38 Tips to Open Brickwork Industry

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Open Brickwork Industry : In recent years, the need to maintain or regain market positions.

By improving product quality and service has also become apparent in the brickwork industry.

This has prompted operators to search for new technological solutions.

Able to obtain the desired objectives through flexible methods of production.

Optimal work cycles, with production costs in line with the value of the product.

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In the ceramic tile industry, dry pressed products.

The turning point came with the introduction of rapid methods of drying and firing.

Made possible mainly by research and development in the field of the preparation of raw materials.

For this reason, this particular production stage is of fundamental importance.

In order to achieve a radical and decisive technological innovation.

In the process and the product, including extruded products.

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Therefore, BusinessHAB wishes to offer producers the benefit of experience.

Which have enabled people to be at the forefront in the production of plant for pressed tiles.

Extruded cotto floor and wall tiles, stoneware.

Clinker and porcelain stoneware, roofing tiles and structural brick.

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Open Brickwork Industry: http://www.gobrick.com

Open Brickwork Industry

In these years, using a wide range of applications.

We have continued to update and transform our ceramic technology.

Adapting it as necessary to the different specific needs.

Both economical and commercial, for the various types of products.

Once you’ve decided you want to start a small business.

Formulated your business plan, lined up financing, and secured a site.

The time will finally come to actually open up shop.

While planning a business may present challenges.

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The actual act of opening a business.

And bringing the business concept to fruition has its own set of difficulties.

To have a better chance of long-term success, you need to get your business off to a good start.

Here are a few tips on how to legally establish your business.

Hire your first employees, spreading the word, and organizing a grand opening.

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Open Brickwork Industry

1. Ensure you have a business plan.

A business plan is critical to the success of a business and can be seen as a plan that describes your business, products/services, market, and describes how your business will go about expanding for the next three to five years. It is essentially a “road map” for your business to follow going forward.

2. Determine the legal structure of your business.

Before starting your business and filing the necessary papers, it is important to decide on how your business will be legally structured. Generally speaking, you will be establishing either a sole proprietorship; partnership; corporation; or limited liability company (LLC). There are important legal and tax implications for each.

  • A sole proprietorship is owned and run by one person, and there is no distinction between the owner and the business. This means that all the business’ profits, losses, debts, and liabilities are your responsibility. Choose this if you are the sole owner and want full responsibility for the business.
  • Partnership. A partnership occurs when two or more people share ownership. In a partnership, each partner has equal share (unless specified) in the profits, liabilities, and management of the business. This can be useful in terms of pooling capital and expertise to start the business.
  • Corporation: A corporation is an independent legal entity owned by shareholders. Generally, this structure is not appropriate for small businesses.
  • Limited Liability Company (LLC): An LLC is similar to a partnership, except members are protected from personal liability for actions of the LLC. For example, if the LLC is sued, the personal assets of the partners are typically exempt. If you are worried about personal exposure to lawsuits or debts arising from your business, this may be a good option.

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Open Brickwork Industry

3. Form the necessary legal structure.

A different procedure exists for forming each one of these structures, and some require more work while others are extremely simple.

4. Register your business name.

Unless you are running the business under your own name, such as “John Smith Painting,” most states require you to register a “Doing Business As” (DBA) name for tax and legal purposes. Registering a DBA is done with your state government or county clerk’s office. Search the specific requirements of your state online.

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5. Obtain a business license.

The city or county which you operate within will require a business license.

Typically, these forms can be found on the website for your city.

  • These forms will require your business type, address, # of employees, EIN, and possibly information regarding revenue (estimations will work fine here).
  • Keep in mind that licensing requirements often apply to online and home-based businesses as well as typical brick-and-mortar businesses. Requirements do vary according to location, so be certain to contact your local and state government to determine specific requirements.

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Open Brickwork Industry

6. Inquire as to other necessary permits.

Unfortunately, each city or county has different permit requirements for businesses.

These can include things like “Home Occupation Permits” for home based businesses, “Alarm Permits” if your business requires a commercial alarm, or various alcohol and firearm permits.

  • Contact your local government’s permitting bureau or similar authority, or seek out the local chamber of commerce or business association for advice.

