New Technologies

1. BioSintering® (Biological Sintering Without High-Temperature Kilns)

Dekiln has introduced a process in which tiles are produced without firing at high temperatures. Instead of the usual 850–1250°C, products are dried at temperatures below 90°C and then stabilized. This method significantly reduces energy consumption and CO₂ emissions. It also allows for a high use of recycled materials and bio-based binders.

2. Advanced Digital Printing (Digital Printing / Inkjet Decoration)

This technology has been used in the tile industry for years, but recent advancements include:

  • The use of high-quality Drop-on-Demand print nozzles for precise application of designs and glazes.
  • The adoption of water-based inks instead of harmful chemical compounds, reducing air pollution.
  • The ability to combine multi-bar print heads to produce complex and highly detailed patterns. For example, Infinity SKY technology from System Ceramics is one such innovation.

3. Fusion Granulation Technology and Dry Body Preparation (Dry Preparation + Fusion)

Companies such as Manfredini & Schianchi, through technologies like Fusion granulation in tile body preparation, have reduced water consumption by up to 90%, electricity usage by around 20%, and fuel consumption (gas or coal) by up to 60%.

4. 3D Forming Technology (3D Printing / Robotic Extrusion)

There are projects using 3D printing to manufacture tiles with complex forms and textures, such as façade elements with wavy surfaces or volumetric patterns that were previously difficult to produce with conventional methods. Example: the work of Studio RAP in the Netherlands.
In addition, improved print heads for ceramic or clay extrusion ensure higher durability, consistent flow, and enable large-scale or continuous printing.

5. Advanced Quality Control and Micro-Granulation Technology

European projects such as MIGRATECH 4.0 are developing technologies that use micro-granulation to reduce water and energy consumption and CO₂ emissions, while also improving product quality.

Challenges and Limitations

  • The initial investment required for installing advanced digital equipment or 3D printing systems can be high.
  • Some technologies are still in prototype or laboratory stages and need further maturity for mass production.
  • Ensuring mechanical properties, frost resistance, water absorption control, and long-term stability of color and glaze under large-scale industrial conditions remains a challenge for certain methods.