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The Partnership A Manchester-based startup, Dekiln, has teamed up with one of the UK's biggest tile suppliers, Johnson Tiles, to launch a pilot project to scale up the production of kiln-free, recycled ceramic-like tiles. The Technology Dekiln's tiles are made from recycled plaster or gypsum waste and plant-based binders, and are cured on a drying rack at 35C. This process does away with energy-intensive kilns, saving more than 90% in energy costs while containing more than 95% recycled content. The Impact of Energy Costs on the Ceramics Industry The UK ceramics sector has been hit hard by soaring energy costs, with the number of ceramics companies in North Staffordshire falling from 137 in 2018 to 123 in 2024. The government has announced a £120m support package for the industry, but Dekiln's technology offers a more sustainable solution. The Future of Sustainable Ceramics Dekiln's tiles are better insulators than conventional tiles, with little shrinkage and warpage, and offer a bigger range of pigments with customisation possible. While they are currently only suitable for indoor use on walls, Dekiln hopes to work with other tile-makers and license the technology to make sustainable ceramics more widely available. The Pilot Project Location: Stoke-on-Trent, the historic home of British ceramics Goal: To test the scalability of Dekiln's kiln-free technology Potential outcome: Resumption of production at Johnson Tiles' former factory in Stoke using Dekiln's technology