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7. Establish a bank account for your business.

It is very important not to mix business and personal finances, as this can lead to issues with the IRS.

Having separate bank accounts for business and personal transaction simplifies accounting and makes tax requirements easier to understand.

  • To open a business account, simply contact your local bank or credit union.

Open Brickwork Industry

8. Hire the right people.

The first impression is critical for a new small business, and unless you’ll be doing all the work yourself, that impression will be made at least in part by the people you hire.

Ideally you can find someone who is familiar with the business — someone who has twirled dough if you’re opening a pizza shop, for instance — but even more important is finding a person who is willing and eager to learn. You need employees who want to learn to do things (and represent your business) your way.

You do have to be willing to let go a little, however. This business has been your baby for a long time, but as you let it out into the world, you’ll need help taking care of it. Look for employees who are eager to contribute ideas and adapt as the business goes through its early growing pains.

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9. Do your homework.

Look over resumes. Call references. Don’t just hire your nephew to make your brother happy. (Wait until your business gets on its feet.)

Key questions like “Can you provide an example of a problem that you successfully solved?” may offer insights into a potential employee’s ambition, ingenuity, and work ethic.

 Keep in mind that such questions are common.

However, and the interviewee may have prepared stock answers already.

An inability to answer effectively is thus a bad sign.

In addition, try to think up a few problem-solving hypotheticals.

For instance, that are specific to your small business.

Open Brickwork Industry

10. Prepare your site.

Whether you have a physical or virtual business site.

The impression it makes on your initial customers will go a long way toward determining your chances of success.

  • If your business involves a storefront — a candy shop or used-book store, for instance — set up your space to represent your vision for the business. Coordinate color patterns and décor with your logo, for example, or consider personalizing it with family photos to establish your essential connection to this business. Consider hiring a professional interior designer and/or decorator.
  • A web presence is becoming (if not already) essential for any new small business, so don’t take this aspect for granted. Especially if your business has a substantial web-based component, make your site intuitive, manageable, and suited to the brand identity you want to build. Hiring a professional web designer may be a good idea.
  • If your budget is tight, and/or your business does not require a traditional storefront, don’t overspend on a fancy space. A local coffee shop can make a good place to meet clients, or you can rent a space as needed for such gatherings. Wait until your business has a solid foundation before expanding into a nicer space.

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11. Consider a “soft” opening.

There is no rule that says your first day of business has to also be your Grand Opening.

Give your business a chance to work out the kinks before announcing itself to the world.

Open Brickwork Industry

12. Start early.

Don’t wait until opening day, or even until you know when opening day will be.

Be proactive in establishing brand awareness and generating anticipation.

A “coming soon” sign on your in-preparation storefront is a good start, but not enough on its own.

  • Preserve the bulk of your initial marketing budget for the Grand Opening, but before that time utilize budget-friendly options like flyers, targeted direct mail, and a social media presence.
  • Try to build your brand even before your location is ready. If you’re going to be selling handcrafted necklaces or handmade pierogies, seek out a local craft or food festival where you can set up a table and sell your wares. (Be sure to advertise your forthcoming retail presence.) If you’re an accountant, maybe you can volunteer to offer tax advice at the local community center or library (and hand out business cards).

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13. Establish a marketing budget.

The run-up to opening and first few months of operation may very well make or break your new small business, so make sure you give your initial marketing push a strong effort.

  • One suggestion is to dedicate 20% of your first year’s marketing budget to your Grand Opening. This amount should be significant enough to spread your message widely at a time when your ads are likely to be their most effective, but at the same time isn’t an “all your eggs in one basket” situation that leaves you with limited ability for subsequent advertising.
  • Spend, for example, $4,500 advertising your Grand Opening, because that amount should be sufficient for two media buys. If that amount is beyond your reach, you may be able to utilize a mix of flyers, direct mailings, promotional items (balloons, banners, etc.), and a “sign spinner” at a busy intersection for around $1,500.
  • This, of course, assumes you have a fairly large marketing budget of $22,500 ($4,500 is 20% of $22,500). Since many businesses have much smaller marketing budgets (maybe only a few thousand dollars), always work within whatever 20% of your marketing budget is.

