Transcript Marseilles - Tim Colyer paintings

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
History
• 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.
• The second kiln was operational in late 2000, early 2001.
• Glen-Gery purchased Marseilles Plant in December 2001.
Reasons for the purchase:
• Have a modern plant in the Midwest market.
• 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.
• Marseilles is only 60 miles away from Chicago – the 3rd 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.
Marseilles Plant
Marseilles Modernization
$3 million upgrade*
Modifications to Kiln, Setting Machine,
Dehacker, Manufacturing Dept., Yard
*The cost of the modernization was factored into the buying price.
Laser search and
locate system
Marseilles Plant
REASON FOR UPGRADE
Make the plant compatible with
Glen-Gery’s manufacturing
processes.
Marseilles Modernization Overview
SETTING MACHINE
• Relieve the edges on architectural brick to minimize chippage
• New textures for residential product development
• More efficient production of size formats (make king size)
DEHACKER
• Better blending within a hack
• Better cube blending between two kiln cars. Blending is now broken down to
include brick from different hacks and separate courses.
KILN
• Upgrade older kiln to achieve better color consistency on flashed products and
consistency overall
• Better color matching from kiln to kiln
MANUFACTURING
• Pug Mill – auto-moisture controls to assure size consistency
• Grinding Dept. – new equipment for accurate measuring of raw materials and
additives will contribute to color uniformity in fired products
• Extruders will be outfitted with automatic hydraulic die changers for quick and
efficient size switching
YARD
• Rail Siding and loading dock added so that shipping is now done by railroad,
a faster method of transportation, rather than truck
• Concrete pads for inventory will be installed
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
Marseilles Plant
Marseilles Plant
Overview
Marseilles Plant
Site
Marseilles Plant is located on a 40-acre site in
Marseilles, IL, about 75 miles southwest
Chicago.
Raw Materials
Raw materials are extracted from two locations:
• Shale (red brick) – from an 80-acre leased site
about 40 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.
Marseilles Plant
Production Details
Marseilles Plant makes extruded brick in 100%
shale and clay and clay-shale blends, in both
flashed and clearburn ranges.
Production capacity
120,000 million
Kiln capacity
36 cars
Kiln car capacity
10,080 modular
Kiln car size
14 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.
Marseilles Plant
Sizes
Size:
Width x height x length
Modular
Econo
Utility
Engineer
3-5/8 x 2-1/4 x 7-5/8
3-5/8 x 3-5/8 x 7-5/8
3-5/8 x 3-5/8 x 11-5/8
3-5/8 x 2-3/4 x 7-5/8
(Engineer also called “70 Series”)
Queen
King*
3 x 2-3/4 x 7-5/8
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.
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
Marseilles Plant
Product Line
Marseilles Collection
Top selling residential products
Cashmere
Merlot
 St. Thomas
 London Mist
 Morning Dove
 Silver Aspen
 Cashmere*
 Irish Crème
 Heathermist
 Colonial Rose
* Introduced in 2002, Cashmere is the #5 top seller of all
Marseilles products. Cashmere was developed to
compete with General Shale’s popular “Cortez” product.
Chicago Collection
Top selling commercial products
 Red Velour
 Colonial Sand
 Sahara Velour
Marseilles Plant
Red Velour
Product Line
Chillicothe Products
These products from the former Chillicothe
Plant are now being made at Marseilles:
 Glacier Bay
 Cedarcreek
 #888 Laredo
 Rosebud
 Roseboro
 #924 Laramie
 Polar Bay
Also, Marseilles’ Cabernet is a look-alike
replacement for Chillicothe’s Monterey
Chillicothe’s “Sunberry” and “#930 Tucson”
are now in testing phase for production.
Marseilles Plant
Velour texture
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.
• VELOUR texture is achieved by blade cutting a smooth
column of clay after extrusion. Coarser raw materials result
in a rougher texture.
Smooth texture
Note: Marseilles products look like they are wire cut, but this in
an incorrect description. The are “blade cut.”
“Worm” (also called
“Indented”) is a
texture treatment
used on some
residential products.
(See Cashmere and
Merlot samples.)
Marseilles Plant
Marseilles 2003 Market Overview
Primary markets / brick shipments
1. Illinois
17,077,000
(Jan - Jun)
49.0%
Chicago alone represents 14,428,000 BE’s (or 85%) of this figure.
2.
3.
4.
5.
Indiana
Ontario
Michigan
Wisconsin
4,221,000
3,937,000
2,660,000
1,264,000
12.1%
11.3%
7.6%
3.6%
Total Shipments = 34,841,000
Total Residential shipments = 23,171,000
Total Commercial shipments = 11,507,000
Marseilles Plant
Marseilles 2003 Customer Overview
Top customers / brick shipments (BE’s)
1. Prairie Brick Co.
Illinois
10,187,114
2. Brampton Brick Ltd.
Ontario
3,852,288
3. Chicago Block & Brick
Illinois
1,013,793
4. Northern IL Brick & Supply
Illinois
869,819
5. Edgewood Building Supply
Indiana
927,465
Marseilles Plant
Marseilles 2003 Customer Overview
Use in Construction / Brick Shipments (Jan - Jun)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Marseilles Plant
One-family houses
Two-family houses
Apartments
Hotels/motels/dorms
Commercial
Manufacturing bldgs
Education/Science
Hospital/Health
Public
Religious
Dealer stock
7,912,000
590,000
858,000
48,000
3,635,000
4,000
1,821,000
271,000
441,000
336,000
18,350,000