LOCATION:

1
LOCATION 1401 Broadway Street Marseilles, La
Salle County, Illinois Plant Manager Bailey
Wilson Asst Plant Manager Richard Barrett Plant
Controller Lyle Jobst Distribution Manager John
Mansson
Marseilles Plant
2
History

• Marseilles was built in 1990 as a one-kiln plant.
• Global Clay Products LLC (Georgia) bought the
  plant in 1999, and in that year, started
  construction on a second Ceric kiln.
• The second kiln was operational in late 2000,
  early 2001.
• Glen-Gery purchased Marseilles Plant in December
  2001.

Reasons for the purchase

• Have a modern plant in the Midwest market.
• Enlarge our territory and introduce Glen-Gery
  products to new areas.
• Get closer to the large brick-loving Chicago
  market and overall Midwest market. Being closer
  means getting brick there faster and cheaper than
  our competition.
• Marseilles is only 60 miles away from Chicago
  the 3rd largest brick consuming city in the U.S.
  Chicago uses 250 million brick per year.
• With the addition of Marseilles Plant, our
  production is evenly split between the East and
  Midwest regions of the U.S.

Marseilles Plant
3
Marseilles Modernization
3 million upgrade
Modifications to Kiln, Setting Machine, Dehacker,
Manufacturing Dept., Yard
The cost of the modernization was factored into
the buying price.
REASON FOR UPGRADE
Make the plant compatible with Glen-Gerys
manufacturing processes.
Laser search and locate system
Marseilles Plant
4
Marseilles Modernization Overview

• SETTING MACHINE
• Relieve the edges on architectural brick to
  minimize chippage
• New textures for residential product development
• More efficient production of size formats (make
  king size)
• DEHACKER
• Better blending within a hack
• Better cube blending between two kiln cars.
  Blending is now broken down to
• include brick from different hacks and separate
  courses.
• KILN
• Upgrade older kiln to achieve better color
  consistency on flashed products and consistency
  overall
• Better color matching from kiln to kiln
• MANUFACTURING
• Pug Mill auto-moisture controls to assure size
  consistency
• Grinding Dept. new equipment for accurate
  measuring of raw materials and
• additives will contribute to color uniformity
  in fired products
• Extruders will be outfitted with automatic
  hydraulic die changers for quick and
• efficient size switching
• YARD
• Rail Siding and loading dock added so that
  shipping is now done by railroad,

Marseilles Plant
5
Improved blending Transfer grippers add to blend
and start cube building process. No more than 5
brick that were together in the hack are together
in the cube
Marseilles Plant
6
Marseilles Plant Overview
Marseilles Plant
7
Site
Marseilles Plant is located on a 40-acre site in
Marseilles, IL, about 75 miles southwest Chicago.
Raw Materials

• Raw materials are extracted from two locations
• Shale (red brick) from an 80-acre leased site
• about 40 miles from the plant
• Fireclay (buff brick) from an 80-acre,
  Glen-Gery owned site about 20 miles from the
  plant.

Raw material reserves estimated at 30-year
minimum for both and shale.
Marseilles Plant
8
Production Details
Marseilles Plant makes extruded brick in 100
shale and clay and clay-shale blends, in both
flashed and clearburn ranges.
Production capacity 120,000 million Kiln
capacity 36 cars Kiln car capacity 10,080
modular Kiln car size 14 ft long x 21 ft. wide
Push rate (varies by size) 10 11 econos,
utilities 14 15 king, queen, 70 series
(engineer) 18 modular
The push rate is the amount of time it takes to
move a kiln car one length. An 18-car push rate
means that a car is removed every 18 min.
Marseilles Plant
9
Sizes
Size Width x height x length Modular 3-5/8 x
2-1/4 x 7-5/8 Econo 3-5/8 x 3-5/8 x
7-5/8 Utility 3-5/8 x 3-5/8 x 11-5/8 Engineer
3-5/8 x 2-3/4 x 7-5/8 (Engineer also called 70
Series) Queen 3 x 2-3/4 x 7-5/8 King 3 x
2-3/4 x 9-5/8
Marseilles king size is different from
traditional king size of 3-5/8 x 2-3/4 x 9-5/8
Marseilles recently made a premier size --
measuring 3-1/2 w x 3 h x 9-3/4 l for a
large order in Canada. Defined as a cross between
king and utility, premier is a common size in
Canada.
Marseilles Plant
10
Product Line
Marseilles products are divided into two
collections
Chicago Collection
Commercial market 13 products on Price List
Marseilles Collection
Residential market 26 products on Price List
Marseilles Plant
11
Product Line
Marseilles Collection Top selling residential
products
Cashmere

• St. Thomas
• London Mist
• Morning Dove
• Silver Aspen
• Cashmere
• Irish Crème
• Heathermist
• Colonial Rose

Merlot
Introduced in 2002, Cashmere is the 5 top
seller of all Marseilles products. Cashmere was
developed to compete with General Shales popular
Cortez product.
Chicago Collection Top selling commercial products

• Red Velour
• Colonial Sand
• Sahara Velour

Red Velour
Marseilles Plant
12
Product Line
Chillicothe Products These products from the
former Chillicothe Plant are now being made at
Marseilles

• Glacier Bay
• Cedarcreek
• 888 Laredo
• Rosebud
• Roseboro
• 924 Laramie
• Polar Bay

Also, Marseilles Cabernet is a look-alike
replacement for Chillicothes Monterey
Chillicothes Sunberry and 930 Tucson are
now in testing phase for production.
Marseilles Plant
13
Textures
Velour texture

• The plant predominantly makes Smooth and
  Velour textures
• SMOOTH is technically a die skin texture. The
  clay, which is made from a finer grind, passes
  smoothly through the extruder no wires are
  used.
• VELOUR texture is achieved by blade cutting a
  smooth column of clay after extrusion. Coarser
  raw materials result in a rougher texture.

Smooth texture
Note Marseilles products look like they are wire
cut, but this in an incorrect description. The
are blade cut.
Worm (also called Indented) is a texture
treatment used on some residential products.
(See Cashmere and Merlot samples.)
Marseilles Plant
14
Marseilles 2003 Market Overview
Primary markets / brick shipments (Jan - Jun)

1. Illinois 17,077,000 49.0
2. Indiana 4,221,000 12.1
3. Ontario 3,937,000 11.3
4. Michigan 2,660,000 7.6
5. Wisconsin 1,264,000 3.6

Chicago alone represents 14,428,000 BEs (or 85)
of this figure.
Total Shipments 34,841,000
Total Residential shipments 23,171,000 Total
Commercial shipments 11,507,000
Marseilles Plant
15
Marseilles 2003 Customer Overview
Top customers / brick shipments (BEs)

1. Prairie Brick Co. Illinois 10,187,114
2. Brampton Brick Ltd. Ontario 3,852,288
3. Chicago Block Brick Illinois 1,013,793
4. Northern IL Brick Supply Illinois 869,819
5. Edgewood Building Supply Indiana 927,465

Marseilles Plant
16
Marseilles 2003 Customer Overview
Use in Construction / Brick Shipments (Jan - Jun)

1. One-family houses 7,912,000
2. Two-family houses 590,000
3. Apartments 858,000
4. Hotels/motels/dorms 48,000
5. Commercial 3,635,000
6. Manufacturing bldgs 4,000
7. Education/Science 1,821,000
8. Hospital/Health 271,000
9. Public 441,000
10. Religious 336,000
11. Dealer stock 18,350,000

Marseilles Plant