Global Swadeshi


We have demonstrated a production rate of 4 bricks per minute in our first test production runs.

We ran the CEB machine with 3 people, low-medium throttle on LifeTrac, about 12 gallon per minute hydraulic flow, a hydraulic pressure of 2200 psi, and a force of about 20 tons on the bricks. The hopper cylinder was adjusted with a needle valve to reduce its speed. We pressed 53 bricks in a sample 13.5 minute run.
These are amazing results – bricks coming out of the machine as fast as we could handle them. For soil preparation, we roto-tilled a small part of our earth pile with the LifeTrac rototiller, followed by a small, walk-behind 6 hp rototiller – to break the soil into a flowing powder. Thereafter, I ran the CEB controls, Nick loaded the hopper, and Bob stacked the bricks as fast as he could on a pallet. Nick was shoveling soil into 5 gallon buckets as fast as he could from the prepared soil. He then poured 5 gallon buckets into the hopper.Learnings and challenges: The critical step was pulverizing the soil to about 1/4 inch pieces. We mixed in about 5% sand into the soil, which helped make the soil flow better. If we used soil with particles larger than 1/4”, distinct grain boundaries were forming – there were fault lines in the bricks. Once we went to 1/4” particles – the bricks got larger and stronger. There was less air space in the soil mix.

The limiting step in the sample run was bridging of soil in the hopper. I had to poke the soil by hand in the hopper – for every brick – so it would fill the compression chamber evenly. To address this, we will operate the machine at a slight angle, or possibly change the slide angle within the hopper. We concluded that with this simple improvement, we could get to 6 bricks per minute. We would then be able to produce about 3 thousand bricks in a day – or enough bricks for our 1200 square foot facility in under three 8-hour days of pressing. This means going through our 20 tons of soil per day.

We believe this is achievable with a minimum 4 person team. One person runs the controls, one person loads the hopper, one person stacks bricks, and the fourth person goes through the soil pile continuously, pulverizing the soil to the required size with a walk-behind rototiller. Come down to Factor e Farm – we’ll be pressing in this coming week.

Here’s the good part. If we achieve the 6 brick per minute rate, that would make The Liberator the highest-performance CEB machine in the world. The highest production rate that we know of is 5 bricks per minute from a machine that is 5 times higher in cost. We are talking of entry-level, manually controlled, one-brick-at-a-time, hydraulically-driven CEB machine types. We actually think we can get to 8 bricks per minute with the same, manual machine. Hmmm.

We think that we are on the way to demonstrating the full promise of open source economics– the promise of highest performance, lowest cost, lifetime-design products. Period. If you want to see this machine go into production– donate here. Be a part of changing the world. We are operating entirely on volunteer donations.

Categories: Compressed Earth Block Press, Industrial Swadeshi, Open Source Economic Development

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Friends, the latest developments on the Solar Turbine project, outside of the documentation clips in Factor e Live 6 and Factor e Live 7, are ambitious. We are presently leaning to mirrors and a modern, high-recirculation ratio uniflow steam engine as the heat engine of choice. The long-term motivation for the latter is to not rely on industrial detritus – such as some turbine from another application or non-modern steam engine from other suppliers. The long-term supply of the former is uncertain, and performance and cost of the latter are in question.

The results of the Solar Turbine convergence are promising. We got hands-on insight into what may or may not work – and that is what informs our direction. We still have a promise on the whiteboard – of $3/W as Milestone 1 with a 5% efficient heat engine – and $1.5/W as Milestone 2 with a 10% efficient heat engine. Talk to me or join the Solar Turbine google group if you are interested in understanding these cost predictions deeply.

Here’s the good part. The above predictions rely on off-shelf mirrors at $2/sq foot. In the long term, we have to replace this cost, which now constitutes over 50% of the cost in our design, with industrial swadeshi mirrors. I predict a mirror cost of 50 cents per square foot in this scenario. Critics, of course, say that we can never beat commodity production costs for mirrors – but I think open source production can, given that sand or glass cullet feedstock is readily available – and the commodity production process is fraught with inefficiencies of global supply chains. Plus, mirror production is old technology – we’re not talking about rocket science.

