Manufacturing Process
1. MATERIALS PREPARATION PROCESS
Photos below showing gathering, crushing, grinding, screening & mixing the raw materials.
2. SETTING PROCESS
The pictures are showing the Column which produced by the Extruder. The Column is cut by Wire to produce individual bricks. After Brick Unit is formed, they will be hand carry onto kiln car to process. However, a Fully Automated Stacking Operation will be replacing the current hand stacking method by early 2016.
3. DRYING PROCESS
Prior to entering the kiln, the unfired or green brick must be properly dried. Moisture in the brick must be limited at this time to prevent certain mechanical defects from occurring when the brick is subjected to the intense heat of the kiln. The drying process is done by placing the green brick in enclosed dryers which utilize excess heat from the cooling kiln.
4. FIRING PROCESS
The green bricks pass through a long length of the kiln moving on the rail. The continuous tunnel kiln employs a combination of the vertical & horizontal drafts. The preheating, burning & cooling in zones varying in temperatures up to 1000–1050 degree Celsius.
5. PACKAGING PROCESS
After exiting the kiln, the bricks are allowed to cool prior to handling. Proper sorting ("dehacking"), broken, twisted and mechanically defective brick are discarded at this stage. Bricks are carefully monitored to assure a quality product. The finished product is packaged and banded into cubes of approximately 720 bricks, inventoried by lots and distributed to customers.
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