Thank you! Your submission has been received!
Oops! Something went wrong while submitting the form.
The ceramics industry emits 19 million tonnes of CO2 annually in Europe alone, with firing and drying processes accounting for 80% of emissions. Up to 30% of production costs are related to energy.
As regulations tighten and energy prices fluctuate, there's a growing market demand for sustainable building materials that can help manufacturers reduce their carbon footprint while maintaining product quality and aesthetics.
By eliminating the high-temperature firing step (850-1250°C) and replacing it with our low-energy process, BioSintering® reduces CO2 emissions by 94% and particulate air pollution by 99% compared to conventional ceramic tiles.
Our process transforms problematic waste streams into valuable products, currently incorporating over 95% recycled gypsum plaster into our pioneering Eralith® tiles. This is obtainable from plasterboard, helping to address an enormous waste challenge estimated at 980,000 tonnes annually in the UK alone.
BioSintering® integrates seamlessly with existing tile manufacturing equipment (minus the kilns), enabling producers to adopt our technology without significant capital investment or extensive workforce retraining.
We source waste gypsum plaster and recycle it into a base material with optimal properties for tile production.
Our bio-based active ingredient is combined with the recycled base material according to our carefully developed formulation, creating a precursor that behaves in a similar way to conventional ceramic tile precursor powder.
The mixture is compressed using standard tile presses, forming tiles that achieve excellent mechanical strength without requiring high-temperature sintering.
The formed tiles undergo our low-energy curing process at <90°C, dramatically reducing energy consumption while developing material properties that meet industry standards.
.webp)
.webp)
Unlike other sustainable tiles that have time-consuming hot pressing or bacterial consolidation steps, our process runs at conventional tile manufacturing line speeds, enabling practical commercial-scale manufacturing without specialised facilities.
Unlike technologies requiring specialised biofabrication or hot pressing facilities, BioSintering® works with conventional tile manufacturing equipment, requiring minimal modifications and operator training.
Our tiles achieve up to 25 MPa flexural strength, exceeding the 12 MPa minimum requirement for ceramic tiles.
Our process utilises locally available waste streams and bio-based materials, lowering transportation mileage, reducing reliance on imports and minimising supply chain vulnerabilities.
Sustainable tile competitors use a number of expensive processing steps. Our process removes process steps and utilises widely available waste materials, so manufacturing costs should be lower than conventional tiles at comparable volumes.
BioSintering® enables a wider range of colours and design options than conventional fired ceramics, as our low-temperature process is compatible with a wider range of pigments and aesthetic treatments.
