The machine made process begins with the crushing
of the material which is performed by a set of high
speed rolls. Then the clay is moved into a mixing unit
where water is added to lift it to the correct moisture
content. A mixing process follows where the many tonnes
of pressure allow the stored clay to distribute its
water content equally.
To achieve the desired
shape the clay is fed into an extruder or press where
the
air is removed by
passing the material through a vacuum chamber.
The de-aired plastic material is then forced through
a shaped mouthpiece at huge pressure, resulting
in
a formed ribbon of clay. Further forming takes
place by cutter or die, producing the final product
which
is then stacked into setters or cassettes ready
for drying or firing.
A few days are taken up
by drying the newly formed
clay products. The water in the clay body is
slowly removed by gradually increasing the temperature
in
the drying chamber or tunnel. A lot of care
has to be taken here in order not to crack or distort
the
clay ware. The tiles are then moved into the
kiln
for firing, at a top temperature of 1,100 degrees
centigrade, which can take several days to
complete. Slowly increasing and decreasing the kiln
temperature
and pressure allows the clay material to change
to a hardened durable state.
The roofing process does
not finish with the manufacturing of the tiles. As
with all roofing products, a quality
end product requires skilled craftsmanship
when laying a clay tile roof. The days of the apprentice
are
undergoing a revival due to the work of the
Roofing Industry Alliance, a government-sponsored industry
body which aims to improve the competitiveness
of
the UK roofing sector, addressing the fundamentals
such as product marketing and training.