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Hanley Plant LOCATION: Route 28 Summerville, Jefferson County, PA (approx. 80 miles NE of Pittsburgh) Plant Manager: Terry Bullers General Manager: Phil.

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Presentation on theme: "Hanley Plant LOCATION: Route 28 Summerville, Jefferson County, PA (approx. 80 miles NE of Pittsburgh) Plant Manager: Terry Bullers General Manager: Phil."— Presentation transcript:

1 Hanley Plant LOCATION: Route 28 Summerville, Jefferson County, PA (approx. 80 miles NE of Pittsburgh) Plant Manager: Terry Bullers General Manager: Phil Raub Distribution Manager: Craig Wonderling Hanley Plant

2 History The original Hanley plant was built in 1893 in Bradford, PA, and ran until 1983, when it was sold to an unknown buyer.The original Hanley plant was built in 1893 in Bradford, PA, and ran until 1983, when it was sold to an unknown buyer. The Hanley Plant in Summerville was built in 1925.The Hanley Plant in Summerville was built in Hanley Plant was built by Lee Hanley, brickmaker and celebrated tunnel kiln designer. Considered visionary in his approach to brick- making, Hanley was also famous for building notoriously quirky kilns.Hanley Plant was built by Lee Hanley, brickmaker and celebrated tunnel kiln designer. Considered visionary in his approach to brick- making, Hanley was also famous for building notoriously quirky kilns. Glen-Gery purchased Hanley Plant in February 1986.Glen-Gery purchased Hanley Plant in February The two Hanley kilns present at the time of our purchase were the last Hanley tunnel kilns in the world. They were built around 1960 and razed for the Modernization project that began in the fall of 2001.The two Hanley kilns present at the time of our purchase were the last Hanley tunnel kilns in the world. They were built around 1960 and razed for the Modernization project that began in the fall of Hanley Plant

3 Hanley Modernization $18 million upgrade Improve availabilityImprove availability Improve product qualityImprove product quality Broaden range of product offeringsBroaden range of product offerings REASON FOR UPGRADE Hanley Plant

4 Hanley Modernization AVAILABILITYAVAILABILITY – the plants capacity is increased 32% from 35 million (former) units to 50 million (new) Specifically... QUALITYQUALITY – consistent color, tighter color ranges (3 vs. 5 shades) – products conform consistently to FBX specs SELECTIONSELECTION – addition of flashed brick (vs. clearburn only) – clay/shale blends (vs. shale only) Hanley Plant

5 Hanley Modernization $18 million upgrade began in Nov and was completed – on time and within budget – in 18 months ft. Ceric, air-tight tunnel kiln and attached dryer (total length 503 ft.) replace 2 old Hanley kilns1 280 ft. Ceric, air-tight tunnel kiln and attached dryer (total length 503 ft.) replace 2 old Hanley kilns Robotic dehacker (new to Hanley – carousel in use prior)Robotic dehacker (new to Hanley – carousel in use prior) New robotic setting equipmentNew robotic setting equipment Advanced-design kiln carsAdvanced-design kiln cars New glaze application boothsNew glaze application booths State-of-the-art computer management system to track manufacturing processState-of-the-art computer management system to track manufacturing process Installation of environmentally-friendly wet scrubberInstallation of environmentally-friendly wet scrubber PROJECT HIGHLIGHTS Hanley Plant

6 Hanley Plant Overview Hanley Plant

7 Hanley 2002 Market Overview 1.New York10,018, % 2.Pennsylvania3,700, % 3.Illinois2,737, % 4.Maryland2,576, % 5.Ohio2,461, % 6.Michigan2,331, % Primary markets / brick shipments Total Shipments = 34,745,000 Total Production = 31,683,000 Hanley Plant

8 Hanley 2002 Customer Overview 1.Tri-State Brick (NY)2,302,610 2.Glenwood Mason Supply (NY)2,158,369 3.Prairie Brick Co. (Chicago)2,021,000 4.Capital Brick & Tile (D.C.)1,607,795 5.Extech Industries (NY)1,516,174 6.The Thomas Brick Co. (Cleveland, OH)1,151,953 Top customers / brick shipments Hanley Plant

9 Hanley Product Overview First and most importantly... ALL Hanley brick is FBX. FBX brick conforms to a higher degree of precision and lower permissible variation in size than permitted for Type FBS (general use masonry). Cf. ASTM C Basically, that means a superior, precision-smooth face (and not necessarily the edge!) that shows little or no chips, bumps or cracks. Hanley attributes the quality of its FBX brick to find grind that they use on their raw materials. Hanley Plant

