A Manchester-based startup that produces ceramic-like tiles from waste without the need for an energy-intensive kiln has partnered with one of the UK's largest tile suppliers to launch a pilot project aimed at scaling up its innovative technology.
Dekiln's Revolutionary Approach
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. The tiles developed by Roberts and his team of four resemble conventional ceramic tiles but are crafted from recycled plaster or gypsum waste combined with plant-based binders. They are cured on a drying rack at a mere 35C, eliminating the need for energy-hungry kilns that fire tiles at temperatures up to 1,000C. This process saves more than 90% in energy costs while incorporating over 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.
Government Support and Industry Challenges
The announcement of the pilot project comes shortly after the government unveiled a £120 million support package for the ceramics industry, which has seen several companies go bust in recent years due to soaring energy costs. The number of ceramics firms in North Staffordshire has declined from 137 in 2018 to 123 in 2024. Stoke-on-Trent City Council noted last week that the local industry has been severely impacted by rising gas prices since Russia's invasion of Ukraine in 2022.
"The UK ceramics sector is facing a hammer blow. The high energy costs are another nail in the coffin for the industry," Roberts said, highlighting high-profile closures including Royal Stafford, Heraldic Pottery, and Moorcroft Pottery last year, though Moorcroft 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 help, stated that the support package likely came too late to save Denby.
Another challenge is that 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' Revival Plan
Johnson Tiles, which dates back to 1901, ceased manufacturing in 2024. However, if the pilot proves successful, the company hopes to resume production at its former factory in Stoke using Dekiln's technology. Jason Bridges, procurement director at Johnson Tiles, who participated in a management buyout in 2024, said: "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."
Advantages and Limitations
Roberts noted that Dekiln's tiles offer better insulation than conventional tiles, with minimal shrinkage and warpage. The technology also allows for a wider range of pigments and customization, as there are no high-temperature firing limitations. However, while the tiles are waterproof, they are currently only suitable 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 companies waste disposal fees. The business is backed by Green Angel Ventures and Frontier IP, and was awarded £3 million by the Royal Academy of Engineering in December.
Broader Sustainability Push
There is a growing movement to make ceramics more sustainable. 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-makers 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."
