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British technology creates sustainable tiles with recycled gypsum and plant-based binders, drastically reducing energy consumption, reusing construction waste, and attracting the attention of Johnson Tiles, a traditional ceramics manufacturer in the UK
The tile that looks like ceramic but does not require extreme heat is an innovation by Dekiln, a British startup specializing in sustainable construction solutions. The material is made from discarded gypsum, also known as plasterboard, combined with plant-based binders, and cures at just 35 degrees, far below the thousand-degree kilns used in traditional ceramics.
Low-temperature production reduces energy consumption by more than 90 percent and allows for the use of waste that would otherwise be discarded. The company has already started a pilot with Johnson Tiles, a historic ceramics manufacturer in the UK, testing the feasibility of commercial-scale production without compromising the appearance or durability of the tiles.
The development offers more economical and sustainable alternatives, with the potential to transform the interior coatings industry, reducing costs and environmental impacts.
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Why traditional tiles need giant kilns
Conventional ceramic production requires kilns that reach thousand degrees to harden the clay, fix pigments, and ensure resistance. This process consumes enormous amounts of energy, increasing costs and emissions of polluting gases.
The intense heat eliminates moisture, burns organic materials, and consolidates the tile structure. The uniformity of the temperature also prevents cracks and defects that compromise durability. Therefore, finding low-energy consumption alternatives is crucial for the industry.
How discarded gypsum becomes coating
Construction and renovation gypsum is crushed and turned into powder. Combined with vegetable binders, the powder can be molded into tiles that cure at just 35 degrees, preserving the strength and appearance of ceramic.
This low temperature allows for reduced energy consumption, prevents deformations, and maintains stable physical properties. The result is an internal coating with an appearance similar to traditional ceramic, ready for wall application.
What changes for the ceramic industry
The innovation represents economic and environmental advancement. Reducing energy means lower production costs and less environmental impact, while reusing gypsum decreases the amount of waste in landfills.
Dekiln, a British startup, has already closed a pilot with Johnson Tiles, a historic ceramic manufacturer in the UK, to assess commercial production. The project demonstrates that it is possible to maintain aesthetic quality and strength while adopting more sustainable practices.
Limits and current application
For now, tiles made with recycled gypsum are recommended only for internal wall use. Floors and outdoor areas have not yet been tested due to resistance in humid conditions and intense wear.
Certifications and durability tests are necessary before expanding production, but initial results indicate a viable and ecological alternative for residential and commercial coatings.
Impact on consumers and constructions
For those seeking greener construction solutions, the technology offers energy savings, waste reuse, and reduced environmental impacts. Additionally, the aesthetics and strength remain close to traditional ceramic, without compromising the internal finish.
The trend is that such alternatives encourage the global industry to explore recyclable materials and less aggressive production methods for the environment, making constructions more sustainable.
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