Rooftile manufacturers are turning to quality production equipment to produce concrete rooftiles that are more in keeping with modern developers requi
Rooftile manufacturers are turning to quality production equipment to produce concrete rooftiles that are more in keeping with modern developers requirements for durable and cost-effective rooftiles that are more aesthetically appealing with stronger colours and finer finishes.
For local tile producers the acquisition of ABECE equipment gives them an edge in a highly competitive roofing market where every cent counts. The advanced machinery maximises efficiency and reduces material usage with the added benefit of allowing individual producers to continuously develop their product lineup and introduce new innovations that are constantly being developed by the equipment manufacturer.
ABECE is a Swedish company with more than 100 years of industrial experience. Its machinery for concrete roof tile production is built tough and capable of operating reliably in even the most challenging African conditions. Supplied locally by PMSA the equipment ranges from small-scale manual units producing 500 tiles per day to fully automated plants capable of producing over 60 000 tiles in a standard shift.
According to ABECE sales manager, Andreas Hasselmose, the company has fine-tuned its equipment in response to global demand for the production of tiles that are less expensive to produce with modern innovations that allow them to easily exceed functional and especially aesthetic demands of the buying public. This puts producers in a strong position at the business-end where world-class, aesthetically pleasing tiles can be produced at a lower cost per tile compared to traditional tiles.
Local advantage
“Having spent more than a decade in South Africa and now working back at head office, it is a huge advantage for the company to understand South African conditions and the specific challenges for tile manufacturing. These range from area to area and includes anything from varying sand quality and temperature extremes to local labour availability price sensitivity and pressure from low-cost manufacturers.
“As a result our machines are designed to tackle these realities. Models such as the SPS extruder feature dual stop-start safety functions while the extrusion head is fully accessible to allow operators to maintain and clean it efficiently even in smaller production plants. This type of ease of operation is the kind of adaption we have made for local producers to ensure lower learning curves for new staff while also minimising downtime due to maintenance issues,” says Andreas.
He explains that not all concrete tile manufacturing equipment is created equal. One of the most significant advantages of ABECE roof tile equipment is the ongoing research and development by the manufacturer to improve products that can be produced with its machines. An example is the constant improvement of existing profiles such as the Double Roman tile which has led to the development of a new tile that uses 6.4% less material, is lighter and equally strong as current designs yet can still be used in place of existing Double Roman tiles.
In practice, this translates to up to a reduction in both material consumption and end-product weight which is an impressive saving in a business where even small efficiencies dramatically impact profitability.
The reduction in weight and material also benefits logistics. Lighter tiles reduce transport costs and handling issues on site, while the precision of ABECE machines ensures every tile produced is consistent in dimension and quality. For manufacturers this precision minimises breakages, reduces waste and maximises the usable output from raw materials. This is an important consideration in parts of the country where sand quality can vary significantly depending on the source. ABECE machines are engineered to accommodate different sand types without compromising tile density or structural integrity giving manufacturers more flexibility when sourcing materials locally.
Efficient curing
In addition, quick and balanced curing systems are available to mitigate losses as a result of weather events as well as being less likely to crack, chip or warp which saves manufacturers costs related to rejected or returned tiles. As energy prices continue to increase the use of ABECE Greenbox provides manufacturers with a smarter solution where the exothermic reaction of the concrete is utilised to maintain the heat needed for the tiles to cure.
Andreas adds that correct curing ensures that concrete tiles achieve optimal strength and durability faster and tiles are stronger which directly reduce warranty claims and improve the long-term reputation of the manufacturer. ABECE equipment integrates advanced curing systems that control temperature and humidity, creating ideal conditions for tiles to cure and harden without additional heating and energy usage.
As the sole distributor of ABECE concrete tile manufacturing equipment in southern Africa, PMSA is well positioned to supply and support the machines through its branch network. It is also best positioned to meet market trends for tile profiles and finishes. This provides the kind of flexibility that is required locally with new trends and architectural styles often driving sales. These range from classic Roman styles to Tudor and a variety of other tile profiles in a variety of colours and finishes.
PMSA’s Quintin Booysen explains that colour consistency in tile production is a significant advantage with ABECE machinery. “In competitive markets, like ours, aesthetically uniform tiles command higher prices and coatings applied during production or through-coloured concrete tiles provide longevity over post treated painted roofs. Multi-colour and antique effects can also be added to give architects and developers the freedom to offer visually distinct roofs without compromising on tile performance.
“PMSA offers producers the ability to manufacture tiles that are lighter, stronger and more consistent than older production methods and our range of solutions allow companies to experiment with designs that meet evolving market trends. This ability to produce a variety of profiles allows manufacturers to innovate as well as respond more quickly to consumer demands without the need for multiple machines,” says Quintin.
Market trends
Concrete roof tiles are seeing increased sales in both urban and rural developments due to their durability and low maintenance requirements. According to recent market research the South African concrete roof tile market is expecting an annual growth of 5–7% due to urbanisation, residential expansion and commercial construction projects.
This growth is driving demand for high-capacity and reliable production equipment capable of producing large volumes without compromising on quality. ABECE’s modular systems also allow manufacturers to scale up production as demand increases and the long-lasting nature of the equipment ensures that producers can scale their operations over the years as demand increases.
ABECE machines are “built to last” and are designed to endure decades of operation with minimal major overhauls. This durability aligns with South African producers’ need for reliable returns on investments. Solid local support through PMSA also means operators can receive training, guidance and troubleshooting assistance quickly to ensure production targets are consistently met.
For local investors or existing plant owners considering establishing a concrete roof tile manufacturing plant in South Africa the case for ABECE machinery is compelling:
• Ongoing support and innovation ensures customers can adopt the lates tile designs and innovations to make stronger, lighter and more cost-effective tiles.
• Versatility: Multiple tile profiles, finishes and trim options to suit the local market.
• Curing excellence: ABECE Greenbox curing systems provide a smart solution where the exothermic reaction of the concrete is utilised to maintain the heat needed for faster more efficient tile curing.
• Market alignment: Machines designed to meet current and growing demand in the R1-billion plus South African roof tile market.
• Local support: PMSA provides training, spare parts and technical assistance, ensuring minimal downtime.
• Sustainability: Reduced material use, lower energy consumption and environmentally friendly design.
• Long-term reliability: “Built to Last” philosophy ensures decades of productive operation.
“When investing in an ABECE solution producers are buying machinery capable of handling the unique challenges of the South African market with an extremely competitive edge due to the exceptional quality and operational efficiencies. Whether producing small volumes for niche markets or high-volume output for large-scale housing projects, PMSA has an ABECE solution to meet any requirements,” Quintin concludes.
