Introductory Conveyor to the Rumbling Barrel. Haith Equipment at work inside the Rumbling Shed. Haith Equipment at work inside the Rumbling Shed. Haith Equipment at work inside the Rumbling Shed.

Haith help resolve Waste Issues for Tyrone Brick.

28th July 2008

Part of CRH - the International Building Materials Group, Tyrone Brick has since the 1970's been the only clay brick manufacturer in Northern Ireland. Continually developing new brick types using the latest technology and manufacturing equipment all their clay is extracted locally once a year from four nearby reserves in County Tyrone and County Down. As sustainability of building materials is becoming increasingly important for architects, specifiers and end users; the company has with regard to impacting on the environment, invested heavily in ways to further reduce their carbon footprint.

Where possible the company re-uses process waste materials and utilise them in the manufacturing process.  For example, the excess heat produced by the kilns is recaptured for use in the drying process, ensuring that all energy is employed as efficiently as possible. Grey water gathered from collection points around their factory mix with their clay keeps mains water consumption to an absolute minimum which is aimed to meet their Energy Reduction Targets of 2% per annum up to 2010.  

Some brick types have a 20% recycled content. These are created by crushing ‘Non First' bricks and using the resulting ‘Brick Grog' material, instead of natural sand. An extra bonus is that these bricks can be fired in a shorter cycle time, therefore ensuring that all energy is used as efficiently as possible. Old Colliery, Restoration Blend, Kingston Red and the Rumbled Brick Range contain this recycled material and these bricks now represent approximately 15% of the company's total sales. 

A wide range of brick types are produced, with stocks of all the popular types being available. The company also has a dedicated facility for the production of special shape bricks. With a flexible production process Tyrone Brick can offer shorter lead times on purpose-made special shapes.

In a recent project for the company Haith Industrial supplied a Brick Rumbler and two conveyors for the waste processing line of the plant. Taking into consideration several issues of space and after consultations with the client Haith produced a working plan to achieve the maximum result.

Haith supplied a 7000 x 1200mm Brick Rumbler for the brick production. Constructed with a steel barrel the rumbler is internally fitted with a steel backed wear resistant rubber lining. Supported by a single line shaft mounted above the barrel the rumbler is driven by a shaft mounted 11kW motor fitted directly to the line shaft. A pressed steel guard fitted over the top of the barrel also acts as a dust cover should dust extraction be employed. A main frame mesh guard whilst eliminating any access for safety reasons incorporates enough area to allow any waste fall-out from the machine.

Design of the machine also facilitates the angle of the machine to be changed allowing control of the throughput and the amount of distress on the brick edges. Fitted in-feed and out-feed chutes were also supplied complete with replaceable steel liners.

Material is fed from the brick rumbler onto a 16.5 metre long x 1 metre wide Haith standard totally enclosed design heavy-duty picking conveyor. This picking belt also extends back under the rumbler enabling the belt to catch any dust or waste that spills out between the barrel and chute. A small hopper is also incorporated at the tail end of this conveyor which included a 1 metre tunnel guard extending back from the head of the conveyor.

The rumbled bricks are manually packed by a team of selectors at the picking belt. The remaining brick material moves off the picking belt onto an inclined waste conveyor to a collection bin at the line end. This material is subsequently recycled in the brick production process.

Overall the successful installation has provided Tyrone Brick with the ability to create a range of ‘Old World' type bricks, and minimize the amount of brick wastage due to the process.

Ian Irwin of Tyrone Brick, commented, "Haith have a good understanding of what the market requires from this type of equipment. The ability to optimize material use including waste is very important for manufacturers in this age of sustainability."