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Ceramic manufacturing faces unprecedented challenges from tightening emissions regulations, volatile energy prices, and increasing market demand for sustainable products. The firing step alone accounts for 75% of total energy costs and generates 265 kg CO₂ per tonne of finished material.”
Our BioSintering® process integrates seamlessly with your existing production line, enabling you to significantly reduce energy consumption, carbon emissions, and operational costs while delivering new aesthetic options.
By eliminating high-temperature kiln firing at 850-1850°C and operating at just 60-90°C instead, our technology delivers up to 90% energy savings compared to conventional manufacturing processes.
BioSintering® technology is designed to integrate with your existing equipment and production lines, requiring minimal modifications and staff retraining for a smooth transition.
New manufacturing lines using our technology require significantly less capital investment by eliminating the need for expensive kilns, enabling more cost-effective expansion of production capacity.
Our process delivers an independently verified 94% reduction in carbon footprint and 99% reduction in particulate emissions compared to conventional ceramic tiles, helping you exceed regulatory requirements and sustainability commitments.
Without high-temperature firing limitations, our technology enables access to a much wider range of pigments and colourants, including options traditionally unavailable to ceramic manufacturers.
By using recycled plaster and locally-sourced materials instead of specialised clays, our process reduces vulnerability to supply chain disruptions and creates benefits to broader local communities.
Recycled plaster and gypsum waste is collected and processed into a fine powder, creating a base material with over 98% recycled content that would otherwise go to landfill.
Our proprietary bio-based binder is combined with the recycled powder to create a precursor material that achieves ceramic-like properties without requiring high-temperature firing.
The mixture is pressed using standard ceramic manufacturing equipment at room temperature, forming tiles with precise dimensions and minimal shrinkage or warpage.
Tiles are cured at just 60-90°C rather than kiln-fired at 850-1850°C, delivering a 94% carbon footprint reduction while maintaining the strength, durability, and aesthetic qualities of traditional ceramics.
While other solutions focus on modest efficiency improvements or alternative energy sources for kilns, our technology completely eliminates firing, delivering unmatched energy savings of up to 90%.
With a flexural strength of up to 25 MPa compared to competitors' 3.5-8.9 MPa, our tiles significantly outperform other sustainable alternatives while meeting all EN14411 standards.
Our technology enables manufacturing without specialised facilities or lengthy incubation periods, resulting in production times measured in minutes rather than days.
Our manufacturing cost compares favorably to both conventional ceramics and sustainable competitors.
BioSintering® works with your existing equipment and staff knowledge, avoiding the need for specialised biofabrication facilities or extensive workforce retraining.
Unlike other sustainable ceramics alternatives that require specialised ingredients, conditions, and face fundamental scaling limitations, our process uses abundant recycled materials, enabling truly industrial-scale production.