14. Use traditional media.

If your marketing budget allows, consider using traditional media like radio or newspaper. If you can manage television advertising as well, it is always a good idea to diversify your ad presence.

  • Before tossing radio aside as an outdated media format, note that some three-quarters of U.S. adults listen to radio at least occasionally, and often do so when driving somewhere. Thus, radio can be a particularly good advertising method for retail stores and restaurants. Target your advertising by format (Top 40, Country, Talk, etc.) and time of day to maximize impact.
  • Newspapers are popular among over-35 adults, but even a decent percentage of younger adults read a paper occasionally. Newspapers are still a cost-effective way to reach thousands of potential customers.

Consider including coupons as well; they provide not only motivation to visit but a tangible connection between a potential customer and your business. It is also easy to track their effectiveness, as more coupons coming in mean they are doing their job.

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15. Open Brickwork Industry

You may assume that TV advertising is beyond your small business budget, but there are options for producing and placing lower-cost ads, sometimes with the assistance of the local broadcast network. Consider bunching your ads during programs relevant to your targeted customer base — TV judge shows for a legal practice or the nightly news sports report for a golf training academy, for instance — so that you seem like a major sponsor.

16. Consider when to make your opening “grand.

As mentioned, there is no requirement to hold your Grand Opening on your first day of business.

And it is often advisable to wait even a couple of weeks before staging it.

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17. Make it an event.

Work hard to build excitement in the days and even weeks leading up to your Grand Opening.

  • Use the term “Grand Opening” in your marketing — it makes it seem more special than just an “open for business” notice. Create excitement by offering prizes, giveaways, demonstrations, special deals, etc., for visitors that day.
  • Hire a photographer to capture the event for media (traditional or social) consumption. Bring in live entertainment, extra staffing, even security if you expect an especially large crowd.
  • If your business and/or its location aren’t conducive to a large public Grand Opening, consider having an event more along the lines of a “launch party” at a nearby restaurant, banquet hall, etc.

Open Brickwork Industry

18. Guarantee a positive customer experience.

Plan ahead and do whatever you can to ensure that attendees walk away from your Grand Opening with a positive first impression of your new business. Oversights as simple as inadequate parking, long food lines, or running out of paper products in the restrooms can sour an otherwise enthusiastic reception.

  • Have extra staff on hand to make sure customers don’t have to wait too long for service or attention.
  • If parking may be an issue, try to work out arrangements beforehand with other businesses or community groups — perhaps setting up satellite parking at a nearby church, for instance.
  • Send attendees home with a token of your appreciation — ideally something with your logo on it — along with a coupon / special deal for a return visit.

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19. Involve the community.

Establish your connection to the local community from the very start of your business. Let people envision your business having a positive community impact for years to come.

  • Invite the local press to your event, but also other local business and community leaders. Network with as many as possible and establish yourself as a member of the local team.
  • If possible, align your Grand Opening with a community event, when local crowds will already be gathered. Make it seem like a part of that larger celebration. Sponsor the entertainment at the holiday lighting celebration or midsummer festival. Advertise both your business and your deep connection to the community.

20. INTRODUCTION TO PROCESSING PLANTS FOR EXTRUDED HEAVY CLAY PRODUCTS AND BRICKS

Ceramic products are obtained by processing clayey raw materials mixed with additives which correct their basic chemical and mineral characteristics, eliminate harmful components and improve the workability of the mixture for any given product.

The final mixture is the result of careful, continuous and at times difficult research and of the application of both recognised theories and practical experience, which can be very diverse but also very useful.

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In the pre-processing of the selected raw materials, the pieces which have come directly from the quarry are crushed and reduced to particles of the required size and the powder thus obtained is then mixed and homogenised.

This is of fundamental importance in order to achieve good control of the production process.

The main elements to be considered when planning production plant are the following:

  • Chemical and mineral characteristics of the raw material
  • Natural state and workability of the raw materials
  • Maximum required particle size and percentages of other particle
  • End product and its technical and commercial requirement

Production process as a whole.