In short, we will pursue mirror fabrication and high-recirculation ratio uniflow steam engine fabrication in house. If you know anything about these topics or know people that do – help us with the engineering. Here we have great opportunity for open source engineering – on a topic of huge relevance to societal well-being. Concentrator solar power is in vogue – read the commentary in the next post.

Categories: Industrial Swadeshi, Solar Turbine

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Stuart, Elliot, and I are here on the Solar Turbine:

For the next two weeks we will iron out the details – right now it looks like a set of 40 foot long, 2-foot wide slats – 4 of these in total – with 48x solar concentration. Cost is about $750 for this phase, including collector.

Regarding the CEB press, you’ve seen the open source tractor. That is on hold until September 3, when the Solar Turbine project Phase 1 Prototype ends. We’re way behind schedule on CEB. We need help. Unless there are others who can help, by physically coming here, camping out, and turning wrenches – it is slow progress.

This calls for a direct invitation in the true nature of open source collaboration – so if you know of anyone who can help, let us know. Requirements of candidates are:

  • Strong vision for a better world
  • Can turn a wrench
  • Have spare time to commit
  • Be able to cooperate

Come and visit, be part of nothing short of creating history. The CEB, tractor, and solar turbine are all serious products – in my opinion the 3 most important products in the Global Village Construction Set. We will take these proven concepts to full practical viability and production – as they have transformative potential.

Categories: Challenges, Collaborators, Industrial Swadeshi

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There is a significant set of open source technologies available for rapid prototyping in small workshops. By combining 3D printing with low-cost metal casting, and following with machining using a computer controlled Multimachine, the capacity arises to make rapid prototypes and products from plastic and metal. This still does not address the feedstocks used, but it is a practical step towards the post-centralist, participatory, distributive economy with industrial swadeshi on a regional scale.

  • RepRap – open source 3D Printer – has just achieved self-replication. In itself, this is a rapid prototyper for objects in plastic.
  • Small-scale metal casting technology is readily available for backyard-scale metal casting, such as the melting of hubcaps in this picture – using free waste vegetable or motor oil: (source)
  • In particular, a waste oil burner such as the Babington burner may be utilized as the heat source.
  • Multimachine – an open source multipurpose machining tool is available for milling, drilling, lathing, metal forming, and other applications.

The interesting part is that the budget is $500 for RepRap, $200 for the casting equipment, and $1500 for a Multimachine with CNC control added. Using available knowhow, this can be put together in a small workshop for a total of about $2200 – for full, LinuxCNC computer controlled rapid fabrication in plastic and metal. Designs may be downloaded from the internet, and local production can take place based on global design.

This rapid fabrication package is one of our near-term (one year) goals. The research project in this area involves the fabrication and integration of the individual components as described. Factor e Farm is willing to provide materials funding for students interested in taking this on as a development project – please contact us if you are an engineering or independent student, or if you know somebody who is qualified to take on this project.

Such a project is interesting from the standpoint of localized production in the context of the global economy – for creating significant wealth in local economies. This is what we call industrial swadeshi. For example, I see this as the key to casting and fabricating low-cost steam engines ($300 for 5 hp) for the Solar Turbine – as one example of Gandhi’s mass production philosophy.

Categories: Digital Fabrication, Flexible Fabrication, Global Village Construction Set, Industrial Swadeshi, Open Engineering

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It has taken me a while to allow my experiences and inspirations from this weekend at Factor E to gestate, to ferment into tangible thoughts that I can easily disseminate to readers. Being lucky enough to sit down with Brittany and Marcin and talk face to face about what people are dealing with in this world, what we can do, and putting plans into action that can move to empower us all to have more control over our lives, has been a remarkably rewarding experience. We jokingly talked about the concept of “sitting-on-ass” (a reference to the movie Idiocracy), and how helpless many of us tend to feel, sitting around on our computers using grid power, posting blogs about how we can change the world as we often actively and knowingly perpetuate the status quo to our own guilt and disdain. My fellow sustainability junkies and myself know this feeling all too well, yet getting off the grid, if only for days at a time, and more importantly living among those who live for Global Swadeshi is more than enough to convince me that what you and I work for is possible and that we really can do something about it.

