Masonry Magazine December 1986 Page. 32
NEW FRENCH TECHNOLOGY RESULTS IN
LOWER COST TILE AND BRICK PRODUCTION
Ceric tunnel kiln: Mold cars waiting to be lowered to the transport level.
Side view of front end of Ceric kiln and mold cars.
The French manufacturer CERIC has created a wholly automated system of producing structural clay tile and brick for a fraction of the fuel cost and production time of conventional kilns. Using one or two men per shift for the entire operation versus seven to eight workers, Ceric's "Hydrocasing" process produces finished unit masonry for 30% less energy and time.
Called Hydrocasing because the brick are transported in water-sealed cars into the kiln, the entire production line is easily installed from modular prefabricated components that need only a light foundation to construct. The manufacturing process is computer-run from a single console. From the time raw materials enter the line they remain on a single product support during forming, drying, firing and palletizing, thus eliminating handling that can cause breakage and waste.
Thanks to the use of water-sealed cars that carry the product, the kiln is air-tight on the bottom as well as on all sides. This allows high pressure and a strong air flow, making the heat exchange during firing 10 times as great as with other kilns.
Approximately 600 BTUs are used per pound of clay for firing and drying, versus 1.200 BTUs for conventional plants. Power consumption is reduced by 30%, while production time is shortened from 48 to 15 hours per load. The kiln is designed to produce up to 50 million brick per year and can be fired with liquid, gas or solid fuel.
The Ceric Hydrocasing plant produces 100 tiles, covering a 10-by-10 square foot area, for $25 to $30, which is 40% less than what can be accomplished by an average plant. Products that can be manufactured include
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