Manufacturing and Production

Clay Brick Manufacturing and Kiln Operations

A brickworks turns a clay deposit that varies across the pit into a product sold on strength and appearance, and fires it in a kiln that consumes most of the factory's energy bill. This course covers both problems. Delegates work through clay geology, winning and the stockpiling and blending that even out a variable deposit. Preparation follows through crushing, grinding, screening and the water addition that gives workable body. Forming is covered across extrusion and soft mud methods, with die design, wire cutting and the lamination faults extrusion introduces. Drying is treated in detail, since most cracking happens before a brick reaches the kiln: shrinkage, drying rate and humidity control. Firing follows, covering the tunnel and clamp kilns used in the region, firing curves, soaking and the reactions that develop strength and colour. Fuel use and energy cost per thousand are addressed. Testing is covered for strength, absorption and efflorescence. The course closes on colour consistency, on sorting and on kiln troubleshooting.