Manufacturing
Since the beginning Fireclay has prided itself on going above and beyond to create the most sustainable manufacturing facility possible. Our manufacturing systems are continually being adjusted to insure that our recycled materials, clays, and water are used with utmost efficiency and conservation.
We consider recycling in three ways: first by formulating our tile bodies utilizing a majority of post-consumer and post-industrial waste materials that we purchase, second by processing internally produced scrap materials back into our clay bodies, and third by finding special markets for tiles that do not meet our exacting specifications.
Click the images below to see a slideshow of our manufacturing process:
Clay manufactured but not used in tiles can be collected as scrap and recycled back into the production loop prior to firing. 99% of all scrap clay generated in the tile forming process is recycled back into new tile. 80% of all glaze over-spray is collected and recycled. Any waste we do produce is inert and non-hazardous.
Though we make tile to order, inevitably we end up with seconds or overstock. We sell these tile at a discount to individuals, designers, and contractors through our "Boneyard." We also seek non-profit organizations who can put our tile to good use for up to a 90% discount off standard retail prices.
Materials
The glass we use is waste contaminated glass from consumer curbside glass recycling. When bottles are crushed into small chunks to be re-melted into new glass bottles there are small particles generated. This small particle glass can not be reused in the glass bottle making process. The use of this glass is limited so we are using it to make our beautiful handmade Debris Series tiles.
The granite dust we use is a by-product from asphalt production. When gravel is ground to mix with the binder and petroleum components to make asphalt there are fine dust particles that can not be incorporated into the mix. We use this granite dust as the basic ingredient of our Debris Series tile. In fact the Debris Series was developed to keep this dust from going to landfill.
In 1998 Granite Rock asked us if we could develop a product using a granite dust byproduct from their gravel and asphalt production. After 12 months of R & D research we realized that we could not make a viable product from this material. Our trials and many errors lead us to the idea of combining recycled glass and the dust together to make a high quality tile product. After another 12 months of research we launched our Debris Series tile in April of 2000.
People
Since inception Fireclay has taken enormous steps to care for its employees by providing fare wages, substantial benefits, and other perks.
Many of our employees have been with us for over 15 years, and over the years Fireclay has helped numerous employees purchase their first home, put children through school, and provided a challenging work environment that allows and promotes individual expression and decision making.
