Ceramics
Ceramic Manufacturing: Traditional Materials and Advanced Technologies
Ceramics have long served a dual role in both domestic and industrial applications. Traditional ceramics include bricks, tiles, pipes, tableware and sanitaryware, along with the refractory materials essential for high-temperature processing. These refractories are especially important in the production of other ceramic materials.In contrast, modern or technical ceramics are made from advanced non-metallic inorganic compounds and are used in a broad range of industries. Their exceptional properties-such as hardness, thermal resistance and chemical stability-make them suitable for critical applications including disc brakes, body armour, superconductors, cutting tools, medical devices and precision bearings.
The Industrial Rise of Stoke-on-Trent
During the Industrial Revolution, Stoke-on-Trent became Britain's leading centre for ceramic production. This development was driven by easy access to local clay, salt and lead for glaze making, as well as abundant coal for firing kilns. The region quickly became synonymous with large-scale pottery manufacturing.
The most distinctive kiln design of this era was the bottle kiln. Constructed of brick with a circular base, these kilns featured an inner firing chamber surrounded by an outer skin, with fireplaces at the base and flue systems channeling hot gases upward. Ceramic ware was placed inside fire clay boxes called saggars, which were stacked in tall columns. Although bottle kilns enabled mass production, they were inefficient, consuming large amounts of coal and producing heavy pollution. They remained in use well into the 20th century, until phased out by the Clean Air Acts.
The Shift to Continuous Firing
The mid-nineteenth century saw a major technological advance with the development of continuous batch firing. One of the earliest innovations was the Hoffmann kiln, consisting of multiple chambers arranged in a circular or oval formation. Only one chamber was fired at a time, while the exhaust heat was directed to preheat the next. This significantly improved energy efficiency and was widely adopted in brick manufacturing. However, it lacked the versatility needed for producing tableware, which required varied shapes and firing conditions.
Modern Kilns: Clean, Efficient and Precise
Today's kilns are engineered for energy efficiency, precision control, and reduced emissions. For continuous production of uniform products like bricks or tiles, the tunnel kiln is typically the preferred option. Ware is loaded onto kiln cars and gradually moves through temperature-controlled zones-from preheating to firing and cooling-ensuring consistent quality. These kiln cars must be both lightweight and thermally stable to endure repeated cycling.
For more specialised or variable production needs, shuttle kilns offer greater flexibility. Operating in batches, they allow kiln cars to be moved in and out of a static firing chamber, making them well suited for intermittent use and frequent changes in product type or firing profile.