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Shannon Malone

Shannon Malone

Social Media Maven

Shannon joined the team in 2013 as Fireclay's Social Media Maven. After graduating from the University of California Santa Cruz with a degree in Cultural Anthropology, Shannon pursued her lifelong passion for interior design by working as a freelance writer for Houzz. Her interest in design related content eventually led her to Fireclay where she gets to spend her day spreading the Fireclay word and help get tile to the people!

Favorite thing about Fireclay: The beautiful handmade nature of our tile, especially our new Handpainted Collections.

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Susanne Redfield

Susanne Redfield

Creative Consultant

Tile designer and ceramist Susanne Kibak Redfield merges her Danish roots and love of traditional crafts with a modern sense of restraint that brings just enough to the design without going over the top. After graduating from the University of California Santa Cruz in 1981, Susanne started her own business making ceramic tiles. She introduced Kibak Tile through Kneedler Fauchere, a revered interior showroom to the trade, then spent twenty five years in a successful relationship with Ann Sacks. "I began hearing about Fireclay Tile, their sustainable story and youthful energy really captured my imagination, I absolutely wanted to be part a company that really cares about tomorrow. Designing product for Fireclay Tile is energizing, truly inspirational.

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Casting the Mold: Production of Crush Molds

Casting the Mold: Production of Crush Molds

Casting the Mold: Production of Crush Molds
Q & A with Nolan Johnson – Fireclay Tile's Glass Factory Manager

What’s the overarching approach of the glass factory?
NJ - In the crush factory we are constantly striving towards being a leader in the sustainable tile industry. We use as much recycled material in our glass tile production as possible, in an effort to reduce the amount of waste going to our local landfills.

Nolan Johnson - Fireclay Glass Factory Manager

Fireclay's glass tile is made out of 100% recycled content. What about the molds they're made from? Are they recycled material as well? 
NJ - The process begins when we receive recycled window and solar tubing glass from our local vendors. We “crush” that recycled glass into a fine, medium and large frit. The next step is making the tile molds. Our molds are made out of pulverized recycled clay tile and other recycled components mixed together and placed in a casting form. After being in the form for 12 hours, the molds go into the kiln for another 12 hours to cure.

Casting the Mold

Once the molds have cured, what’s next?
NJ - The molds are brought to the factory floor where they’re filled with glass frit. Color is added to the glass frit by mixing in a powdered pigment to get the desired color. Next up is selecting the size of tile to make. The glass and pigment mixture is then poured into the molds and lightly shaken to create a nice even distribution of material. Once the molds are filled with pigment and glass mixture, it’s time to start loading them on the belt kiln. Each mold runs through the belt kiln for about an hour at 1630 degrees fahrenheit. The tiles are then moved to a cooling rack for about 30 minutes. After cooling, the order is matted or sheeted and ready to ship.

Pouring glass frit into molds and feeding through the kiln.

For more information about Crush, download the .pdf of Fireclay's Crush 100% Recycled Glass Tile Brochure.

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