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LOCATION: 1401 Broadway Street Marseilles, La Salle County, Illinois Plant Manager: Bailey Wilson Asst Plant Manager: Richard Barrett Plant Controller:

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Presentation on theme: "LOCATION: 1401 Broadway Street Marseilles, La Salle County, Illinois Plant Manager: Bailey Wilson Asst Plant Manager: Richard Barrett Plant Controller:"— Presentation transcript:

1 LOCATION: 1401 Broadway Street Marseilles, La Salle County, Illinois Plant Manager: Bailey Wilson Asst Plant Manager: Richard Barrett Plant Controller: Lyle Jobst Distribution Manager: John Mansson Marseilles Plant

2 History Marseilles was built in 1990 as a one-kiln plant.Marseilles was built in 1990 as a one-kiln plant. Global Clay Products LLC (Georgia) bought the plant in 1999, and in that year, started construction on a second Ceric kiln.Global Clay Products LLC (Georgia) bought the plant in 1999, and in that year, started construction on a second Ceric kiln. The second kiln was operational in late 2000, early 2001.The second kiln was operational in late 2000, early Glen-Gery purchased Marseilles Plant in December 2001.Glen-Gery purchased Marseilles Plant in December Marseilles Plant Reasons for the purchase: Have a modern plant in the Midwest market.Have a modern plant in the Midwest market. Enlarge our territory and introduce Glen-Gery products to new areas.Enlarge our territory and introduce Glen-Gery products to new areas. Get closer to the large brick-loving Chicago market and overall Midwest market. Being closer means getting brick there faster and cheaper than our competition.Get closer to the large brick-loving Chicago market and overall Midwest market. Being closer means getting brick there faster and cheaper than our competition. Marseilles is only 60 miles away from Chicago – the 3 rd largest brick consuming city in the U.S. Chicago uses 250 million brick per year.Marseilles is only 60 miles away from Chicago – the 3 rd largest brick consuming city in the U.S. Chicago uses 250 million brick per year. With the addition of Marseilles Plant, our production is evenly split between the East and Midwest regions of the U.S.With the addition of Marseilles Plant, our production is evenly split between the East and Midwest regions of the U.S.

3 Marseilles Modernization $3 million upgrade* Make the plant compatible with Glen-Gerys manufacturing processes. REASON FOR UPGRADE Marseilles Plant Modifications to Kiln, Setting Machine, Dehacker, Manufacturing Dept., Yard Laser search and locate system *The cost of the modernization was factored into the buying price.

4 Marseilles Modernization Overview Marseilles Plant SETTING MACHINE Relieve the edges on architectural brick to minimize chippageRelieve the edges on architectural brick to minimize chippage New textures for residential product developmentNew textures for residential product development More efficient production of size formats (make king size)More efficient production of size formats (make king size)DEHACKER Better blending within a hackBetter blending within a hack Better cube blending between two kiln cars. Blending is now broken down toBetter cube blending between two kiln cars. Blending is now broken down to include brick from different hacks and separate courses. include brick from different hacks and separate courses.KILN Upgrade older kiln to achieve better color consistency on flashed products and consistency overallUpgrade older kiln to achieve better color consistency on flashed products and consistency overall Better color matching from kiln to kilnBetter color matching from kiln to kilnMANUFACTURING Pug Mill – auto-moisture controls to assure size consistencyPug Mill – auto-moisture controls to assure size consistency Grinding Dept. – new equipment for accurate measuring of raw materials andGrinding Dept. – new equipment for accurate measuring of raw materials and additives will contribute to color uniformity in fired products additives will contribute to color uniformity in fired products Extruders will be outfitted with automatic hydraulic die changers for quick andExtruders will be outfitted with automatic hydraulic die changers for quick and efficient size switching efficient size switchingYARD Rail Siding and loading dock added so that shipping is now done by railroad,Rail Siding and loading dock added so that shipping is now done by railroad, a faster method of transportation, rather than truck a faster method of transportation, rather than truck Concrete pads for inventory will be installedConcrete pads for inventory will be installed

5 Marseilles Plant Improved blending: Transfer grippers add to blend and start cube building process. No more than 5 brick that were together in the hack are together in the cube

6 Marseilles Plant Overview

7 Marseilles Plant is located on a 40-acre site in Marseilles, IL, about 75 miles southwest Chicago. Marseilles Plant Site Raw Materials Raw materials are extracted from two locations: Shale (red brick) – from an 80-acre leased siteShale (red brick) – from an 80-acre leased site about 40 miles from the plant; about 40 miles from the plant; Fireclay (buff brick) – from an 80-acre, Glen-Gery owned site about 20 miles from the plant.Fireclay (buff brick) – from an 80-acre, Glen-Gery owned site about 20 miles from the plant. Raw material reserves estimated at 30-year minimum for both and shale.

