Stoke-on-Trent’s ceramics industry has received a second major boost in less than a week, with tile production set to return to the city through a new low-carbon manufacturing partnership.
Johnson Tiles is working with materials technology company Dekiln to scale up a kiln-free, low-energy alternative to traditional ceramic tiles, with plans for a pilot or demonstration manufacturing plant in Stoke-on-Trent, the historic heart of the British ceramics industry.
The announcement follows last week’s £120 million Government support package for the UK ceramics sector, which includes funding to help manufacturers invest in equipment, energy efficiency and sustainability. The Government said the industry remains a major source of employment in Staffordshire and other ceramic-producing areas. (GOV.UK)
Dekiln’s technology creates ceramic-like composite materials by combining plant-derived binders with waste mineral powders, including recycled gypsum plaster. The tiles are designed to look and perform like ceramics but do not need to be fired or glazed at high temperatures, avoiding the energy-intensive kiln process used in conventional production.
According to the companies, the material has a carbon footprint 94 per cent lower than conventional tiles and contains more than 95 per cent recycled content. Johnson Tiles will support Dekiln with manufacturing expertise, market access and sector knowledge as the technology moves from laboratory development towards industrial-scale production.
The move is being seen as a significant vote of confidence in Stoke-on-Trent’s ceramics capability after years of pressure from high energy costs, overseas competition and the decline of domestic tile manufacturing.
Rob Flello, chief executive of Ceramics UK, welcomed the development.
He said: “The UK ceramics industry has always innovated as well as looking for ways to reduce energy consumption. Indeed over the last decade alone the UK industry has spent £750 million of its own money on decarbonisation. The industry has been looking at reduced temperature and reduced numbers of firings over many years.
“We welcome all advances in the industry and given there are only a very few floor and wall tile manufacturers remaining in the UK, this is good news. We hope the venture is a great success.”
Jason Bridges, procurement director at Johnson Tiles, said the partnership was “really exciting”, adding that Dekiln founder Dr Aled Roberts’ approach to recycling waste and removing the sintering process was “a real game-changer”.
