash bricks. It includes:

The entire line is semi‑automatic – one operator plus three labourers can run it comfortably.

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Daily Production Reality – 10,000 Fly Ash Bricks & 15,000 Tuff Tiles

The plant operates in two shifts (16 hours/day). With the fly ash brick mould, output is:

By changing the mould to a paver/tuff tile mould, the same machine produces 15,000 interlocking tiles per day. This flexibility allows Nishat Power to switch production based on market demand.

“We never imagined that our waste fly ash could become a steady source of revenue. The SSM 15 plant from Silver Steel Mills has been running flawlessly for over five years.”
– Plant Manager, Nishat Power Ltd, Lahore

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Multi‑Product Capability – One Machine, Endless Designs

The SSM 15 machine at Nishat Power is equipped with multiple moulds, enabling production of:

Each mould is precision‑made by Silver Steel Mills from imported steel (wear‑resistant, long life). Changing a mould takes less than 30 minutes.

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Environmental & Financial Impact – From Cost to Profit

Environmental Benefits

• 35 tons of fly ash are no longer dumped in landfills. Approximately 15‑18 tons are consumed daily in brick production (the remainder is sold to cement plants).

• Air quality around the power plant improved drastically – no more fly ash clouds during dry weather.

• EPA compliance – Nishat Power now meets all environmental regulations and has received positive recognition from the Punjab Environment Department.

Financial Benefits

Before the SSM 15 plant, Nishat Power spent:

• Disposal cost : Rs 8,000 per ton × 35 tons = Rs 2,80,000 per day.

• Annual disposal cost : approx. Rs 10 crore.

After the plant:

Even after deducting raw material (cement, sand, electricity, labour), the net margin exceeds Rs 30 lakh per month.

“We turned our biggest environmental headache into a business that now contributes to our bottom line. Silver Steel Mills made it possible.”
– Finance Director, Nishat Power Ltd

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Silver Steel Mills’ Role – Complete Turnkey Support

From the initial consultation in 2017 to the plant’s commissioning in 2018 and ongoing support, Silver Steel Mills provided:

1. Feasibility study – Analysed fly ash samples, recommended mix designs.

2. Custom machine design – Adapted SSM 15 for high‑fly‑ash content mixes.

3. Manufacturing – Fabricated the machine, moulds, and accessories at our Gujranwala factory.

4. Installation & commissioning – Our engineers erected the plant at Nishat Power’s site in 15 days.

5. Operator training – Trained their team in batch mixing, mould changing, and maintenance.

6. After‑sales service – 3 months free support, plus rapid supply of spare parts (bearings, seals, blades).

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Long‑Term Performance – Still Running Strong (2025 Update)

The SSM 15 plant installed at Nishat Power Ltd in 2018 continues to produce fly ash bricks and pavers to this day – over seven years of reliable operation. Regular maintenance (oil changes, blade replacement, bolt tightening) has kept downtime minimal. Silver Steel Mills’ local spare parts availability ensures that any wear part can be replaced within days, not weeks.

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Conclusion – A Benchmark Project for Pakistan’s Power Sector

The fly ash bricks project at Nishat Power Ltd, Lahore, is a shining example of how industrial waste can be transformed into a valuable resource. The SSM 15 block making machine from Silver Steel Mills not only solved a critical environmental problem but also created a new profit centre for one of Pakistan’s largest conglomerates.

 

Pakistan ke industrial sector mein coal power plants aur manufacturing units ke liye sab se bada challenge toxic waste management hai. Nishat Power Ltd Lahore ke thermal power operations ke nateejay mein rozana 35 Ton Fly Ash (koiley ki raakh) bachti thi, jo hawa aur mitti ko aaluda (pollute) kar rahi thi aur environment ke liye ek nihayat bad-asur carbon footprint chor rahi thi.

Is environmental aur waste management challenge ko ek profitable business model mein tabdeel karne ke liye Nishat Group ne Pakistan ke sab se bade brick machinery manufacturer Silver Steel Mills (SSM) se rabta kiya. Silver Steel Mills ne nihayat kamyab trial aur lab testing ke baad, Nishat Power Ltd ke plant par hi unki toxic fly ash waste ko aala tareen tameerati material (construction bricks) mein tabdeel karne ke liye SSM 15 Fully Automatic Plant kamyabi se install kiya.

Yeh industrial portfolio article aapko batayegi ke kaise ek heavy industrial unit ne SSM ki engineering technology ke zariye carbon waste ko Zero Waste Green Development aur Money-Making Asset mein badla.

The Challenge: 35 Ton Daily Fly Ash Waste Aur Environmental Hazards

Nishat Power Ltd Lahore ke paas rozana 35 ton fly ash jama ho rahi thi. Is raakh ko landfill sites par dump karna na sirf mahnga sauda tha balki local environmental laws ke mutabiq yeh hawa ke miyaar (AQI) aur underground paani ko bhi nuksan pahocha sakti thi.

