The structural ceramics manufacturing process is a chain of closely interconnected operations. From the moment the clay enters the plant until bricks, blocks or other products are ready for drying and subsequent firing, the material must be crushed, screened, metered, shaped, cut, conveyed and handled under controlled conditions.
The quality of the final product therefore does not depend on a single machine. Irregular particle size during preparation can subsequently affect extrusion; an inaccurate cut can cause dimensional issues; and overly rough handling before drying can damage a product that is still highly sensitive to mechanical stress.
This interdependence between stages explains why the plant must be analysed as a complete process. Auxiliary machinery is no longer simply a collection of independent units; it becomes the link that maintains production continuity.
At IFAMAC, we design and manufacture bespoke machinery for the structural ceramics industry, developing solutions that cover everything from raw material preparation and conveying to product handling and the movement of dryer cars or kiln cars.
1. Raw material preparation: quality begins before extrusion
Before a ceramic product can be made, the raw material must be sufficiently homogeneous and suitable for the process conditions. Clay from the quarry can vary in moisture content, particle size and compaction, and may contain oversized particles. The initial operations are therefore intended to condition the material.
Poor preparation does not disappear during the subsequent stages. On the contrary, it can carry through to extrusion, drying and firing in the form of dimensional irregularities, shaping difficulties or product defects.
1.1 Clay shredders, grinding mills and screens: conditioning before shaping
Clay shredders help reduce and homogenise the material so that it is easier to handle. They also perform a particularly useful function in the internal recovery process: rejected slugs from the extruder outlet can be broken down to facilitate their conveying and subsequent return to the production circuit.
This ability to recover material is important from both a production and an environmental standpoint. Rather than treating certain rejected slugs as waste, the clay can be reconditioned for reuse.
Grinding mills perform another essential part of preparation: reducing the particle size of the raw material. Achieving the appropriate particle size facilitates subsequent homogenisation and provides more stable conditions for the following operations.
The vibrating screens for ceramics then classify the material through different screening stages and replaceable meshes. Their purpose is to separate particles by size and prevent unwanted fractions from continuing to downstream equipment.
The combination of crushing and screening therefore makes it possible to control two fundamental variables: reducing the material and determining which particle sizes continue to the next stage.
1.2 Hoppers, feeders and conveyors: maintaining a stable supply
Once the raw material has been prepared, it is also necessary to control how it is stored and delivered to the next machine. Irregular feeding can create periods with too much or too little material and disrupt process stability.
Storage hoppers and feeders provide an intermediate reserve and regulate material discharge according to production requirements. IFAMAC develops hoppers in different sizes and capacities, as well as belt feeders adapted to the characteristics of each installation.
Conveyors complete this stage by connecting the different points in the plant. Belts can be configured with smooth or profiled surfaces when steeper inclines are required, with widths, lengths and routes adapted to the available space.
The purpose of this group of machines is simple but crucial: to ensure that the downstream process receives the right quantity of material, with the required characteristics and on a continuous basis.
2. Shaping and cutting: turning a continuous slug into accurate products
Once the clay has been prepared and mixed, it reaches one of the key stages in the process: extrusion. The material is forced through a die that determines the cross-section of the product and forms a continuous slug that must subsequently be divided.
From this point onwards, accuracy becomes particularly important. The dimensions obtained during cutting will affect product uniformity and performance during the following stages.
2.1 Continuous cutting or cutting with the slug stationary?
The choice of system depends on the product characteristics and the line configuration. The Slug cutter performs the cut while the slug remains in motion. IFAMAC develops this equipment with working widths from 500 to 1,200 mm and synchronised movement to maintain a perpendicular cut.
Its main advantage is that it avoids interrupting the flow, which is particularly valuable when a high production rate must be maintained.
The Multi-wire push through cutter and Multiwire vertical cutter, on the other hand, operate while the material is stationary. This configuration provides greater control over movement during cutting and can be adapted to products and geometries that require specific operations.
There is also a third option: the Synchronous side cutter. Servomotors and encoders synchronise the movement of the system with the advance of the product, combining accuracy with production continuity.
There is therefore no single technology suitable for every line. The cutting system must be selected according to the format, speed, geometry and production requirements of each installation.
3. Handling before drying: protecting a product that is still vulnerable
Once shaped and cut, the product still contains a considerable amount of moisture. This makes handling particularly delicate: impacts, sudden movements or incorrect positioning can cause deformation that will later become apparent during drying or firing.
