Production of clay bricks

An interesting insight into the world of making bricks.

Extraction of Clay
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As a first step, the assessment of the quality of raw material is done by experienced geologists.

After that the excavated clay is laid in layers on stockpile and is kept outside for about one year to ensure consistency.

Processing of Clay
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At the second stage clay is collected from the stockpile and shoveled into box feeders. Water, sand and other additives are added to the clay and mixed to the correct consistency in a mixer.

The clay mixture is then fed into the grinding machine where it is ground and homogenized. A conveyor transports the ground clay to the clay stock.

Finally the mixed clay is dropped into the extruder.

Extrusion
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During this step the brick mass is extruded through a die and then automatically cut into individual

bricks. One die is sufficient for up to 10mn. brick units.

The 'green' (wet) bricks are put on pallets and automatically transferred to the dryer.

Drying
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Drying can take up to 1 - 2 days. Moisture content of a brick drops from 20% to 2%. After the process of drying the bricks are grouped and set on kiln cars and transferred to the kiln.

Firing
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After drying, the bricks are then fired for 6-36 hours in the kiln, which is usually heated by natural gas or coal at a temperature >900°C.

Through firing, clay gets strength, while additives create small holes inside the bricks, which increases the thermal insulation.

After firing the bricks, the thermal energy is reused in the dryer to save energy.