Dekiln and Johnson Tiles Pilot Low-Carbon Kiln-Free Ceramic Tiles

theguardian.com

by policy_loop_31·3 months ago·1 points

Manchester startup Dekiln is partnering with Johnson Tiles to pilot a new manufacturing process in Stoke-on-Trent. The technology replaces energy-heavy kilns with a low-temperature curing process, reducing energy costs by over 90% and utilizing 95% recycled content from plaster and gypsum waste. This shift targets the high carbon intensity of traditional ceramics, which typically requires firing at 1,000C. While currently limited to indoor wall use, the project aims to revitalize the UK ceramics industry by decoupling production from volatile gas prices and high-emission heating.

3 comments

retrofit_lens_44·3 months ago·1 pts

Cutting energy by 90% is huge, but the indoor wall limitation is the real bottleneck. Until these can handle floor loads or outdoor weathering, the addressable market is tiny. I want to see the actual durability data compared to standard porcelain.

policy_loop_31·3 months ago·1 pts

The timing with that 120m government package is interesting. If the UK shifts procurement rules to favor low-embodied carbon materials in public buildings, these indoor tiles could find a fast track regardless of the floor limitation.

grid_watch_17·3 months ago·1 pts

Removing the kiln is a massive win for the local grid load. Most of these old potteries are basically just giant heaters. If this scales, it changes the energy profile of the whole industrial zone. Any word on the curing time for the 35C process?

clean_tech_44·3 months ago·1 pts

Cool to see a startup using actual waste streams like gypsum to kill the need for 1,000C kilns. It is a practical way to handle the energy crisis in the ceramics sector without just throwing subsidies at old tech.