8 Marseilles Plant Marseilles Plant makes extruded brick in 100% shale and clay and clay-shale blends, in both flashed and clearburn ranges. Production Details Production capacity120,000 million Kiln capacity36 cars Kiln car capacity10,080 modular Kiln car size14 ft long x 21 ft. wide Push rate* (varies by size) 10 – 11 econos, utilities 14 – 15 king, queen, 70 series (engineer) 18 modular * The push rate is the amount of time it takes to move a kiln car one length. An 18-car push rate means that a car is removed every 18 min.

9 Marseilles Plant Sizes Size:Width x height x length Modular 3-5/8 x 2-1/4 x 7-5/8 Econo 3-5/8 x 3-5/8 x 7-5/8 Utility 3-5/8 x 3-5/8 x 11-5/8 Engineer 3-5/8 x 2-3/4 x 7-5/8 (Engineer also called 70 Series) Queen 3 x 2-3/4 x 7-5/8 King* 3 x 2-3/4 x 9-5/8 * Marseilles king size is different from traditional king size of 3-5/8 x 2-3/4 x 9-5/8 Marseilles recently made a premier size -- measuring 3-1/2 w x 3 h x 9-3/4 l – for a large order in Canada. Defined as a cross between king and utility, premier is a common size in Canada.

10 Marseilles Plant Product Line Marseilles products are divided into two collections: Chicago Collection Commercial market 13 products on Price List Marseilles Collection Residential market 26 products on Price List

11 Marseilles Plant Product Line Marseilles Collection Top selling residential products St. Thomas St. Thomas London Mist London Mist Morning Dove Morning Dove Silver Aspen Silver Aspen Cashmere* Cashmere* Irish Crème Irish Crème Heathermist Heathermist Colonial Rose Colonial Rose * Introduced in 2002, Cashmere is the #5 top seller of all Marseilles products. Cashmere was developed to compete with General Shales popular Cortez product. Cashmere Merlot Chicago Collection Top selling commercial products Red Velour Red Velour Colonial Sand Colonial Sand Sahara Velour Sahara Velour Red Velour

12 Marseilles Plant Product Line Chillicothe Products These products from the former Chillicothe Plant are now being made at Marseilles: Glacier Bay Glacier Bay Cedarcreek Cedarcreek #888 Laredo #888 Laredo Rosebud Rosebud Roseboro Roseboro #924 Laramie #924 Laramie Polar Bay Polar Bay Also, Marseilles Cabernet is a look-alike replacement for Chillicothes Monterey Chillicothes Sunberry and #930 Tucson are now in testing phase for production.

13 Marseilles Plant Textures The plant predominantly makes Smooth and Velour textures: The plant predominantly makes Smooth and Velour textures: SMOOTH is technically a die skin texture. The clay, which is made from a finer grind, passes smoothly through the extruder – no wires are used.SMOOTH is technically a die skin texture. The clay, which is made from a finer grind, passes smoothly through the extruder – no wires are used. VELOUR texture is achieved by blade cutting a smooth column of clay after extrusion. Coarser raw materials result in a rougher texture.VELOUR texture is achieved by blade cutting a smooth column of clay after extrusion. Coarser raw materials result in a rougher texture. Note: Marseilles products look like they are wire cut, but this in an incorrect description. The are blade cut. Velour texture Smooth texture Worm (also called Indented) is a texture treatment used on some residential products. (See Cashmere and Merlot samples.) (See Cashmere and Merlot samples.)

14 Marseilles 2003 Market Overview 1.Illinois17,077, % 2.Indiana4,221, % 3.Ontario3,937, % 4.Michigan2,660, % 5.Wisconsin1,264, % Primary markets / brick shipments (Jan - Jun) Total Shipments = 34,841,000 Marseilles Plant Total Residential shipments = 23,171,000 Total Commercial shipments = 11,507,000 Chicago alone represents 14,428,000 BEs (or 85%) of this figure.

15 Marseilles 2003 Customer Overview 1.Prairie Brick Co. Illinois10,187,114 2.Brampton Brick Ltd.Ontario3,852,288 3.Chicago Block & BrickIllinois1,013,793 4.Northern IL Brick & SupplyIllinois869,819 5.Edgewood Building SupplyIndiana927,465 Top customers / brick shipments (BEs) Marseilles Plant

16 Marseilles 2003 Customer Overview 1.One-family houses7,912,000 2.Two-family houses590,000 3.Apartments858,000 4.Hotels/motels/dorms48,000 5.Commercial3,635,000 6.Manufacturing bldgs4,000 7.Education/Science1,821,000 8.Hospital/Health271,000 9.Public441, Religious336, Dealer stock18,350,000 Use in Construction / Brick Shipments (Jan - Jun) Marseilles Plant


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