So, before I get so much into what we talked about over the weekend, I’ll fill everyone in on what it was like to experience daily life on Factor E. I got in late at night, and thanks to the generosity of Mrs. Crowther was able to be guided to the farm (it’s a bit off the map, get directions when you go!). And just in the first night I was overwhelmed by what a different world I had been catapulted into: reading Ishmael (Daniel Quinn) by a compact flourescent bulb run on off-grid power, in a cordwood house, replenishing my thirst with barrel collected rainwater (the well is nearly done for the wary), and immediately I was engulfed with an abundance of generosity and hospitality by the folks there. Outside I smelled the fresh, cool night air, free of the stench of exhaust fumes and the noise of the city.


The next morning I awoke to the sound of roosters crowing and chicks tittering and goats braying (is that what its called?) and Brittany letting the ducks out of their nest. I enthusiastically took to the garden with her, pulling unwanted plants (notice how I didn’t call them “weeds”, more about wild plants later), and feeling much better than when I do the same at my landscaping job, where I work in sterile, chemicalized, “aesthetic” beds. From the garden, while I was there, we ate broccoli, green onions and perennial onions, garlic, and various other foods.

Brittany and I, the next day, would find ourselves going out to the reservoir (in biking distance!) and encountering an abundance of wild fruit… among the wild grape vines and flowering blackberry brambles, the wild strawberries were delicious and ripe for the picking (we would eventually make some yummy jam thats been a hit back here in Columbia).

While out there we discussed the concept (and reality) of wild food forests, and how many wild plants on the Panamerican continent there are that have been selected for over thousands and thousands of years by indigenous peoples, carefully and with a profound knowledge of the ecosystems and bioregion so nuanced that it would probably escape some plant biologists. This knowledge of wild plant propagation and food forest management had been passed down through multitudes of generations through folklore and through experience in the field. They had encouraged these plants to be self managed, adaptive, resilient and fruitful, and in such a manner as to prevent invasiveness. And, as she pointed out, on a higher level, these humans were entrenched in the environment, such that even the animals around them were selecting for these plants as well, and these plants evolved to spread their seeds through multitudinous means. The implications of this kind of resource management are huge and point to some of the fundamental underlying principles of permaculture. The potential for ecological sensibility, sustainability, and abundance is obvious. Not to dis more euro-traditional sustainable agriculturalists who use less biomimicry, and more row cropping techniques (though i suggest intercropping, agroforestry and wise encouragement of wild influence), as these techniques seem to work well enough. However, time will tell which techniques work better in different situations and for different uses, though I’ve got my wild berries bet on permaculture. The experience of wild food, for someone who was raised in a suburb in the ‘rustbelt’, is transcendental to say the least.

It is impressive what insight Brittany has been developing with her approach to flora and fauna, how she is learning by written knowledge and field experience how to break down many of the preconceptions western society has about food and medicine and the properties of life in this world. Oftentimes her perspective is similar to that of those we learned about in my Anthropology of Food class at the University of Akron, wherein the life that makes up the environment we live in becomes not something to exploit or harvest so much as something to be a part of, enmeshed in. Where we are to interact with it on a moment by moment basis, and what we put into our bodies transcends mere applications of nutrition and science but nourishes the mind, the body, the soul and becomes something to bring people together and connect us on the most nuanced levels to the world we are unavoidably a part of. Folk knowledge about wild food, wild medicinal plants and how to positively and sensibly interact with our environments is becoming resuscitated and reinvigorated, as food and other ecological crises mountingly face us in our day to day lives.

