New Plants

Metal Tile Roof Plants for profit performance

Take a return-driven approach to your green-fields factory. Go from concept to commercialisation with Bradbury Metal Tile Roofing Solutions, for precision-engineered solutions in modular tile designs that offer efficient production and grow as you grow. The 5-Step Plan to creating your turn-key plant is not just about selecting and installing equipment, it’s about designing the operating plant that will make a strong contribution to your bottom line.

The 5-Step Plan to turnkey plan success

The 5-Step Plan from Bradbury Metal Tile Roofing Solutions delivers bottom line advantage because it is driven by sound engineering and commercial principles.

All turnkey plants are fully commissioned for testing before transport to your site for installation.

1 Needs analysis

  • Market analysis.
  • Production requirements.
  • Tile design.
  • Local materials overview.

2 Asset plan & budget

  • Equipment schedule.
  • Materials specification.
  • Installation budget.

3. Operational plan

  • Floor plan to fit the space.
  • Operational staff plan.
  • Maintenance plan.
  • Operational budget.

4.  Project Management

  • Installation on-time and to spec.
  • Delivery to budget.
  • Pre-commission testing.
  • Full operations testing.
  • Go–live supervision.
  • Operator hand-over.

5.  Operational Support

  • 24/7 remote diagnostics support.
  • Local service back-up.
  • Warranty where it counts.

Why metal tile importers are now manufacturing

The move from tile importer or distributer to manufacturer, is a profit-motivated investment and if well-planned, it pays dividends.

Reducing dependency on an off-shore supplier or local manufacture, not only removes a layer from the supply chain, it reduces costs.

Many governments, especially in developing nations, are eager to foster self-sufficiency in the economy and will fund development.  Bradbury Metal Tile Roofing Solutions works with clients to develop a sound case that fits the requirements of funding agencies.

Cost control is not the only benefit of producing locally.  It also allows the product to be better tailored for local conditions, such as by using local stone chip, decorative coil and better control over product availability.

Modular design key for great commercialisation

Keep tight control on your upfront investment without compromising long-term capacity by future proofing your new tile manufacturing plant.

Bradbury Metal Tile Roofing Solutions plants are designed and purpose built for the metal tile industry and your manufacturing business.  A manufacturing plant is a long-term investment and you need to strike a good balance between immediate affordability and long-term capacity.

Taking a modular approach allows your investment to grow as you grow. There is nothing worse in manufacturing than overcapitalising on a production facility with way too much production capacity.   Talk to the team at Bradbury Metal Tile Roofing Solutions about future proofing your new metal tile plant.

Precision tooling and the perfect press

Great tooling means consistent product quality and high throughput.

There’s no doubt tooling is important, Bradbury Metal Tile Roofing Solutions bring years of experience in tooling  technology advantages to the table.  But great tooling will only work as well as the press it is housed in. Experience has taught us how to get the right level of rigidity around the tool for a high stroke rate per minute.  When changing from one tile profile to another quickly – a strong press systems guarantees the tooling will be held securely in place even at high speed production rates for product consistency.

A fast-track transfer system boosts output

Many production facilities will at first operate efficiently with a pneumatically controlled transfer system.

Bradbury Metal Tile Roofing Solutions can provide the right technology with either a servo driven system or robots when you need to boost production.

Changing the transfer system is a simple and cost effective way to boost production; however, there is no point paying for rapid transfer until demand requires it.

Advanced self-cleaning spray booth technology

A self-cleaning paint booth minimises time loss for colour changes and clean up at day’s end, but booth technology doesn’t stop there.

In a typical line the first paint booth adds a base coat of high-build acrylic, then chip is added, then a low build acrylic over-glaze is added.  Some plant designs allow the chip stage to be bypassed to run both painted and chipped tile options through the same line.

Either way, your choice of spray booth technology is critical to product quality and production efficiency.  Bradbury Metal Tile Roofing Solutions uses advanced automated electronically controlled booth technology for consist of application.

Two-stage chip booth for tile style advantage

A two-stage chip booth gives you flexibility to have one main colour, spot colour and blended colour options.

You might want to use just local natural stone chips today, but market demand and changes in material cost can mean a sudden shift to vermiculite, or a need for vermiculite.  It’s important to choose booth technology that handles all materials equally well, from Bradbury Metal Tile Roofing Solutions.

A two-stage chip booth gives you the flexibility to have one main colour and a spot colour.  The keys to an effective finish are PLC controlled randomisation of spot colour, and cutting edge air knife system extraction of excess chip.  The air knife system is also a lot more efficient than the old tipping process.

Boost your run rate with a wicket-oven

A wicket curing oven - LPG, natural gas or electric - bakes more tiles in a smaller footprint and is modular so it can be easily extended to increase throughput.

If a tile isn’t well cured, its longevity and performance will be severely compromised, which means headaches for customers and installers.  Effective curing needs a three stage process, where the tiles pass through a pre-heat, baking and cooling process.

The wicket curing oven provides for all three in a small space because it flips the tiles from horizontal to vertical, allowing more to be baked in a shorter oven.  Being modular, the oven can be extended by 1200mm (4’) lengths to increase production capacity as required.


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