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Production - Low Smoke Chulha



What you need for production

For making the stove, there is a need for a work space that is large enough to have a curing tank for the stove pieces, space to lay out the cured pieces and dry them, and a space to store raw materials, stove parts and tools.

The tools required to make the chulha are basic masonry tools and basic hand tools like pliers, hammers, screwdrivers, GI wire, chisel, etc.

Apart from this there should be an adequate amount of raw materials like cement, stone grit, wire mesh, and MS rods to make the required number of stoves.

Certain parts like the grate, chimney and chimney caps need to be ordered from suppliers as well.

How to cast the chulha

Casting Preparation

Chulha Production 002.jpg Chulha Production 001.jpg Chulha Production 003.jpg
Mixture of cement and stone grit is prepared with water to a semi dry mixture Molds are applied with oil as a releasing agent. Concrete mixture is filled in the molds and compacted with a ramming stick.


Chulha Casting.jpg Chulha Production 004.jpg Casting Brim.jpg
The process is repeated till the mold is filled The filled mold is smoothened for good finishing Molds are filled till the brim.

Cast Parts.jpg Cast parts are kept in the mold for 3-8 hours, depending on the mixture consistency and weather.

Cast Releasing

Chulha Production 005.jpg Unbolting.jpg Chulha Production 008.jpg
Filled molds are inverted on flat surfaces and left for 30 minutes Unbolt and carefully release the cast parts. Mold parts are separated

Cast Parts Curing

Chulha Production 009.jpg Chulha Production 010.jpg Cured Cast Parts.jpg
Cast parts kept for drying Cast parts are cured under wet jute in areas without good sunlight Cast parts are cured under water in dry areas

How to finish the parts

When the cast parts have been released from the mold, excess cement should be removed with the help of a chisel or rasp. Otherwise this can create a problem when assembling the parts during installation. If wanted, the stove parts can be painted using exterior quality cement paint (e.g. brick red/terracotta) which is available in powder form in most hardware stores.

Excess cement should be taken off the parts with the help of a rasp or chisel as shown in image below

Excess cement.jpg

Mold maintenance

When releasing the cast pieces from the mold, do not hit the mold pieces or bang them against the floor.

After the casting is done the mold should be wiped clean and made free of any cement that might still be sticking to it. Wipe the mold with a lightly oiled cloth and store the pieces away from direct sunlight. Clean the nuts and bolts used to hold the mold pieces together thoroughly, and store them in a container with some oil to prevent rusting.

Production FAQs

Tracking production

Tracking the number of stoves produced, amount of time taken for curing the stoves, dates when orders were placed and executed, etc. can be useful for build a good case for stove funding. This information can also be a valuable resource for stakeholders and can be included in this site as part of the Low Smoke Chulha knowledge base and case studies.

Production kit

The Production Kit consists of all documents related to Production

If you want to share additional resources on this topic, please edit this wiki page.