Open Brickwork Industry

21.NATURAL STATE OF THE RAW MATERIALS

The characteristics of the natural state of the raw materials of interest to us are the following:

  • Initial size received at the factory
  • Relative humidity measured in relation to the dry weight of a sample
  • measured hardness on the Mohs scale

    The clayey raw materials can be classified according to their rate of humidity when extracted, as follows:
  • Dry (relative humidity up to 6%)
  • Semi-dry (relative humidity from 7% to 10%)
  • Semi-humid (relative humidity from 11% to 18%)
  • Humid (relative humidity from 18% to 25% and over)

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22. Open Brickwork Industry

The moisture content can vary according to the degree of malleability of the clayey component.

However, it must be specified that it is extremely difficult on the basis of the above classification to make homogeneous comparisons among the varieties of clayey raw materials, therefore an equal moisture content does not necessarily lead to similar results in the particle size reduction and sifting process.

Preliminary analysis and workability tests should always be done on a significant range of samples to see whether they are suitable on an industrial scale basis.
Bear in mind that raw materials differ according to the geographical location and subconsequently the prevailing climate, the location of the quarry, environmental conditions and working methods.

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23. Open Brickwork Industry

Extracted pieces can be of considerable size (up to 600 mm) as these can be processed by pre-crushing machines.
Pieces up to 200 mm in size can be fed directly into the primary mills which have wide feeding inlets.
The raw materials are subdivided according to their hardness, that is whether they have good workability or can be ground easily, as follows:

  • Hard, from a value of 6 to 7 on the Mohs scale
  • Semi-hard, from a value of 5 to 6 on the Mohs scale
  • Soft, under a value of 4 on the Mohs scale

24. Open Brickwork Industry

It is evident that hard or semi-hard crushable raw material even with a high clay content but with levels of humidity not over 18% are best suited for dry grinding.

When the values and characteristics are less favourable, for decades now methods of preparing the raw materials have been used, which recall the simplest and oldest traditional ones practised by farmers for treating the soil. Nowadays these have been made easier by the use of earth moving equipment with appropriate mechanical devices.

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25. Open Brickwork Industry

The operations can be summed up as follows:

  • The clay is extracted in the low rainfall months and stored in heaps, even in the open air.
  • In the summer months, the stored clay is spread over a large area and left to dry in the sun. While the clay is drying a machine from the quarry turns it over so that the lower layers are exposed to the sun and thereby surrender some of their humidity.
    This drying process takes about 1 to 2 days. After this treatment, the clay humidity has been reduced sufficiently to allow the dry working process to begin.
  • In an industrial plant, the treated clay is stored under canvas or a canopy in sufficient quantities to enable production to continue during the months when climatic conditions are at their worst.

26. Open Brickwork Industry

This also helps to amalgamate the different clayey components extracted from the quarry.

Non-clayey raw materials do not present problems as the traditional components for ceramic mixes, such as sand, feldspar, calcined clay, are not of high humidity content and in any case not being plastic they release water very easily.

When the clay cannot be treated in this way, artificial dryers are used to force-reduce the moisture content.

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27. ADDITIVES IN EXTRUDED HEAVY CLAY PRODUCTS AND BRICKS

Mixtures are normally corrected as required by using additives with low malleability.

Contrary to what is generally believed, some of these additives, for example fired rejects in small quantities (5–10%), do not actually increase wear and tear on the milling parts but actually improve the efficiency of the mills; when introduced together with the clayey material, they in fact facilitate the treatment and milling of the so-called “soapy” clays by improving the milling operation and the flow of the product inside the milling machines.

In addition, the use of “chamotte” has a positive effect on all the production process leading to the following advantages:

  • It is a lean component which stabilises the mixture without reducing its malleability
  • It increases mechanical resistance of the dry product by up to 10% – 15%
  • It helps drying and firing as it improves the total porosity of the humid and dried mixture
  • It performs a “binding” function, resulting in better amalgamation of the clay particles, and therefore of all the mixture.

28. Open Brickwork Industry

As well as these technical and productive characteristics, the use of “chamotte” in different particle sizes creates special aesthetic effects such as the dotted black and white surface of the renowned “Cotto Fiorentino”.

Compared to other types of lean additives, “chamotte” maintains in the fired product the characteristics of the base raw materials and amalgamates with them, whereas sand,for example, remains on the surface of the final product.

