February 24, 2025 Sustainable Ceramic Tiles Without Spray Drying Ceramic tiles have long been a cornerstone of interior design, offering versatility, durability, and aesthetic appeal. However, their traditional production processes pose significant environmental challenges. In this article, we explore innovations in the manufacturing of sustainable ceramic tiles and introduce Skip Tile, a revolutionary sustainable alternative to traditional ceramic tiles. They are produced without the harmful production step of spray drying. The Environmental Cost of Ceramics Manufacturing One of the most energy-intensive steps in ceramic tile manufacturing is spray drying, a method that transforms raw materials into granules suitable for pressing and firing. In short, it forms a dry powder from a liquid by rapidly drying it with a hot gas. Spray drying is a key step in the traditional ceramic tile production process to ensure uniformity and consistency. While effective, this process relies heavily on natural gas and electricity, mainly spent to evaporate water, and related CO2 release. This technique also suffers from a considerable water consumption, as slurries usually contain 30–35% water (by weight) while powders suitable for pressing need 5–7% moisture[1]. According to recent studies, spray drying accounts for about 30% of the total energy consumed and about 70% of the total water used in tile production[2]. The reliance on virgin raw materials further compounds the environmental toll. Mining and processing these materials lead to habitat destruction, resource depletion, and additional emissions. Sustainable Ceramic Tiles: Skip Tile Skip Tile: A Game-Changer in Sustainable Ceramic Tiles Skip Tile is leading the way towards a more sustainable future in ceramics. Produced by UK-based Alusid® in their factory in Spain, this tile sets a new standard for eco-friendly design. Its creation is rooted in a groundbreaking research project at the University of Central Lancashire. Unlike traditional tiles, Skip Tile eliminates the need for energy-intensive spray drying. Instead, it employs a low-energy dry granulation process to prepare raw materials. This innovation reduces energy consumption by 45%[3], significantly lowering the emissions typically associated with traditional methods. Skip Tile ranks among the lowest-emission (floor) tiles available. Skip Tile is composed of at least 95% by-products sourced from multiple industries, ranging from ceramic production scraps to glass by-products, both pre- and post-fired. This approach not only reduces landfill waste but also repurposes low-value materials into high-quality tiles. After granulation, the materials are pressed into tiles. Unique colours and patterns are added during this stage, resulting in high-quality, innovative designs that align with modern aesthetic trends. Skip Tile is ideal for interior applications, including furniture, walls, and flooring. Its unique composition and design flexibility make it suitable for any design project. At FRONT, we love to demonstrate that sustainable solutions are within reach. And we believe that the future of sustainable ceramic tiles lies not just in innovation alone, but also in responsibility. The construction industry accounts for 39% of global CO2 emissions, with 11% linked to material production[4] – so we’re proud to keep growing the FRONT collection with more and more sustainable alternatives for standard building materials! Meet Skip Tile. By choosing Skip Tile, you can contribute to a greener planet without compromising on quality or aesthetics in their projects. Interested? Learn more + Order samples Sources: [1] “Improving the sustainability of ceramic tile-making by mixing spray-dried and dry-granulated powders” [sciencedirect.com] [2] “A novel dry granule preparation technology and comparison of granule properties with conventional wet system for ceramic tiles production” [journalssystem.com] [3] alusid.co.uk [4] worldgbc.org Further reading: Ways to reduce energy for spray drying [IP&D experts] “Life cycle assessment in the ceramic tile industry: a review” [sciencedirect.com] “Thorough Lifecycle Analysis of Ceramic Tiles” [azom.com] “World ceramic tile industry and market: forecasts to 2025” [ceramicworldweb.com] “Thermo-Ecologic Evaluation of a Spray Dryer for Ceramic Industry” [sciencedirect.com]
The Environmental Cost of Ceramics Manufacturing One of the most energy-intensive steps in ceramic tile manufacturing is spray drying, a method that transforms raw materials into granules suitable for pressing and firing. In short, it forms a dry powder from a liquid by rapidly drying it with a hot gas. Spray drying is a key step in the traditional ceramic tile production process to ensure uniformity and consistency. While effective, this process relies heavily on natural gas and electricity, mainly spent to evaporate water, and related CO2 release. This technique also suffers from a considerable water consumption, as slurries usually contain 30–35% water (by weight) while powders suitable for pressing need 5–7% moisture[1]. According to recent studies, spray drying accounts for about 30% of the total energy consumed and about 70% of the total water used in tile production[2]. The reliance on virgin raw materials further compounds the environmental toll. Mining and processing these materials lead to habitat destruction, resource depletion, and additional emissions. Sustainable Ceramic Tiles: Skip Tile Skip Tile: A Game-Changer in Sustainable Ceramic Tiles Skip Tile is leading the way towards a more sustainable future in ceramics. Produced by UK-based Alusid® in their factory in Spain, this tile sets a new standard for eco-friendly design. Its creation is rooted in a groundbreaking research project at the University of Central Lancashire. Unlike traditional tiles, Skip Tile eliminates the need for energy-intensive spray drying. Instead, it employs a low-energy dry granulation process to prepare raw materials. This innovation reduces energy consumption by 45%[3], significantly lowering the emissions typically associated with traditional methods. Skip Tile ranks among the lowest-emission (floor) tiles available. Skip Tile is composed of at least 95% by-products sourced from multiple industries, ranging from ceramic production scraps to glass by-products, both pre- and post-fired. This approach not only reduces landfill waste but also repurposes low-value materials into high-quality tiles. After granulation, the materials are pressed into tiles. Unique colours and patterns are added during this stage, resulting in high-quality, innovative designs that align with modern aesthetic trends. Skip Tile is ideal for interior applications, including furniture, walls, and flooring. Its unique composition and design flexibility make it suitable for any design project. At FRONT, we love to demonstrate that sustainable solutions are within reach. And we believe that the future of sustainable ceramic tiles lies not just in innovation alone, but also in responsibility. The construction industry accounts for 39% of global CO2 emissions, with 11% linked to material production[4] – so we’re proud to keep growing the FRONT collection with more and more sustainable alternatives for standard building materials! Meet Skip Tile. By choosing Skip Tile, you can contribute to a greener planet without compromising on quality or aesthetics in their projects. Interested? Learn more + Order samples Sources: [1] “Improving the sustainability of ceramic tile-making by mixing spray-dried and dry-granulated powders” [sciencedirect.com] [2] “A novel dry granule preparation technology and comparison of granule properties with conventional wet system for ceramic tiles production” [journalssystem.com] [3] alusid.co.uk [4] worldgbc.org Further reading: Ways to reduce energy for spray drying [IP&D experts] “Life cycle assessment in the ceramic tile industry: a review” [sciencedirect.com] “Thorough Lifecycle Analysis of Ceramic Tiles” [azom.com] “World ceramic tile industry and market: forecasts to 2025” [ceramicworldweb.com] “Thermo-Ecologic Evaluation of a Spray Dryer for Ceramic Industry” [sciencedirect.com]
