In the world of ceramics, a quiet revolution is brewing, and it's not just about the latest trends in tile designs. The story of Dekiln, a Manchester-based startup, is a testament to the power of innovation and the potential for a greener future in the industry. Founded by biomaterials engineer Aled Roberts, Dekiln has developed a groundbreaking technology that challenges the traditional methods of tile production. Personally, I find this story particularly fascinating as it not only offers a sustainable solution but also has the potential to revitalize an industry struggling with energy costs and supply chain disruptions.
A New Approach to Tile Making
Dekiln's tiles are not your average ceramic creations. They are crafted from recycled plaster or gypsum waste and plant-based binders, cured at a modest 35°C on a drying rack. This process eliminates the need for energy-intensive kilns, where tiles are traditionally fired at temperatures up to 1,000°C. By doing so, Dekiln not only saves over 90% in energy costs but also ensures that its tiles contain more than 95% recycled content. What makes this even more impressive is the fact that the tiles look and perform like conventional ceramic tiles, with little shrinkage or warpage, and offer a wider range of pigments for customization.
A Pilot Project and a Much-Needed Support Package
The collaboration between Dekiln and Johnson Tiles, a major UK supplier, is a significant step forward. The pilot project, set to take place in Stoke-on-Trent, the historic heart of British ceramics, aims to scale up the technology. This comes at a crucial time, as the UK government has announced a £120 million support package for the ceramics industry, which has been hit hard by soaring energy costs and the loss of high-quality clay from the Donbas region in Ukraine. The number of ceramics companies in North Staffordshire has declined from 137 in 2018 to 123 in 2024, with notable closures like Royal Stafford, Heraldic Pottery, and Moorcroft Pottery in recent years. The support package, however, may have come too late for some, as seen with Denby Pottery's administration filing.
The Broader Implications and Future Developments
The implications of Dekiln's technology are far-reaching. By sourcing plaster waste from the ceramics industry for free, Dekiln not only reduces waste disposal fees for these companies but also creates a circular economy within the industry. The business is backed by investors like Green Angel Ventures and Frontier IP, and has already secured £3 million from the Royal Academy of Engineering. The potential for Dekiln's tiles to be used in outdoor and floor applications, though still in development, could further expand their market. Additionally, the technology's ability to offer better insulation and customization options could disrupt the market, making it more accessible and affordable in the long run.
A Green Future for Ceramics
The push for sustainability in ceramics is evident, with companies like Alusid in Preston producing tiles from industrial waste ceramics and glass at lower temperatures. Dekiln's technology, combined with the support package, could be a game-changer for the industry. As Aled Roberts hopes to work with other tile-makers and license the technology, the future looks bright for a greener, more sustainable ceramics industry. While there are still challenges to overcome, such as making the tiles suitable for outdoor use and floors, the potential for a low-carbon, circular economy in ceramics is a compelling prospect. Personally, I believe that Dekiln's story is a powerful reminder of the innovative solutions that can emerge from the challenges faced by industries, and it's exciting to see the positive impact it could have on the ceramics sector and beyond.