So, after pulling weeds in the garden and mulching some cabbage, we took to the well pipe. On the spot we made a robust, collaborative decision as far as the best engineering practice to encourage a well pipe with a lifetime design, based on immediately available materials. We used plastic pieces cut from a filter they had built before and that had not tested well to fix screens along four 10 foot sections of PVC pipe.

Though I had done similar kind of work before, doing it off the grid was a unique learning experience, and in retrospect the whole deal turned out to be an example of applied ‘participatory action research’. On the ground, those with a stake in the outcome the decision making process developed and implemented a design that best suited their needs, instead of being developed by some guy in a corporate office on a computer (though good things can be done that way as well). This seems to be a well rounded method for participatory open design of appropriate, liberatory technology. However, the problems caused by a “design for dumpster” well drilling rig they used resulted in problems with dropping that 6 inch pipe that we spent an entire afternoon putting together. They have since succeeded in dropping a 4 inch the full 80 feet. This is an important step in developing their infrastructure to be able to support more collaborators on the farm.


The next element to work on is to develop a more sustainable energy supply (instead of local waste veg oil) based on the PV cells donated by Ersol. You can read more below, but to update that post we will be soldering, assembling and encapsulating the panels in a few weeks based on our efforts and successes during this past weekend to research and develop a firm and robust action plan to ensure that the DIY approach will be successful and lead to panels that will have a long and fruitful life, considering the current capacity for fabrication work on the farm (no open-source, off grid solar encapsulation machines that I know of yet!). I and my friend Vince and hopefully others will venture out to take on this project while Marcin finishes the much anticipated LifeTrac (I helped him unpack an 800lb shipment of materials and parts into his new converted silo workshop). Once that and the panels are finished, they can use the tractor to run the CEB press mobile and use the energy to fabricate necessary parts and amenities for the new buildings and, in turn, support more folks. It is exciting to know that the co-laboratory is growing and that it is plausible that there will be as many as a dozen people living in a well established facility by this time next year, built brick by brick with CEBs and ingenuity. There is talk of a root cellar, full kitchen, fancy restroom facilities and a knowledge/resource library with a few computers, and smoke house for preserving widely available deer meat, among living accommodations and garden terraces.
Additionally, they have been in contact with some important folks in the free school movement, and the implications for the experimental blend of learning, living, research, design and application off the grid for the benefit of all is overwhelming to say the least. It amalgamates the ideas of Brazilian pedagogacist and political dissident Paulo Freire and the legendary social theorist and independent marxist Antonio Gramsci’s concept of the organic intellectual, combined with the general drive for liberated knowledge and participatory, grounded and practical learning (this is just my impression). This seems to be a just and sensible approach to educating ourselves and our progeny in the attempt to reach the goals of sustainability and resilience. In addition, to combine this movement with the appropriate technology movement seems to present a formidable partnership in the global struggle for self sufficiency and Swadeshi. The implications and readily possible results are enormous. Both movements have achieved so much already, and things are unmistakably in motion. As different active and concurrent fronts join forces and new approaches and concepts continue to emerge, develop and be applied, the possibilities for what we can create and live day to day will be endless. So for all of you who are out there sitting-on-ass, like I was only so long ago, its time to put our shoulders to the wheel and connect ideas and put them into action and live passionately for the future. Its high time we turn ourselves from passive consumers to active producers, from passive viewers to active participants, from those who abandonedly ride the increasingly volatile wave of change to those who harness it for the betterment of all. From farmers in India to factory workers in Malaysia to miners in Guyana to researchers, bloggers and activists in the privileged realm (not to leave out integral and citizen actors in the underprivileged realm), citizens of the world are crying out for change on all levels, and putting their inspirations, knowledge and ideas into action. It sure is a great time to be an ‘enlightened’ optimist, as those who are pessimistic about the future of humanity increasingly find themselves counterpointed by these concepts being put into action. So, let us achieve a world where the only times you hear the word ‘power’ are when talking about electrical things off-grid and empowerment (instead, participation, decision making, collaboration, etc.) , where the oppressed and the subaltern become mere historical anecdotes, examples of the injustice wrought by the disempowerment and malice of the past.
I can only look forward with ready hands and a reeling mind to further collaboration with Factor E and others in the broader global movement for Swadeshi. So much being done, so much to do, and the movement grows and grows. Abundance and Justice awaits.