• The Problem: 35 Ton daily hazardous fly ash waste.

• The Solution Required: Ek aisi industrial machinery jo is baray paimane par paida hone wali raakh ko bind karke solid construction materials mein convert kar sake.

• The Partnership: Silver Steel Mills ne Nishat Group ke chemical aur engineering parameters ke mutabiq concrete aur fly ash ka perfect ratio formula design kiya aur trial test run kiya.

The Turning Point: 2000 PSI High-Strength Bricks Ka Kamyab Trial

Silver Steel Mills ne Nishat Power Ltd ke trial run mein fly ash, cement aur sand ka behtareen mixture taiyar kiya. SSM 15 machine ki heavy under-bed compaction aur high hydraulic pressure control systems ki badolat jo bricks taiyar huween, unki compressive strength 2000 PSI (Pounds per Square Inch) haasil hui.

• Result: Yeh 2000 PSI fly ash bricks standard laal mitti ki eenton (clay bricks) se kahin zyada mazboot, perfectly square, aur water-resistant thien.

• Economic Benefit: Nishat Group ne is lagat se na sirf waste disposal ki fees bachayi, balki unhone isi waste material se commercial-grade eentein bana kar unhe market mein supply kiya aur apni society development mein use karke lakhon rupe ka profit (money-making asset) generate kiya.

Technical Specifications: SSM 15 Plant Capabilities

Nishat Power Ltd Lahore ke is green project ke liye lagaya gaya SSM 15 Plant aik mukammal heavy-duty machinery setup hai jo automatic pallet aur single trolley system par chalta hai. Is unit mein darj-zeel automatic systems integrate kiye gaye hain:

1. High-Performance Mixing & Conveying Unit

• Heavy-Duty Mixer Machine: Fly ash, aggregates aur water ke dense mixture ko short time mein chemical bonds banane ke liye aala capacity ka core mixer lagaya gaya hai.

• Automatic Conveyor Belt: Mixer se chemicalized concrete material ko bina kisi human touch ke machine ke main feed hopper tak shift karne ke liye specialized rubber conveyor belt lagayi gayi hai.

2. Multi-Mould Versatility (Premium Geometric Designs)

Nishat Power Ltd ke is plant par interchangeable die-moulds lagaye gaye hain, jo premium wooden pallets (650mm × 750mm × 28mm) par darj-zeel products nikaal rahe hain:

• Tuff Tiles & Pavers: Uniblock, H-Section, aur Cobble designs wale modern interlocking pavers.

• Blocks: Heavy-duty load-bearing Solid Blocks aur light-weight Insulation Hollow Blocks.

• Infrastructure Items: Road safety aur parking boundary ke liye standard Curbstones.

Production Outputs & Matrix

SSM 15 plant kam horsepower (63 HP total capacity usage) mein high-scale output dainay ke liye behtareen system hai:

• Fly Ash Bricks Production: Rozana 10,000 high-strength fly ash bricks ki actual production.

• Tuff Tiles / Pavers Production: Agar interlocking pavers banaye jayen toh yeh plant rozana 15,000 daily rectangle/designer pavers ka output deta hai.

• Molding Speed: Is automatic single portion machine ka molding cycle sirf 25 se 35 seconds hai, jo fast stacking aur quick curing yard shifting ko ensure karta hai.

Data-Driven Technical Parameters (SSM 15 Plant)

Google search algorithms real industrial data ko maximum authority aur ranking dete hain. Neeche Nishat Power Ltd Lahore site par maujood plant ka technical profile hai:

Turnkey Trust: Erection, Training, and Validation By SSM

Silver Steel Mills ki expert engineering team ne Nishat Power Ltd Lahore ke site par khud maujood reh kar is plant ki full mechanical installation aur electronic panel calibration ki. Hamare trained operators ne fly ash mass processing ke liye Nishat Group ke site labor aur engineers ko heavy compression timing, vibration matrix control (20 HP motors), aur hydraulic pump efficiency valve set karne ki mukammal training di.

Yeh project is baat ka wazeh saboot hai ke Silver Steel Mills na sirf Pakistan mein construction machinery manufacturing ka leader hai, balki hum bade industrial groups ko Eco-Friendly Green Engineering Solutions faraham karne mein bhi sab se aage hain.

Kya Aap Ka Industrial Unit Bhi Waste Management Ka Shikar Hai?

Agar aap steel mills, power plants, chemical industries, ya housing societies ke developer hain aur apne raw materials ya waste ko building blocks, tuff tiles aur curbstones mein tabdeel karke unhe commercialize karna chahte hain, toh aaj hi Silver Steel Mills se rabta karein