FROM CLAY TO BRICK
01. CLAY PRODUCTION
Our bricks are a genuinely natural product, consisting of 90% clay and 10% sand. Clay from the local Elbmarsch region makes up about 90% of the clay component.
02. PRODUCTION AND DRYING OF THE BLANKS
The clay that is sourced is combined and thoroughly blended with the sand, and compressed to remove even the last impurity. Once a strand of clay has been shaped, it is cut to the desired width. The blanks produced this way are then stacked and kept in drying chambers until they are ready to be fired.
03. THE HISTORIC RING KILN
Once dried, the unfinished bricks are brought to the central piece of the brickyard: the ring kiln. They are manually loaded into the kiln and stacked, layer by layer, until they sit tightly under the ceiling. The kiln is fired, and the fire is kept burning during the whole production cycle, with not even a day‘s break. The masters keep it burning, carefully controlling it in the kiln, hour by hour, day by day, month by month. The bricks are fired following ancient traditions, using hard coal and wood. Shovel by shovel, the fuels are thrown into the kiln through holes in the ceiling.
04. FIRING THE BRICKS
After about 16 days in the oven, the blanks have turned into genuine clinkers. They are removed from the oven in the same way as they were loaded: by hand. They are stacked onto carts inside the kiln and pushed out.
04. THE FINISHED BRICK
The finished bricks are sorted (manually, of course) by colour, appearance and quality into the different categories of the product range. This process relies on the experience of the brickmaker. Every single brick has to be inspected and sorted before it can be packed onto pallets and bundled.