Quality

Raw materials

We are well integrated with our raw material suppliers and know them all very well and for a very long time. We know that they fullfill our demands and the demands of our clients without exception. Our products have to be of constant volume, they are not supposed to lose their shape, they have to withstand fast temperature changes and they have to be resistant against the impact of melts, slags, gases and charging materials.

Natural and synthetic raw materials are combined into a precise mixture which fullfills these demands. The specific and continuously checked mixture is the pre-condition for our high product quality, and is continuously upgraded with the latest knowledge from product applications, production and research. We save on existing resources by using selected recycled materials.

This particular care for the choice of raw materials including their storage and processing, secures maximum product security, and is the basis for all our quality bricks made in Germany. Personal commitment brings security, control creates trust.

Production

Specially trained employees on each product movement handle the product at each production step with optimum care and by making the right decisions. The form of the brick takes shape in the moulding shop, verified by sketches, drawings and measuring data. This takes place in house by specialized toolmakers and mould makers that know their trade and make sure that any shrinkage and swelling of the material during manufacture is corrected.

Complicated special formats with extremely large dimensions and complex shaping geometries are manufactured by hand moulding. Traditional wooden moulds are prepared in our carpentry shop for the purpose moulding of these bricks.  The hand moulding procedure is so demanding that it cannot be replaced by automation. This process requires the entire attention of one man who secures the homogenous compression of the material by intelligent and using different types of specialised manual work. Experience and empathy in combination with the above skills are the only way to deliver the predefined properties. From our perspective, experience and intelligence simply cannot be replaced.

Our modern machinery provides for serial production of all product formats in high numbers. The tools for this area at this time are delivered from our own steel moulding section.  We support our own complete moulding shop and thus keep full control in our hands. This has advantages for our customers even on a daily basis which cannot be overlooked. We act quickly and independently from sub suppliers and thus can guarantee our high production standard also in this area.

Quality Control

The ready pressed blocks seem massive, however, they are fragile like raw eggs. Therefore our employees call on all their skills when they load the kiln cars.  Firing alleys are required to ensure the even firing of the bricks. This procedure requires detailed knowledge of the firing processes by our employees. A suitable furnace is available and is used for each brick type and each brick format.

Quality control is effected by taking each brick from the kiln car after the burning process, visually inspecting it, and then having it undergo a  thorough check.

Products with faults are sorted out from flawless ones by this procedure. Quality is always in its prime and proper place. Quality control without our capable specialists themselves being involved  is not possible in our philosophy. A role however that our specialists are readily able to handle .

Our specialists are able to recognise the differant formats immediately and to handle them with expertise. This close association with the product is a guarantee shown in the known quality of our products leaving our plant. This quality is certified since we work strictly by ISO 9001 standards.

Thus, P-D Refractories‘ products have become irreplaceable for use in the manufacture of almost all of the industrial products that form part of our daily life.

Dispatch

Prior to shipping each order is finally inspected once more. Random samples are taken and checked out in our laboratory and vetted thoroughly.  The customer is advised the exact parameters of the requested chemical, physical and mineralogical properties shortly thereafter. This is the last opportunity for us to verify the brick. After that, samples are taken, sealed, and then archived.

It is of great importance to us, that our products reach our customers in exactly the same state as they left our plant. Therefore, packaging of the bricks and all of the pallets is performed with special care.  Each order is packaged with a sophisticated packaging material which withstands the stress of handling especially on long deliveries. This ensures secure transport.