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| A. Raw materials,
shale and fireclay, are trucked into the facility daily from
nearby pits. The material is stored until being sent to the
grinding room where it is crushed into the proper size. |
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B. After the material has
been reduced in the crusher, the fine material is screened through
a series of screens where any larger material is caught and
the rest is sent on to holding bins. |
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| C. Crushed and screened
material is dumped into a holding area where it is stored, waiting
to be sent to the blenders. |
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D. The color blending station
mixes the fine-ground clay and shale in varying proportions
and adds the color-enhancing additives necessary to achieve
Whitacre Greer’s wide variety of color. |
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| E. Following blending, the
fine material is sent to the presses. Mechanical type, 400-ton
presses produce four 4x8 pavers with each stroke. Whitacre Greer
products are dry-pressed, not extruded, which allows for the
production of a variety of sizes and textures. |
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F. Kiln cars are loaded
with the ‘green’ (unfired) brick and then placed
in dryers to begin the firing processes. After 24 hours in the
dryer the cars are moved to the kiln where they are fired at
2000 degrees. The firing process is a thermo-chemical that produces
the strength and color of a clay paver. The firing process requires
up to a week’s time to complete. |
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| G. Kiln cars that have completed
the firing process await unloading. Each car has firebrick on
the bottom of the car and pavers stacked on top. |
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H. Paving brick are unloaded
and placed on a conveyor belt where they are sent to the sealing
and packaging machine. Whitacre Greer pavers are sealed in a
bath of siloxane sealer. |
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| I. Pavers are submerged
in the sealing solution and then stacked and packaged. |
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J. Pavers are labeled and
packaged for delivery. |
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| K. Whitacre Greer custom
blends standard colors according to project specification. |
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L. Whitacre Greer has a
large inventory of both firebrick and clay pavers to meet all
your needs. |
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