Clay is excavated from the quarry using a huge mechanical digger called a knot. Massive metal rods called crushers break down the knot of clay into smaller pieces so they can be processed.
These are pushed through sieves called screens to make even smaller pieces. Lime, shale and sand may be added. All the ingredients for the brick go through a feeder into the mixer. This combines them all evenly.
All Roma Bricks are formed by extrusion, the most sophisticated method of brick formation. Our complex extrusion system ensures smoothness, uniformity and edge-precision in each brick.
Using state of the art equipment, pulverized clay materials and water are fed into one end of a pug mill, which uses knives on a rotating shaft to cut through and fold together material in a shallow chamber. The blend is then fed into an extruder at the far end of the mill. The extruder consists of two chambers. The first removes air from the ground clay with a vacuum, thereby preventing cracking and other defects. The second chamber, a high-pressure cylinder, compacts the material so the auger can extrude it through the die. After it is compressed, the composite clay material is forced out of the chamber though a specially shaped die orifice. The cross-section of the extruded column, called the “pug,” is formed into the shape of the die. Sections of desired length are cut to size with rotating knives or stiff wires. The holes in extruded bricks are created by the design of the mould and allow mortar to lock the bricks together when they are laid, allowing your structure to be built more securely.
All Roma Bricks are wire cut using an advanced system of mechanised wire-slicing technology. Wire cutting ensures uniformity and a sleek, high-end finish on the face of each brick.