Categories: Challenges, Collaborators, Global Swadeshi, Guests, Infrastructure, Open Source Technology, Permaculture, Visiting, Volunteers, Water Well Drilling

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Here is an overview of our overall program of action:

On the CEB Press for building – we are presently building the LifeTrac tractor – an agriculture, construction, and general utility device. This device is remarkably pedestrian in appearance – so one has to appreciate the details to grasp its versatility and lifetime design features. A big shipment of most of the parts for LifeTrac is coming in tomorrow – the Freight truck missed today. The status of the Solar Turbine is preparation for construction in August. On the digital fabrication front, CNC torch table is in progress – http://openfarmtech.org/index.php?title=Torch_Table. As far as the CNC-controlled Multimachine – we are preparing an implementation path.

Here is a big point to consider, if you haven’t heard it before. If we can generate a repository of open source design – then with computer controlled fabrication capacity – people can download design and produce anything anywhere. The key is the repository of open source design – plus availability of a low cost multipurpose production capacity – run with open source computer control software. That is the promise of digital fabrication – decentralization of production and, thereby, peer production. You can read more about peer production and free enterprise here. We are contributing by implementing the torch table and multimachine – both coupled to LinuxCNC.

The basic idea on progress is – as soon as collaborators surface to move the project forward – progress accelerates. Our main need is technical collaboration and per-project visitors to Factor e Farm to implement the technical components one by one – towards creating a replicable option of an Unplugged Lifestyle.  (more…)

Categories: Compressed Earth Block Press, Digital Fabrication, Global Swadeshi, Global Village Construction Set, Solar Turbine

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Change is continuous at Factor e Farm. You may have seen this post on how our place has evolved from a plain soybean field to rich diversity on many fronts.

To record these changes as they happen, we have begun the Factor e Live series. These are videos, aired every two weeks, that show the ongoing changes – and serve as a future record of the process of building a village. As the titles say – we are Farm Fresh Ideas – for sustainable, regenerative, and transformative development – through open source collaboration.

This is our first in the series. Enjoy. Click below, or download the file (28 MB). Please comment profusely.

Categories: Accomplishments, Factor e Live, Global Swadeshi, Global Village Construction Set, Quality of Life

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Last week, Frank Aragona from Agricultural Innovations published a podcast interview regarding some of our work at Factor e Farm. Agricultural Innovations is a research and consulting organization involved with biodiversity, fair trade, community supportecd agriculture, permaculture, and appropriate technology, among others areas.  Its aim is to promote cutting edge practices in all of these areas. Click on the picture below to hear the podcast:

Categories: Global Swadeshi, Global Village Construction Set, Interviews

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Yesterday, Vinay interviewed me for the first of the Global Swadeshi Dialogues weekly interview series. This interview is perhaps the most clear description to date of the essence of our experiments with Open Source Ecology, and its implementation lab – Factor e Farm. If you can bear the 54 minutes of time, this will definitely be insightful regarding the forthcoming peer-to-peer economy – and provide much insight into the threads of thought and motivations behind our work. At Factor e, we grow ideas, and winnow for the truth.

Categories: Global Swadeshi

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It is interesting to reflect upon the changes that Factor e Farm has gone through in just one year. We started at Factor e with a clean slate: bare land – after its last ever soybean monoculture was harvested.

Now the place looks a little different, to say the least. A diversity of plants and animals now populate this land. It’s our secret lab – a mix of interesting structures and agricultural equipment scattered about – an ever-changing animal house of sorts. The locals drive by frequently to stay up to date. Say, are those wool socks that she’s wearing in the middle of summer? Step on a tour and see for yourself – a visual tour from Year 1 of our adventure.

Read about this in Spanish, care of Lucas Gonzalez.

Categories: Global Swadeshi, Open Source Agroecology (OSA), Permaculture

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