Shaping the future of ceramics: System Ceramics and University together for sustainable innovation
In a global context characterized by the instability of natural gas costs and a growing urgency towards independence from fossil fuels, rethinking production paradigms is no longer just an option, but a long-term strategic commitment.
It is from this vision and necessity that the project “Study and implementation of a pilot production process for the manufacture of low energy consumption and reduced emissions ceramic slabs” was born. Funded by MIMIT, the Ministry of Enterprises and Made in Italy, this ambitious Research and Development program sees System Ceramics in the role of proponent and strategic coordinator.
The objective is clear: to develop an innovative pilot line for the production of ceramic slabs that contribute to sustainability by significantly drastically reducing energy and reducing CO₂ emissions.
Rethinking an energy-intensive process of ceramic slabs production
Historically, industrial ceramic production requires a high amount of thermal energy. This condition represents the most significant cost item and environmental impact of the entire supply chain, as it remains closely linked to the use of natural gas today. The most critical phases are drying and firing: moments when the material is shaped and stabilized, heavily affecting the global energy balance.
To overcome these structural limits, System Ceramics adopted a systemic approach: the project aims at optimizing both individual technologies and the entire production flow. The new pilot line will become a real industrial testing ground to test high-potential solutions and verify their actual scalability on production volumes.
The macro-areas of technological innovation include:
- Next-generation compaction systems designed to reduce the energy required for initial shaping.
- Advanced forming technologies capable of enabling the complete and immediate recovery of scrap, reducing raw material waste as much as possible.
- Advanced digital printing systems, designed and optimized to minimize energy consumption during decoration.
- Deep efficiency improvement of thermal machines thanks to targeted interventions on burners and heat management in the drying and firing modules.
These innovations are complemented by constant energy analyses and predictive studies oriented towards the progressive integration of renewable sources. Together, these technologies aim to define a new industrial standard, laying the foundations for the creation of a future-ready sustainable ceramic tile.
The value of research: synergy with universities
A project of such complexity requires a solid scientific basis. For this reason, System Ceramics has chosen to combine its industrial know-how with academic expertise through a strategic collaboration with the University of Modena and Reggio Emilia.
This collaboration develops through a very precise operational model. While the overall management and industrial vision remain firmly within System Ceramics, the university team is involved in a targeted manner in specific research activities.
The academic contribution focuses on the numerical modelling of processes and the development of advanced multiphysics simulations. These mathematical models faithfully replicate the energy behavior of thermal machines in a virtual environment, allowing components to be tested and optimized before construction.
The continuous exchange and technical alignment between corporate teams and researchers generate extraordinary value: they accelerate development times, reduce error margins in design and guarantee the scientific reliability of solutions for sustainable ceramic manufacturing.
A bridge to young talent
This open innovation model does not only produce technological advantages but creates a direct link with the territory. Working closely with a leading multinational in the sector offers students, researchers and young talents the opportunity to apply theoretical studies to concrete and urgent industrial challenges. Investing in cooperative research is the key to developing real solutions for the global market.
Through this project, System Ceramics strengthens the connection between industry and academia, fostering cooperation, knowledge exchange and new opportunities for young talents to contribute to the future of sustainable ceramics.