10 Tawny Beige – S32 Dolomite Grey – S181 Smoky Quartz – S72 Hanley Plant

11 Example of Hanley shape that conforms to FBX standards. Hanley Plant

12 Hanleys 6 Price List Products Engobe (aka claycoat) Engobe (aka claycoat) Matt Matt Coarse (Canyon Series exclusively) Coarse (Canyon Series exclusively) Hanley also makes: -- Stylo, aka 8-square, in certain textures... but it is not a Price List item -- Complete assortment of shapes to complement product line Hanley Plant Glazed Glazed Wire cut Wire cut Smooth Smooth

13 Hanleys Product Line Overview Glazed Glazed Engobe Engobe Smooth Smooth PRODUCTS: Tuscan(smooth face brick) Tuscan(smooth face brick) Canyon(coarse face brick) Canyon(coarse face brick) SERIES: STOCK SIZES: thickness x height x length Note: All of Hanleys 6 Price List products are made in the above sizes. The plant also makes a jumbo norman (3-5/8 x 2-3/4 x 11-5/8), but it is only as a special order. Hanley Plant Matt Matt Wire Cut Wire Cut Coarse Coarse Modular 3-5/8 x 2-1/4 x 7-5/8 Modular 3-5/8 x 2-1/4 x 7-5/8 Jumbo 3-5/8 x 2-3/4 x 8 Jumbo 3-5/8 x 2-3/4 x 8 Econo 3-5/8 x 3-5/8 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 Utility 3-5/8 x 3-5/8 x 11-5/8 Norman 3-5/8 x 2-1/4 x 11-5/8 Norman 3-5/8 x 2-1/4 x 11-5/8

14 Spice White Blue GreyBlack MaroonEvergreenBermuda Blue Spice White Oyster White/ Speck White/Speck Current stock glazed colors. Hanley also makes custom colors. Glazed Glazed brick are extruded brick to which a non-permeable, smooth coating has been applied. Engobe Engobe brick are extruded brick to which a water vapor-permeable, coating has been applied. The manufacturing process for both glazed and engobe brick is the same: A coating is sprayed on the green column of clay on the extrusion line. The coating is dry to the touch by the time it gets to the setting stage. Hanley Plant

15 Smooth, Wire Cut, Matt, Coarse Hanleys face brick products are all extruded and, at this time, all clay-based materials. At left is an example of Smoky Quartz (72) in smooth texture (top) and wire cut texture (bottom). SMOOTH TEXTURE WIRE CUT TEXTURE Hanley Plant

16 Hanleys Top-Selling Products Rome Grey*(s 93) Rome Grey*(s 93) Tawny Beige(s 32) Tawny Beige(s 32) Smoky Quartz(s/w 72) Smoky Quartz(s/w 72) Toledo Grey(s/w 75) Toledo Grey(s/w 75) Dolomite Grey(s/w 181) Dolomite Grey(s/w 181) *Rome Grey (utility) is the brick used on the outside of the new kiln. It serves only a cosmetic purpose and offers little insulating value. Hanley Plant

17 Hanley Product Development Planned for 2003, is the introduction of Hanley Red (S/W15), a 100% shale, authentic red brick. Hanley Plant

18 Interesting Facts... New kiln normal operating temperature is 2100 – 2200°F New kiln normal operating temperature is 2100 – 2200°F Kiln-dryer combo holds 45 cars (1 car in pre-dryer stage, 17 cars in dryer, 27 cars in kiln) Kiln-dryer combo holds 45 cars (1 car in pre-dryer stage, 17 cars in dryer, 27 cars in kiln) New kiln cars hold about 5,200 modular size brick. Old cars, about 2,000 New kiln cars hold about 5,200 modular size brick. Old cars, about 2,000 New kiln cars measure 10 ft x 15 ft. wide. Old cars, 61 inches wide x 9 ft. long New kiln cars measure 10 ft x 15 ft. wide. Old cars, 61 inches wide x 9 ft. long New kiln push rate is 54 min. Old kiln rate was 36 min. Push rate refers to the amount of time it takes to move a car one car length. Basically, a car is removed every 54 min. New kiln push rate is 54 min. Old kiln rate was 36 min. Push rate refers to the amount of time it takes to move a car one car length. Basically, a car is removed every 54 min. Firing curves from the old kiln are programmed into the new kiln to minimize the adjustment time needed to zero in those temperatures that produce the desired effect. Firing curves refer to those temperatures for individual products known to produce quality brick. Firing curves from the old kiln are programmed into the new kiln to minimize the adjustment time needed to zero in those temperatures that produce the desired effect. Firing curves refer to those temperatures for individual products known to produce quality brick. Pre-dryer stage is where moisture content is reduced to, normally, below ½% in brick. Its important to take out as much moisture prior to entering the higher temperatures. Excess moisture can vaporize and explode brick. Pre-dryer stage is where moisture content is reduced to, normally, below ½% in brick. Its important to take out as much moisture prior to entering the higher temperatures. Excess moisture can vaporize and explode brick. Deck blocks on kiln car Hanley Plant


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