A Manchester-based startup that produces ceramic-like tiles from waste without using energy-intensive kilns has partnered with one of the UK's largest tile suppliers to launch a pilot project aimed at scaling up the technology. Dekiln, led by biomaterials engineer Aled Roberts, is collaborating with Johnson Tiles to establish a trial manufacturing site in Stoke-on-Trent, the historic heart of British ceramics.
Innovative Technology
The tiles developed by Roberts and his team of four resemble conventional ceramic tiles but are made from recycled plaster or gypsum waste and plant-based binders. They are cured on drying racks at 35 degrees Celsius, eliminating the need for kilns that fire tiles at up to 1,000 degrees Celsius. This process saves over 90% in energy costs while incorporating more than 95% recycled content. Roberts founded the company in 2021 after experimenting in his cellar with waste materials like brick dust and kitchen ingredients such as chickpea juice as a binder.
Industry Context
The pilot announcement comes shortly after the UK government unveiled a £120 million support package for the ceramics industry, which has seen several companies collapse due to soaring energy costs. The number of ceramics firms in North Staffordshire has dropped from 137 in 2018 to 123 in 2024. Stoke-on-Trent city council noted that the local industry has been severely impacted by rising gas prices since Russia's invasion of Ukraine in 2022. Roberts commented, "The UK ceramics sector is facing a hammer blow. High energy costs are another nail in the coffin for the industry," pointing to closures including Royal Stafford, Heraldic Pottery, and Moorcroft Pottery, though the latter was later rescued. Wedgwood halted production for three months, and Denby Pottery filed for administration in March. Denby's former marketing director Hayley Baddiley, who petitioned the government for aid, said the support package likely came too late to save Denby. Additionally, much of the high-quality clay used in British ceramics originated from the Donbas region in eastern Ukraine, now occupied by Russian troops.
Johnson Tiles Partnership
Johnson Tiles, established in 1901, ceased manufacturing in 2024. However, if the pilot succeeds, the company hopes to resume production at its former Stoke factory using Dekiln's technology. Jason Bridges, procurement director at Johnson Tiles and participant in a 2024 management buyout, stated, "Reinventing a former high-carbon intensity factory in the heart of the Potteries with this new low-carbon concept would be a fantastic new chapter in UK ceramics production."
Product Advantages and Limitations
Roberts noted that Dekiln's tiles offer better insulation than conventional tiles, with minimal shrinkage and warpage. The technology allows for a wider range of pigments and customization, as there are no high-temperature firing constraints. However, while waterproof, the tiles are currently suitable only for indoor wall use, and further development is needed for outdoor and floor applications. Dekiln sources plaster waste from the ceramics industry free of charge, saving those companies disposal fees. The startup is backed by Green Angel Ventures and Frontier IP, and received £3 million from the Royal Academy of Engineering in December.
Sustainability Efforts
The ceramics industry is increasingly focusing on sustainability. Alusid in Preston, spun out from the University of Central Lancashire in 2015, produces tiles from industrial waste ceramics and glass fired at lower temperatures without energy-intensive spray-drying, supplying ranges to Topps Tiles. Roberts, who has used Dekiln tiles in his own bathroom and kitchen, hopes to collaborate with other tile manufacturers and license the technology. "Not yet, but hopefully in the not too distant future they will be available at a Topps Tiles near you," he said. "In the long run, there's no reason why the tiles shouldn't be as cheap or cheaper than ordinary tiles."
