Stoke-on-Trent based tile designer and supplier Johnson Tiles is working with Dekiln to scale-up an alternative to ceramic tiles that can cut embodied carbon by 94 per cent compared to conventional ceramics. Together, the companies are exploring the possibility of establishing a pilot or demonstration manufacturing plant in ‘The Potteries’ – the historic name for the Staffordshire city of Stoke-on-Trent and the industry’s heartland.
The new patented technology reportedly works by combining plant-derived binders with waste mineral powders, such as recycled gypsum plaster. The finished product looks, feels and has similar properties to existing tiles, but does not need to be fired or glazed at high temperatures – so avoiding energy intensive kilns. Containing more than 95% recycled content, it has been described as perfectly suited for schemes seeking to tackle waste while driving down embodied carbon and without compromising on aesthetics or performance.
The novel composition caught the attention of Intellectual property (IP) commercialisation specialists, Frontier IP, who have a track record in working with cutting edge spin-outs to advance the development of sustainable materials and helped formalise the collaboration.
Dekiln’s founder, Dr. Aled Roberts, received the prestigious title of a Green Future Fellow by the Royal Academy of Engineering at the end of 2025. This secured £3m of funding to accelerate the project. The partnership between Dekiln and Johnson Tiles aims to further advance the development phase of the product by leveraging Johnson Tiles’ manufacturing background and market access.
www.dekiln.com
www.johnson-tiles.com
