Static Adaptor: The Food Cost

Brick-making is a labour-intensive process, but the method of production can significantly impact efficiency and worker strain. The Doubell Jumbo MK3, when mounted on a static adaptor, changes the way blocks are produced. Instead of being laid directly onto a concrete slab (as with an egg-layer machine), the blocks are formed on production boards. This setup allows for good stock brick and paving production, but when used for M6 blocks, the weight quickly becomes a challenge.

Workers lifting the block boards burn over 470 kcal (calories) per hour.

The Weight of Productivity

Each cycle, the machine produces seven M6 blocks, with each block weighing 12.5kg. That means, in every minute of maximum efficiency, two workers need to lift and transport 87.5kg of freshly moulded blocks. These blocks are lifted off the roller conveyor, then carried 15 metres to be set down. Over an hour, this equates to a staggering 5,250kg—over five metric tonnes of lifting and carrying—at a considerable distance.

Energy Expenditure Breakdown

To put this into perspective, let's calculate the calories burned by two workers handling these blocks for an hour. We can approximate two separate factors:

1. Lifting: Using an estimated energy cost of 0.12 kcal per kg lifted, each worker lifting a total of 2,625kg per hour (half of the 5,250kg) would burn around 315 kcal per hour.

   
   

2. Carrying: Walking with a load over 15 metres also takes energy. A rough estimate is 0.002 kcal per kg per metre. For 87.5kg carried 15m each cycle, that’s 2.625 kcal per cycle. Over 60 cycles in an hour, that adds another 157.5 kcal per worker.

Adding these two factors together, each worker burns roughly 472.5 kcal per hour. Together, that’s 945 kcal per hour for two workers.

Fueling the Workforce

Over a full 8-hour shift, one worker would burn about 3,780 kcal—significantly more than the daily recommended intake for the average adult. In a South African context, that's equivalent to any one of these daily meal intakes:

• 6 big servings of chicken and rice

• 7 plates of pap and wors

• 4 large bunny chows

• 24 medium-sized potatoes

• 5 large fish and chips

In other words, day-long production at maximum efficiency demands a massive amount of energy—fuel that must be replaced to keep workers healthy and productive. Realistically, this level of continual heavy lifting and walking is difficult to sustain, so production rates often slow down or require additional manpower to manage the workload. Offset this by rotating workers throughout the day and consider offering calorie-dense food to the workers during the day.

Choosing the Right Method

When it comes to making blocks, the sheer physical toll means using an egg-layer machine is the better choice. This method eliminates unnecessary lifting, allowing blocks to be produced directly on the concrete slab. However, if your focus is on paving or stock bricks, the static adaptor setup can be a little more viable if your production yard doesn't have the facilities to accommodate the large concrete slab needed otherwise.

At the end of the day, choosing the right equipment isn’t just about production numbers—it’s about efficiency, labour, and sustainability. The Doubell Jumbo MK3 gives you the flexibility to make the best decision for your operation and can be used either way.

One thing is for sure, you've probably never thought about the food costs of brick-making quite like this!

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