In 1998, TEJAS BORJA, one of the leading roof tile manufacturers in Spain, selected BERALMAR to carry out a comprehensive upgrade of its Alicante plant. The century-old factory had been built on the outskirts of the city, but by the end of the twentieth century the city had engulfed it and it was unable to add warehouses or expand its existing facilities. This space limitation was BERALMAR’s main challenge in achieving the project objectives, which were:
- Increase production by 50%, from 35,900 (455 x 275 mm and 3.2 kg) to 53,000 mixed roof tiles daily.
- Improve energy consumption.
- Change fuel to natural gas.
BERALMAR built a new seven-chamber dryer in two phases, thus minimizing total factory downtime, which only stopped manufacturing for 2.5 months. The seven new chambers achieved the expected increase of 50% in production compared to the nine old chambers thanks to their large interior dimensions: 27.5 m long, 6.9 m wide and 4.8 m high. Each trolley had 16 shelves and each chamber was equipped with conical recirculating fans and a VA-500 model, 500,000 Kcal/h gas burner unit resulting in a 19-hour drying cycle.
BERALMAR also built a pre-kiln equipped with seven kiln cars to remove residual moisture. The kiln was also modified and equipped with gas burner units replacing the previous fuel-oil system. The entire structure was also upgraded, and the kiln was equipped with a side air injection system, a new quick cooling system and an automatic control for the MICROBER firing process.