Dhokra art involves making crafts by investment casting of non-ferrous metal using wax as pattern material. Most of the kilns used for heating moulds operate in batch firing (having low thermal efficiencies (9-12 %). In this work, we are converting this firing from batch to continuous mode. We are transporting moulds in carts from one end of tunnel and from counter direction combustion air is supplied. Three arrangements of moulds in carts are considered i.e., 1×1, 2×2 and 3×3. High temperature moulds and flue gases are used to preheat incoming air and moulds respectively. For analysis purpose, tunnel is divided in three zones viz., Preheating, Combustion and Cooling zones. Concept of combustion intensity is exploited to calculate the desired heat input and fuel consumption in combustion zone. Effectiveness-NTU model of heat exchangers is used to evaluate outlet temperatures while setting inlet temperatures from reference of previous experimental work on the batch kilns. Mean Beam Length method and flow across tube banks concept are respectively used to account for radiation and convection contributions to the overall heat transfer coefficient. 1-D transient heat conduction in cylinder is considered using first term approximation to obtain the length required of various zones of tunnel. To arrive at the length of each zone, time required for moulds to attain a prescribed temperature at the exit of the zone is evaluated. We found that for 3×3 arrangement of moulds, total length of tunnel and total construction volume is minimum, followed by 2×2 and 1×1 arrangements in that order.