Automation at this stage is not intended merely to increase speed. It also ensures that every movement is repeatable and that the product reaches the dryer in the required condition.
3.1 Loader/unloader of dryer cars
The Loader/unloader of dryer cars automates one of the most important operations in this transition. IFAMAC combines lifting toggle mechanisms, conveyor belts and robust four-column lifts, using servomotors and counterweights to achieve accurate, dynamic positioning.
The system coordinates the arrival of the product with its placement in, or removal from, the dryer cars used in the process, avoiding unnecessary movements and maintaining a rate compatible with the rest of the line.
The conveyors and positioning systems operating around this equipment are also essential. They must ensure that each product arrives in the correct position and with adequate spacing so that the loading operation can be repeated cycle after cycle.
This stage particularly highlights the importance of integration: a fast loader offers little benefit if the upstream conveyor cannot feed it correctly or if the following stage cannot accommodate its capacity.
4. From drying to firing: moving, orienting and loading without breaking the flow
Drying progressively removes some of the water contained in the products before they enter the kiln. When the product leaves this stage, it must continue towards the preparation and loading operations required for firing.
Although the product has gained strength, its handling must still be carefully controlled. Furthermore, the arrangement required during drying is not always the same as the arrangement needed for firing.
4.1 Turning stars and rotating forks
Turning stars alter the orientation of products as they travel along the line. They consist of interlocking stars integrated into the conveying system and are particularly useful when the product must adopt a different position between drying and firing.
Rotating forks complement these operations when groups of products need to be handled or stabilised. Automating these movements makes it possible to repeat operations in a controlled manner and reduce reliance on manual handling of ceramic products.
4.2 Kiln car setting: preparing products for firing
Loading kiln cars is another critical point. Products must be positioned accurately and gently to prevent displacement, impacts or incorrect setting patterns before entering the kiln.
Robotized kiln car setting systems can use pneumatic grippers or forks adapted to the product. By coupling these handling tools to robots, a large number of movements can be performed accurately, gently and repeatedly, particularly when travel distances are short.
Robotic automation also enables the handling tools to be adapted to the dimensions and characteristics of each product, which is especially important in plants that manufacture different structural ceramic formats.
4.3 Draggers and transfer cars: the logistics connecting the plant
Once loaded, kiln cars and dryer cars must also move between the different production areas. This is where auxiliary systems come into play. Although they often go unnoticed, they are essential for maintaining continuity.
Draggers provide controlled movement of cars along defined routes, while the Transfer car enables perpendicular movement of kiln cars, dryer cars or pallets.
Transfer cars can be configured with different drive methods, automation systems, stopping controls and safety devices to suit the specific layout of the factory.
Their importance lies in their ability to physically connect areas that operate with different routes and orientations. Without this equipment, automation of the main machines would be limited by the plant’s own internal logistics.
5. Efficiency lies in the connection between every stage
Analysing the structural ceramics manufacturing process makes it clear why productivity cannot be attributed to a single machine. An extruder may operate correctly, yet the line can still lose performance if it receives irregular raw material. Likewise, a high-accuracy cutting system cannot prevent losses if the products are handled incorrectly before drying.
Efficiency is achieved when preparation, feeding, shaping, cutting, conveying, loading and handling operate as parts of a single system.
Correct integration helps maintain a more stable flow, reduce manual intervention, facilitate the recovery of certain rejects, eliminate unnecessary movements and ensure repeatable operating conditions throughout production.
It also explains why bespoke machinery is particularly important in this industry. Two factories producing bricks can have entirely different layouts, capacities, formats and production methods. Adapting each system to the actual process addresses specific requirements without forcing the entire plant to conform to a standard solution.
From the arrival of the clay to the preparation of the products for drying and subsequent firing, structural ceramics manufacturing requires a sequence of perfectly coordinated operations. Shredders, mills, screens, hoppers, conveyors, cutting systems, dryer car loaders, turning equipment, kiln car setting systems and internal transport systems perform different functions, but pursue the same objective: to maintain a stable process and preserve the characteristics of the product throughout its journey through the plant.
Improving an installation therefore does not always mean increasing the capacity of a single machine. In many cases, the opportunity lies in analysing how the different stages interact, identifying accumulation points, unnecessary movements or processes that are difficult to synchronise, and developing a specific solution.
At IFAMAC, we have more than 35 years of experience in the design, manufacture, assembly and commissioning of bespoke machinery for the ceramics industry, approaching every project with a comprehensive view of the production process.