SUPPLY, INSTALLATION, TESTING AND COMMISSIONING OF A SMALL-SCALE PLASTIC WASTE TO PAVING BLOCKS (CABROS) PRODUCTION LINE IN MOMBASA,KENYA Full Time NEW

1. BACKGROUND AND CONTEXT

The ChildFund intends to establish a small-scale production line for the conversion of post-consumer plastic waste into paving blocks (commonly known as cabros) for use in the construction sector in Kenya. The initiative aims to:

• Reduce plastic waste sent to landfills and the natural environment
• Promote circular economy solutions within the construction industry
• Produce durable, cost-effective, and climate-resilient paving blocks
• Support local employment and skills development

To achieve this, the ChildFund seeks to competitively procure a complete, modular plastic brick production line from qualified and experienced machine fabricators/suppliers based in Kenya.

2. OBJECTIVE OF THE TOR

The objective of this TOR is to invite technically compliant and financially competitive quotations for the design, manufacture/supply, installation, testing, commissioning, and initial training of a plastic waste to paving blocks production line with the following core machines:

1. Plastic crushing/shredding machine
2. Plastic melting/extrusion machine
3. Fume Extraction / Ventilation System at Extruder
4. Hydraulic paving block press with moulds
5. Cooling Bath / Water Cooling Cage

The production line shall be suitable for small-to-medium scale operations and capable of continuous daily production under Kenyan operating conditions.

3. SCOPE OF SUPPLY AND SERVICES

The supplier shall be responsible for:

• Detailed machine design and fabrication/supply
• Supply of all primary machines and auxiliary systems
• Installation and alignment of machines on site
• Testing and commissioning using locally available plastic waste
• Provision of moulds for standard paving blocks (cabros)
• Operator training and basic maintenance training
• Provision of operation & maintenance manuals
• After-sales technical support and warranty

4. CORE MACHINES AND SYSTEMS (MINIMUM REQUIREMENTS)

The production line shall, at a minimum, comprise the following core machines and systems, all of which shall be supplied, installed, tested, and commissioned as part of the base scope.

4.1 Plastic Crushing / Shredding Machine

Function: Size reduction of post-consumer plastic waste prior to melting.

Minimum Technical Requirements:

• Throughput capacity: ≥ 150 kg/hour
• Suitable plastics: LDPE, HDPE, PS,PPE,PET,PVC (supplier to specify exclusions)
• Feed system: Manual or hopper-fed
• Output size: ≤ 10–15 mm flakes
• Motor power: 10–20 kW (three-phase)
• Blades: Hardened alloy steel, replaceable
• Shaft type: Single or twin shaft (to be specified)
• Construction: Heavy-duty mild steel frame
• Safety: Emergency stop, blade enclosure, belt/gear guards

Deliverables: – Complete shredder unit – Electrical starter/control panel – Basic spare blades (recommended)

4.2 Plastic Melting / Extruder Machine

Function: Heating, melting, and conveying shredded plastic to the moulding stage.

Minimum Technical Requirements:

• Throughput capacity: ≥ 90 kg/hour
• Heating method: Electrical band heaters or electromagnetic heating
• Temperature control range: 180–350°C (adjustable)
• Screw diameter: ≥ 120 mm (or equivalent capacity)
• Screw material: Heat-treated alloy steel
• Barrel material: High-temperature resistant steel
• Motor power: 15–25 kW
• Control system: Digital temperature controllers
• Insulation: Thermal insulation to reduce heat loss

Deliverables: – Complete extruder/melting unit – Heating system and control cabinet – Start/stop control panel

4.3 Hydraulic Paving Block Press Machine

Function: Compression moulding of molten plastic into paving blocks.

Minimum Technical Requirements:

• Output: Minimum 4 paving blocks per press cycle
• Press type: Hydraulic
• Pressing force: ≥ 30–50 tons (supplier to specify)
• Cycle time: ≤ 5 minutes per press (including loading/unloading)
• Hydraulic motor power: 5–10 kW
• Control: Manual or semi-automatic

Mould Requirements:

• Mould material: Hardened steel or cast steel
• Standard cabro sizes compatible with Kenyan market (e.g. 200×100×60 mm or equivalent)
• Interlocking paving block profile
• Replaceable mould inserts preferred

4.4 Cooling Bath / Water Cooling Cage

Function: Rapid cooling and dimensional stabilization of hot paving blocks immediately after demoulding.

Minimum Technical Requirements:

• Internal dimensions: Approx. 2.0 m (L) × 1.5 m (W)
• Depth: ≥ 0.6 m
• Construction: Welded mild steel cage or tank
• Plate thickness: ≥ 3 mm mild steel
• Internal finish: Smooth, corrosion-resistant (painted or coated)
• Water capacity: Sufficient to fully submerge cabros
• Drainage: Bottom drain valve or outlet for water replacement
• Handling: Open-top design for manual loading/unloading
• Structural integrity: No deformation under thermal shock

4.5 Fume Extraction / Ventilation System at Extruder

Function: Removal of fumes and heat generated during plastic melting to ensure operator safety and regulatory compliance.

Minimum Technical Requirements:

• Localized extraction hood positioned above or near extruder barrel
• Ducting: Heat-resistant steel or flexible industrial ducting
• Extraction fan: Industrial-grade, sized for continuous operation
• Discharge: Safe exhaust to external environment
• Controls: Integrated on/off control with extruder operation
• Noise and vibration: Within acceptable industrial limits

5. PERFORMANCE REQUIREMENTS

• Machines must be capable of operating 8 hours/day continuously
• Designed for tropical conditions (dust, heat, power fluctuations)
• Easy maintenance with locally available consumables
• Robust construction suitable for workshop/yard environments

6. INSTALLATION, TESTING AND COMMISSIONING

The supplier shall:

• Install and align all machines on prepared concrete floors
• Conduct dry and loaded test runs
• Demonstrate production of acceptable quality paving blocks
• Hand over a fully functional production line

7. TRAINING AND CAPACITY BUILDING

Minimum training requirements:

• Machine operation (minimum 3 operators)
• Routine maintenance and troubleshooting
• Safety procedures

Training duration: Minimum 3–5 working days

8. WARRANTY AND AFTER-SALES SUPPORT

• Minimum warranty: 12 months on machines (excluding wear parts)
• Availability of local technical support
• Lead time for spare parts not exceeding 14 days

Suppliers shall clearly state: – Warranty coverage – Exclusions – Post-warranty support options

9. SUPPLIER ELIGIBILITY REQUIREMENTS

Suppliers must provide:

• Company profile and registration documents
• Evidence of similar machines supplied or fabricated
• At least two references of comparable installations
• Technical brochures/drawings of proposed machines

10. QUOTATION SUBMISSION REQUIREMENTS

Quotations shall include:

• Itemized cost breakdown per machine
• Cost of installation and commissioning
• Delivery timeline
• Payment terms
• Validity period of quotation

Prices shall be quoted in KES, exclusive and inclusive of taxes clearly indicated.

11. EVALUATION CRITERIA

Proposals will be evaluated based on:

• Technical compliance with specifications (mandatory)
• Proven experience and references
• After-sales support and warranty
• Cost competitiveness
• Delivery and installation timeline

12. EXPECTED DELIVERY TIMELINE

• Fabrication/supply: 4–8 weeks from contract award
• Installation & commissioning: 1–2 weeks

13. RIGHT TO ACCEPT OR REJECT

The Client reserves the right to accept or reject any quotation and is not bound to accept the lowest-priced offer. Due to the high volume of applications received, we regret that only shortlisted candidates will be contacted.