1

Why the project matters

The current process of manufacturing ceramic tiles called “wet route” uses spray drying. This process involves high consumption of raw materials, water and energy, making the challenge of achieving a low-carbon and sustainable ceramics industry very difficult. It is estimated that the spray-drying stage is responsible for 95% of water consumption, 34% of energy consumption (mainly thermal energy) and 32% of CO2 emissions (natural gas is used as fuel) of the total ceramic tile manufacturing process. All in all, ceramic tile manufacturing consumes is responsible for about 5% of CO₂ emissions across the EU. Additionally, the use of wet milling associated with the spraying-drying process makes it impossible to employ significant proportions of secondary raw materials (SRMs) as a substitute of raw materials (RMs). These figures highlight the urgent need to improve the sustainability of this stage of the ceramic process, with a view to reducing raw materials and water consumption while contributing to the challenge of decarbonisation.

2

What it aims to achieve

• To scale up and validate a low-carbon semi-wet granulation process that reduces energy use, emissions, and raw material needs in porcelain tile manufacturing.
• To enable the use of local secondary raw materials in place of critical imported resources like feldspar.
• To foster cross-border collaboration and knowledge exchange through the HypocarbonTileTech Network, promoting innovation and sustainability in the ceramic industry.

3

Expected change

• Energy demand reduced by 30–35%, raw materials and water consumption by 10–20%, and greenhouse gas emissions cut by 30–35% through the adoption of semi-wet technology in tile production.
• Increased use of local and recycled secondary raw materials in ceramic manufacturing, reducing dependency on imported critical materials.
• Strengthened collaboration and innovation capacity among Mediterranean tile producers, researchers, and policymakers through a transnational decarbonization network.

4

What the project delivers

• Lab and pilot-scale optimization of the semi-wet granulation process for porcelain tiles.
• Inventory and testing of secondary raw materials available in participating countries.
• Pilot implementation of the technology by industrial partners and its replication in a second country.
• Comparative environmental assessment and life-cycle analysis of the new versus traditional process.
• Creation of the HypocarbonTileTech Network and virtual collaboration platform.
• Organization of Technology Transfer Workshops, Innovation Days and technical training sessions.
• Policy recommendations for sustainable practices in tile manufacturing.

5

Who benefits

• 600 tile manufacturers (70% SMEs) adopting cleaner and more cost-efficient technologies.
• 150 machinery builders, 50 raw material suppliers (80% SMEs) integrating new sustainable processes and materials; and 25 companies (90% SMEs) managing recycled materials, helping to close the loop in resource use.
• 35 research centers and universities engaged in decarbonization and material innovation.
• 350 students and young engineers from fields like chemical and materials engineering exposed to cutting-edge industrial practices.
• 25 Technology Transfer Organizations and 10 Technological and Scientific Parks.
• 8 policymaking bodies and technology transfer organizations benefiting from data-driven guidance to support sustainable manufacturing policies.