New clay roofs for Hungary – Tondach Gleinstätten AG produces large-size roofing tiles at its new Csabai II plant

»1 Overview of the Tondach plants in Hungary

»2 Aerial photo of the new Csabai II plant during the construction phase

»3 Circular souring facility at the Jamina plant

»4 Shaping equipment at the Jamina plant with circular screen feeder, extruder and roofing tile press, dryer car unloading can be seen at the right front

»5 Setting and unloading by hand (Jamina plant)

»6 Preparation line in the Csorna plant

»7 Csorna plant: view of the tunnel kiln

»8 Kató Aladár, CEO at Tondach Magyarország (left), and Peter Horvath, Operations Manager at the Csorna Plant, inspect the fired roofing tiles

»9 Prominent feature of the new Csabai II plant: the 30-m-high souring towers

»10 The two parallel shaping lines start with two circular screen feeders

»11 The large-size clay roofing tiles are pressed on the two DR6/200 3‑mould presses

»12 With the two independent roofing tile presses, two different sizes can be pressed parallel

»13 The tiles lie on ACP (self-centring) plastic setters that can be stacked in each other

»13 View of two coupled dryer cars

»15 The dried tiles are placed on a belt and conveyed via a bypass either directly to the setting station or to the engobing equipment

»14 Thanks to the two engobing lines, there are almost no limits to surface design

»15 Mihaly Féleghy, Technical Director at Tondach Magyarország, and Sabine Linner, Corporate Marketing & Communications, in front of one of the 9-m-wide tunnel kiln cars

»16 The H-cassettes are stored intermediately on the tunnel kiln cars

»17 View of the packing system for flat tiles

»20 The companies taking part in the project

»18 Turntable press for accessories

»19 Engobing equipment for the production of accessories

»20 Flue gas cleaning system

»21a Rumba – natural red

»21b Twist – engobed in black

»21c Bolero – glazed in burgundy

Tondach Gleinstätten has been actively involved with operations in Hungary since 1992, following its acquisition of shares in Jamina AG in Békéscsaba. 1993 saw a second phase of expansion with Tondach taking a stake in Csorna-Beled AG. In 2002 the Austrian company bought 100% of shares in the Tata roofing tile factory. On 27 March 2009, Tondach AG opened its most modern and largest project in Hungary – the Csabai II roofing tile plant – and with this, Tondach has set new standards.

1 Introduction

Employing around 3 100 people in 11 countries, Tondach Gleinstätten AG now produces around 500 mill. roofing tiles and around 305 mill. standard-size masonry bricks. In 2008, its 34 plants at 28 locations generated a turnover of € 258 mill. In the years 1992 to 2008, Tondach invested around € 470 mill. in new plants and the modernization of existing sites, € 155 mill. of which in Hungary alone. Here the company is currently operating at six locations with eight plants:

› Jamina, Békéscsaba

› Csabai, Békéscsaba

› Csorna, Csorna

› Beled, Beled

› Tata, Tata

› Budapest, Budapest (sales...