Manchester Startup Dekiln Partners with Johnson Tiles to Pilot Sustainable Ceramic-Like Tiles

Manchester-based startup Dekiln, founded by biomaterials engineer Aled Roberts, has partnered with Johnson Tiles to pilot a sustainable ceramic-like tile production method. This innovative approach uses recycled plaster or gypsum waste and plant-based binders, curing the tiles at a low 35°C instead of the energy-intensive kiln firing at up to 1,000°C. The process saves over 90% in energy costs and incorporates more than 95% recycled content.

The partnership aims to establish a trial manufacturing site in Stoke-on-Trent, historically the heart of Britain’s ceramics industry, which has been severely impacted by soaring energy costs following Russia’s invasion of Ukraine in 2022. Several notable ceramics companies, including Royal Stafford, Heraldic Pottery, and Moorcroft Pottery (later rescued), have gone out of business, while others like Wedgwood halted production temporarily and Denby Pottery filed for administration in March 2024.

Johnson Tiles, which ceased manufacturing in 2024, hopes to resume production at its former Stoke factory if the pilot succeeds. Dekiln’s tiles offer improved insulation, minimal shrinkage, and a broader color palette due to the absence of high-temperature firing limitations. However, current limitations include indoor wall use only, with further development needed for outdoor and floor applications.

Dekiln sources its waste materials from the ceramics industry, reducing disposal costs for suppliers. Backed by Green Angel Ventures and Frontier IP, the company received a £3m award from the Royal Academy of Engineering in December 2026. Similar sustainable initiatives include Alusid, which produces tiles from industrial waste ceramics and glass at lower temperatures.

Roberts envisions licensing the technology to other tile makers, anticipating that the tiles could eventually match or undercut conventional tile prices. The announcement follows the UK government’s recent £120m support package for the struggling ceramics sector, though the timing may be too late for some, like Denby Pottery’s former marketing director Hayley Baddiley, who notes the package’s potential lateness in saving certain businesses.