**3. Fabricating the hydraulic press machine**

It became expedient to fabricate a hydraulic press machine to facilitate the shaping of the ceramic water filters by the press cast method. This is the most suitable method of forming the ceramic filters because the mix is highly non-plastic and hence cannot withstand other ceramic forming techniques besides slip casting which is not very feasible at the desired dimensions of ceramic water filters.

For this study to ensure the economic feasibility, sustainability and hence the scalability of the manufacture of the ceramic water filter press in Nigeria, it was important to set a cost limit for fabricating the press; and this was set at 350000 naira (approximately \$1000). This was done considering the issue of low access to capital for start-ups, which is common in the country. This study, however, intends to encourage local potters to venture into the production of ceramic water filters by alleviating some of the cost-related challenges of setting up a filter production unit.

The use of a fully manual system was also not desirable because it will increase

**Position of moulds Mould**

Inverted; female above

Upright; removable female mould positioned below

Inverted; male attached to extendable

surface

*Features of the various types of ceramic water filter presses reviewed in this study.*

**material**

— Plastic — Hand/

Aluminium bowls

Nylon Hand-

— Crank-

Upright; male above Metal — Automated

Upright; male above — Hand-

Upright; male above Aluminium Hand-

**Mould moving mechanism**

operated screw system

operated crank system

operated pulley system

operated lever

**Mode of operation**

manual

hydraulic car jack

30-ton hydraulic jack

20-ton hydraulic jack

8-ton hydraulic jack

hydraulic system

20-ton hydraulic jack

— 2-ton

A lever was preferred for the lowering and lifting of the moulds, to the crank (as in the portable PfP press [15]) and the screw (as in [11]) because it makes the

The moulds were preferred fitted to the press frame to overcome the challenge of misalignment of moulds, possible in removable moulds, and as well, the inconvenience and health hazard of lifting heavy moulds in each process of filter pressing

Based on these specific requirements, the Potters Without Borders (PWB) ceramic water filter press design was adapted for manufacture in Akure, Nigeria. The PWB ceramic water filter press is said to have several benefits with respect to design and operation. Its high-strength (20-ton) design allows the pressing of flatbottom filters [10] while creating stability and preventing deformation in the shaped filters. The flat-bottom filters are said to provide more surface area and therefore higher flow rates [10]. Some of the adjustments made to the PWB filter press design, included the replacement of the hydraulic car jack with a locally fabricated industrial hydraulic jack, as well as the design and manufacture of the press mould to fit locally available wide-rimmed plastic containers to meet the

the time taken to press one filter; therefore a hydraulic press mechanism was

filter pressing more cumbersome and time consuming;

(as in the portable PfP press [15]).

water needs in larger households.

desired;

**238**

**Table 1.**

**Ref. no**

14 Hand press mould

*Design and Manufacturing*

10 Low-cost filter press

11 MEC India manufactured press

15 PfP portable press

15 Mani press Round

12 RDI-C Flat

10 PWB Flat

**Description Type of**

**filters**

Ceramic filter component

Round bottom

Flat bottom

Flat bottom

bottom

bottom

bottom

All the materials and manpower used in fabricating this press were sourced from within the country. The hydraulic press machine typically consists of two parts; the moulds and the frame which holds the moulds and the hydraulic component. The procedures engaged in the making of both parts are discussed further.
