Production capabilities · Rajkot works
Refractory Manufacturing & Production Capabilities
firebrickssource.com is the export brand of Agochar Tech LLP — a refractory manufacturer producing pressed bricks, special shapes and custom precast pieces from our Rajkot, Gujarat works. This page describes the route honestly, step by step, so technical buyers can assess our quality system against their plant's needs.
Scope of manufacture
From raw mineral to packed pallet — in one works
Our manufacturing scope covers the full range of refractory brick families: fireclay, high-alumina, insulating fire bricks, basic refractories (magnesia, magnesia-carbon, dolomite), acid-resistant grades, and specialty refractories. We also produce non-standard shapes — wedges, arches, skews, tap-hole blocks, burner-throats — pressed or precast as the geometry demands.
The works is configured for both volume production runs (containerised lots of 20–40 MT pressed standards) and small-batch custom development (sample-to-prototype-to-production over 4–6 weeks). Every batch — standard or custom — runs through the same quality system: raw material check, dry-mix verification, pressed green-density check, fired property test, dimensional inspection and visual sort before packing. Because we are the manufacturer rather than a trading aggregator, the chemistry quoted on the datasheet is the chemistry produced on the floor, and any deviation is traceable to a specific batch, kiln car and operator.
The manufacturing route
Our manufacturing process
Five sequential stages — every batch, every grade.
Raw material selection
Calcined bauxite, magnesia, fireclay, alumina and silica are sourced from established Indian mines, supplemented by selected imports (Chinese DBM, Brazilian bauxite) where chemistry demands. Every consignment is XRF-checked on arrival before it joins the silo.
Mix design
Matrix grain sizing is set per grade — coarse, medium and fines proportioned to deliver target bulk density and apparent porosity. Batch composition and fixed chemistry are locked to BIS or to the customer's written specification, with binder and additive levels calibrated to the press characteristics.
Pressing
Hydraulic friction and toggle presses up to 1000 T form the green brick under controlled pressure cycles. Pressed pieces are released to a specific dimensional tolerance of ±2 mm; green density is sampled at frequency to confirm the press is stable across the run.
Firing
Tunnel kiln firing up to 1600 °C — temperature profile per zone monitored by calibrated thermocouples, with controlled atmosphere where the chemistry requires it (e.g. reducing zone for carbon-bonded grades). Each kiln car is logged with charge date, batch ID and firing curve.
QC & dispatch
Every batch is tested for apparent porosity (AP), bulk density (BD), cold crushing strength (CCS), refractoriness-under-load (RUL) and permanent linear change (PLC). Dimensional and visual QC follows; sorted bricks are shrink-wrapped on pallets or crated for container stuffing.
What we make
Manufacturing capabilities
Three production tracks running in parallel.
Track 01
Standard pressed bricks
Fireclay, high-alumina (40 % to 90 % Al₂O₃), insulating IFB (K-23, K-26, K-28, K-30), silica and acid-resistant — produced to BIS and ASTM dimensional ranges in volumes from a single pallet up to full 40-foot container.
Track 02
Special shapes
Wedges, arches, skews, key bricks, burner blocks, tap-hole and slag-line shapes pressed against bespoke dies. Drawings welcome — we tool up where the order volume justifies, and machine from larger green pieces for one-off jobs.
Track 03
Custom precast
Pre-cast and pre-fired shapes for ladle linings, burner throats, port-necks and similar high-wear positions. Castable formulation matched to thermal cycle, anchors specified per drawing, dimensional and chemistry sign-off before dispatch.
How this connects
Quality system & documentation
The manufacturing route above feeds directly into our published quality system. Every product has a corresponding datasheet with tested properties, every export consignment carries a mill test certificate, and every customer-specified deviation is recorded against batch and kiln-car ID. The result is a fully traceable refractory supply chain — from Indian mine to your plant's furnace door.