Production Process

Extraction and transport
After having drilled the soil and having gathered samples to be analysed, tested and ranked in the laboratory, the ground for the extraction of clay is chosen.








Setting-up of batches and maturation
The different kinds of clay are stored separately in enclosed open-air areas. After a series of laboratorial tests, the mixtures of clay on each batch are carefully determined. Then, each batch is set up. The mixture of the clay is carried out in horizontal layers.

Pre-preparation of the pulp
This stage consists of decompacting, crushing, smashing and making a new mixture of the batch, so that it achieves a grain growth, which is less than 3 mm and the mixture is more homogeneous.

Preparation of the pulp
This stage consists of mixing the pulp, after water is added, with a view to upgrading the level of homogenisation and giving the mixture its final features of plasticity. The pulp is then rolled in order to achieve the desired grain growth.







Pre-configuration: extrusion
The pulp enters an extrusion room and is there subject to vacuum and compression in order to reach a compactness, which allows it to continually go out from a mouthpiece with the shape of a "tongue", whose shape has been previously determined. Then, the "tongue" is cut so that a "ballast" appears, which should have the required size in order to proceed to the pressing stage.




Configuration: pressing
The "ballast" is pressed and the final shape of the wanted model of clay tile is attained.









Configurated Tiles Stock
After the pressing, the tiles are led to a waiting line, where they wait for their turn to enter the drying room.









Drying
This long-lasting stage intends to remove the humidity, which had been added, so that the pulp could obtain the required plasticity. The "dry tiles" are then led to the waiting line of the kiln.







Baking
This is one of the most important stages of the whole manufacturing process. Here we try to get the final characteristics of the tile that determine its good performance on the roof, namely its capacity to be highly resistant and waterproof. After being ordered into "cassettes", the tiles are piled into wagons, especially prepared to resist high temperatures. The loaded wagons start their slow and long-lasting route through the tunnel kiln. As they slide through the kiln tracks, the tiles go through gradual degrees of warming, baking and cooling that cause different kinds of chemical reactions, providing them with the wanted features.

Baked Tiles Stock
When the baking cycle comes to an end, the wagons loaded with baked tiles are led to the waiting line in order to cool, while waiting for their turn to be unloaded and the tiles packed.

Packing
In tandem with the pace of the wrapping process, the wagons are unloaded and the titles, which meet the predetermined quality patterns, are packed.








Expediting
The manufactured clay tiles are classified as finished product ready to be sold. According to their model and category, they are then registered in stock and stored in a park especially built for this matter, and wait there to be expedited.