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Stoke firm reports success with low-energy ceramics firing technology

24 March 2015

Pioneering low-energy ceramics firing technology based on 'Field Enhanced Sintering' is a step closer to implementation following a significant breakthrough.

Tony Kinsella (left), Lucideon’s chief executive with Dr David Pearmain, who is leading the low-energy firing project

Lucideon (formerly Ceram) secured a £1.9m Regional Growth Fund award back in 2012 to develop technology capable of radically reducing energy consumption in the ceramics industry. Now, the technology has its first commercial result: 15 x 15cm tiles have been produced, all showing the same strength as tiles made using traditional, energy-intensive methods.

“We now have material that is a tile, and looks like a tile, feels like a tile, rings like a tile and that’s a Eureka moment," says Tony Kinsella, chief executive of Lucideon. “There is still a lot of work needed but the team has risen to all of the challenges so far.

“Like all scientific and engineering endeavours, the project has had its ups and downs and some slices of luck. However, the team has never lost sight of the goal and, as confidence has grown, they have increased their levels of innovative thinking and application. As a result, we are confident we have a real success on our hands, which will have a profound impact on energy use and the economy of the ceramics industry in the future.”

The technology reduces the temperature needed to fire from 1,150°C to 850°C (and as low as 600°C) and can cut fuel bills by a quarter or more. It also can cut the time needed to fire ceramics from around 45 minutes to as little as 10 minutes - a process that not only slashes energy bills but also enables production to move towards more bespoke, shorter runs.

“We have been working with Lucideon since the start of this project and we can now see real, measurable financial benefits in adopting the technology when it’s ready," says Stephen Dixon, chief executive of Johnson Tiles. "It is a disruptive technology that could give us a real commercial advantage, not just in cost savings. We are constantly competing against overseas industries where energy, a huge part of our costs, is not as heavily taxed. The technology that Lucideon is developing may more than level the playing field.”

Lucideon plans to have the low energy firing technology ready for commercial applications by the end of 2016 – and has secured the use of a full tile manufacturing line for 12 months to help them achieve that goal.

Dr David Pearmain, of Lucideon, is leading the low-energy firing project from the company’s Stoke-on-Trent headquarters. “The tiles have been produced in fractions of the normal firing time and at very significantly reduced temperatures," he says. “Johnson Tiles has been hugely supportive of this project and has supplied us with most of the unfired material to date, along with expert technical support and advice.

“They’ve recently been in to see for themselves the tiles being fired in the development facility and are as excited as we are about the potential and impact of this technology. This is a hugely significant step in the technology’s journey to mainstream application in the ceramics industry and is the culmination of 18 months of development work and experimentation.”

Business secretary Vince Cable says the innovation has the potential to slash energy bills and speed up production times right across the UK ceramics industry, creating hundreds of jobs at home and opportunities with new global markets abroad. 

“I am pleased the Regional Growth Fund has played an important part in supporting the Lucideon team to develop this energy-reducing firing technology from design to delivery,” he adds.

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