When the additives are already available in the required quantity and grain size, they are added to the clay powder directly into the dry mixers using volumetric or weighed batching devices. These have internal devices which guarantee perfect amalgamation between the components even if their bulk density is much different.

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29. PARTICLE SIZE DISTRIBUTION

One of the main characteristics of raw materials dry processing is that, once the appropriate maximum particle size has been identified, it is possible to achieve it and guarantee it by regulating the milling and grading equipment.

Constant control of the working parameters results in high standards in end products with special technical and aesthetic features.

This technology has a wide range of sizes to offer, we can sum them up in the following table:

1) coarse size from 1.5 mm and over
2) semi-coarse size from 0.8 mm to 1.5 mm
3) semi-fine size from 0.4 mm to 0.7 mm
4) medium fine size from 0.25 mm to 0.4 mm
5) fine size from 0.15 mm to 0.25 mm
6) very fine size > 0.15 mm

30. Open Brickwork Industry

By particle size we mean the maximum acceptable size which is at the “apex” of the distribution curve showing the percentages of all the other particles which make up the sample.

Particle size is always guaranteed by sifting control but the percentages of particle distribution can vary mainly due to:

  • Natural state and type of raw material
  • Ttype of refining of the powders during first milling
  • Variations of the operation parameters of the mill

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31. Open Brickwork Industry

To obtain different particle sizes, milling machines with different operations and characteristics are used.
From the results of the experiments carried out so far and which have been replicated by our machines we can state that:

For sizes 1) coarse and 2) semi-coarse the use of hammer mills with appropriately wide grids is sufficient.
These machines have a “double” function, they can both pre-mill and finish the operation after first milling, the powders are returned back to the primary mill

For size 3) semi-fine the use of hammer mills is also sufficient but the operations are subdivided into “primary” (when between 40% and 80% of the material fed in passes through at the milling passage) and finishing.

For sizes 4) medium fine and 5) fine, special finishing mills must be used with the primary mills. These have a grinding track which interacts with the rollers or pendulums with differing characteristics and functions, which make it possible to obtain particularly fine grinding.

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32. Open Brickwork Industry

The very fine siz range is actually found in every ground powder sample and can vary in percentage from 30% after grinding with only hammer mills to 100% after very fine grinding using pendulum or roller mills.

The positive (or in some cases negative) effects of the different particle sizes and relevant distribution curves on the end products are important and decisive. They affect both the technical and aesthetic characteristics of the product and the whole production process. They also affect the production rate and method as well as they influence to a larger extent the balance and efficiency of plant downstream.

Open Brickwork Industry

33. THE FINAL PRODUCT

M&S Dry milling is the only existing technology for the preparation of raw materials which can produce ALL types of clay products obtained through moulding by extrusion and/or subsequent pressing with ALL the technical and commercial characteristics required.

This is valid for all products from the “poorest”, the common brick (structural ceramic) to the most prestigious (extruded porcelain stoneware).

Today the Common Brick, known as structural ceramic, is produced in many varieties using the dry milling process, from non-supporting hollow bricks to wall blocks, standard or light, from the high-finished brick for external use reaching up to ceiling blocks , the whole range of small and large slabs for non-supporting horizontal structures and the most innovative products of this sector, the “bee-hive” support block which is both convenient and with highly technological value.

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34. Open Brickwork Industry

Covering materials, bent tiles and roofing-tiles, which in recent years have been particularly in need of technical and aesthetic improvements (see for example glazed roofing-tiles) which are essential in order to compete in a more and more demanding sector.
Dry processing of raw materials has led to improved transpiration, waterproofing, insulation and resistance to freezing thanks to a more homogeneous porosity, a resistant microstructure and lesser capacity for capillary absorption.

“Cotto” floor tiles, typical product of Italian Industry, has renewed and increased its prestige thanks to research into the composition of the typical Tuscan clay body through surface treatments and different moulding, drying and firing techniques which only dry processing can facilitate. Moreover surface brushed and rustic floor tiles with flashed, shaded, glazed and the handmade rough effects are latest trends ,dry processing system has been contributing to.
Nowadays all these products are suitable for the most varied in and outdoor applications, thanks to renewed characteristics of water absorption, hardness, resistance to flexing, deep abrasion, frost and sudden changes in temperature.

