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Distribution Manager:

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1 Distribution Manager:
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 Hanley Plant in Summerville was built in 1925. 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. 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. Hanley Plant

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

4 Hanley Modernization Specifically . . . AVAILABILITY
– the plant’s capacity is increased 32% from million (former) units to 50 million (new) QUALITY – consistent color, tighter color ranges (3 vs. 5 shades) – products conform consistently to FBX specs SELECTION – 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 PROJECT HIGHLIGHTS 1 280 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) New robotic setting equipment Advanced-design kiln cars New glaze application booths State-of-the-art computer management system to track manufacturing process Installation of environmentally-friendly wet scrubber Hanley Plant

6 Hanley Plant Overview Hanley Plant

7 Hanley 2002 Market Overview
Primary markets / brick shipments New York 10,018, % Pennsylvania 3,700, % Illinois 2,737, % Maryland 2,576, % Ohio 2,461, % Michigan 2,331, % Total Shipments = 34,745,000 Total Production = 31,683,000 Hanley Plant

8 Hanley 2002 Customer Overview
Top customers / brick shipments Tri-State Brick (NY) 2,302,610 Glenwood Mason Supply (NY) 2,158,369 Prairie Brick Co. (Chicago) 2,021,000 Capital Brick & Tile (D.C.) 1,607,795 Extech Industries (NY) 1,516,174 The Thomas Brick Co. (Cleveland, OH) 1,151,953 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 C216-99 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 Hanley’s 6 Price List Products
Glazed Wire cut Smooth Engobe (aka “claycoat”) Matt 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

13 Hanley’s Product Line Overview
PRODUCTS: Glazed Engobe Smooth Matt Wire Cut Coarse SERIES: Tuscan (smooth face brick) Canyon (coarse face brick) STOCK SIZES: thickness x height x length Modular 3-5/8 x 2-1/4 x 7-5/8 Jumbo 3-5/8 x 2-3/4 x 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 Norman 3-5/8 x 2-1/4 x 11-5/8 Note: All of Hanley’s 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

14 Glazed Engobe Hanley Plant
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. Spice White Blue Grey Black Maroon Evergreen Bermuda Blue Oyster White/ Speck Spice White White/Speck Current stock glazed colors. Hanley also makes custom colors. Hanley Plant

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

16 Hanley’s Top-Selling Products
Rome Grey* (s 93) Tawny Beige (s 32) Smoky Quartz (s/w 72) Toledo Grey (s/w 75) 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 “Deck blocks” on kiln car
Interesting Facts . . . 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) 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 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. “Pre-dryer” stage is where moisture content is reduced to, normally, below ½% in brick. It’s 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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