BORAL Montoro, in its entry into the Endeavour Awards, showed that by being innovative it was able to infiltrate the highly competitive US roof tile market.
As manufacturers of terracotta roof tiles for the Australian market and export market in Singapore and NZ, Boral Montoro was approached to design a roof tile for the US market.
The aim of the project was to design, manufacture, and supply a terracotta roof tile substitute for the flammable wooden cedar shakes in the Californian roofing market. The product requirements were met with strict guidelines and had to pass the relevant US building materials standards.
Prototypes were made and tested for the correct strength to weight ratio, and shape and colour samples were sent to USTile, for feedback. Research and development was conducted to find suitable additives to improve the strength to weight ratio as pure clay was insufficient to meet the requirement of less than 600 pound mass per square. A household recycled product was finally proven to be a successful additive to the raw clay material.
The tile mould equipment required specialist design by an Italian company with the challenge being to co-ordinate the equipment manufacturer, Boral Montoro and USTile.
The project took full advantage of the US mandate to have all flammable shake roofs replaced with non-flammable materials within five years following bushfires in California.
Approximately 2 million pieces of Proshake Plus were exported during the 2004/2005 financial year which boosted exports to 13% of total production with a greater proportion expected to be exported in this financial year.
The production of the tile has increased profits, decreased overall costs of production on all products and helped insulate against any downturn in the domestic building cycle.
Judges Comments - An excellent export success by an innovative marketing manufacturing company. Boral must be congratulated for solving the many problems the new product posed.
Schenck Process Australia was highly commended by the judges for its engineered vibrating products which the company has been exporting to China.
Early on, Schenck recognised the market potential offered by the booming Chinese economy and in particular the government focus on cleaning up the environment, through the use of cleaner coal for firing plants which has meant that marginal coal mines were being closed. The use of Schenck’s screening equipment would allow the coal mines to produce better and cleaner product.
Through an already established reputation for supplying heavy-duty equipment Schenck has been able to penetrate the Chinese market with many of its larger screens.