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35. Open Brickwork Industry

Klinker, technical product par excellence in the range of extruded products, thanks to the perfect and controlled reduction in particle size of its raw materials which facilitates firing at high temperatures, reaches perfection for the quality and chromatic effects of its glazed series whilst preserving all its other outstanding technical characteristics.

Extruded porcelain stoneware is the most innovative technical product, being obtained with a selection of kaolin clay mixed with feldspar and gypsum, and fired at high temperatures. To obtain extruded porcelain stoneware, very fine dry grinding of raw materials, perfect amalgamation, humidification, mixing and shaping at a controlled level of humidity are necessary.

36. The main ones are:

A) Treatment and milling of all types of raw materials currently used for the manufacturing of clay products, whether extruded or pressed, irrespective of their chemical, mineral and natural state characteristics.

The relevant advantages are as follows:

  • Existing deposits can be exploited without having to carry out expensive and complicated selections at the extraction stage.
  • Mixes can be made up using preferably the raw materials available or those more easily accessible thus avoiding the very high costs of finding and supplying alternative ones.
  • Reuse of the company’s own dried and fired production waste or that of other producers.

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B) Reduction of the required grain size and precise control of that parameter.

The relevant advantages are as follows:

  • Total elimination of impurities, all kinds of carbon particles, mica
    and others, which cause technical and aesthetic defects to the end products.
  • Possibility to obtain different grain sizes from different raw materials, to be used
    separately or in combination in the production process.

C) High flexibility in the use of milling lines and single machines, according to
different production requirements and the need to vary the required grain size. This is
made possible by designing plant as a series of modules with interdependent segments.

The relevant advantages are:

  • Continuous operation can be guaranteed even when routine or extra-duty maintenance is being carried out.
  • It is possible to react immediately to changes in the supply of raw materials due to changes at the quarry.
  • It is possible to modify the technical and aesthetic characteristics of the end product, or to plan its replacement quickly in accordance with the requirements of the market.
  • It is possible to foresee and to plan extensions, restructuring and technical innovations of the downstream units ensuring that the mixture is suited for the different shaping, drying and firing treatments.

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37. The main advantages of such a stage are:

  • Perfect amalgamation of the powder with partial conversion into pellets leading to a high
    level of fluidity and facilitating treatment in the downstream stages.
  • Elimination of lumps.
  • Precise weighed addition of water used for humidifying and mixing, which is guaranteed to remain constant as a percentage of the final mixture
  • Uniform pressure of the materials during extrusion and elimination of tensions within the mixture which facilitate the drying process and reduce the vacuum pressure required by the pugmill
  • Shaping with smaller quantities of water in the body (1 to 3% according to the chemical and mineral characteristics of the clays) with consequent savings in energy during the subsequent drying process.

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38. The positive effects on the downstream stages are as follows:

  • HANDLING – Better cohesion of the “green” moulded product which facilitates the handling of the material and makes it possible to simplify the plant engineering concerned.
  • DRYING – Homogenous distribution of the apparent porosity which helps to eliminate water at the drying stage thus reducing the production cycles and the percentage of waste materials.
  • TREATMENTS – Better mechanical resistance of the dried products and therefore safer handling of the material, reducing microfractures, and granting better results in the finishing and surface treatment and in the quality of the end product.
  • FIRING – The “skeleton” structure of the mixture resulting from a correct distribution of the size and morphology of the particles, thanks to its apparent porosity, improves preheating, firing and cooling because the organic substances are expelled more quickly.
In addition, the perfect amalgamation of the raw materials which make up the mixture helps to obtain better fusibility and a more efficient vitrification, thereby improving the technical characteristics of the end product.

CONCLUSIONS

Of course like all industrial processes involving raw materials , tests and trials on the Components to handle are essential to guarantee low processing costs and quality consistency in the final products, therefore Manfredini & Schianchi are equipped with skilled technicians, laboratories and pilot plants to conduct all the necessary ceramic evaluations.

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