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CONCRETE PRODUCTS & CAST STONE44 CPI %u2013 Concrete Plant International | India Edition %u2013 5 | 2025 www.cpi-worldwide.comMore than 40 years of experience in manufacturing concrete roofing tiles was abruptly challenged when a devastating fire broke out in January 2023 at Danish company I%u00b7B%u00b7F (A/S Ikast Betonvarefabrik). The fire destroyed the tile production facility at the company%u2019s headquarters in Ikast, Denmark, bringing operations to a sudden halt. Fortunately, no lives were lost, and only one employee sustained minor injuries. Yet, from the ashes of the blaze, a transformation began.The mechanical part of IBF%u2019s tile production had always been a result of in-house innovation. Developed by the company's own machine division%u2014and backed by the deep technical expertise of owners Mogens and Preben Rosenkilde%u2014IBF had become a leading player in concrete roof tile manufacturing in both Denmark and Poland. Though the production building and machinery were beyond repair, the fire was successfully contained, leaving the adjacent nine curing chambers largely undamaged. While demolition was still underway, IBF%u2019s leadership was already charting a course forward: a complete modernization of its tile production. Thanks to strong backup from its Polish production sites, Danish customers remained unaffected during the transition%u2014delivery reliability was maintained at IBF%u2019s usual high standard.Modernizing the Curing ProcessThe decision was made not only to rebuild%u2014but to build smarter. After careful evaluation, IBF opted to convert its existing curing setup from a traditional Last-In-First-Out (LIFO) configuration to a First-In-First-Out (FIFO) system. This shift represented more than just a change in material flow; it was a strategic move to optimize production efficiency, product tracking, and operational safety while ensuring greater product strength and color consistency. Under the old LIFO system, tiles placed into the chambers last were removed first, often leading to uneven curing durations if production was interrupted or batch sequencing changed. With the new FIFO design, tiles now enter and exit in the exact same order. This guarantees consistent curing times for every batch, simplifies scheduling, and reduces handling complexity%u2014ultimately improving product uniformity and plant throughput.To accommodate the installation of a dry-side transfer car%u2014critical for automated, seamless movement of cured tiles to the packaging lines%u2014the existing chambers required shortening. To offset the resulting reduction in curing capacity, IBF expanded its facility to add four entirely new chambers. The final configuration now includes thirteen FIFO curing chambers, each precisely engineered with two insulated doors. This dual-door setup enhances operational flexibility by allowing separate loading and unloading points, improving energy retention within the chamber, and ensuring smoother, safer material flow through the production process.IBF%u2019s Roof Tile Plant Rebuilds Smarter and Stronger with New Curing TechnologyKraft Curing Systems GmbH, 49699 Lindern, Germanyn April Kraft, Kraft Curing Systems GmbH, GermanyLeif Tipsmark, Tipsmark Trading, DenmarkThe chambers before the renovation in 2023