Johnson Tiles has announced a strategic partnership with materials technology company Dekiln to help commercialise an innovative low-carbon tile technology that could significantly reduce the environmental impact of construction fit-out and refurbishment projects.
The collaboration aims to scale up Dekiln's patented alternative tile concept, which is claimed to cut embodied carbon by up to 94% compared with conventional ceramic tiles while containing more than 95% recycled content.
Unlike traditional ceramic tiles, the new material combines plant-derived binders with waste mineral powders, including recycled gypsum plaster, to create a product with similar appearance, feel and performance characteristics. As the tiles do not require firing or glazing at high temperatures, the manufacturing process eliminates the need for energy-intensive kilns, substantially reducing carbon emissions.
The technology attracted the support of intellectual property commercialisation specialist Frontier IP, which helped formalise the partnership between the two companies. Frontier IP Chief Executive Officer Neil Crabb said the agreement demonstrated growing confidence in Dekiln's innovation following founder Dr Aled Roberts' selection as a Green Future Fellow by the Royal Academy of Engineering.
The fellowship, awarded at the end of 2025, secured £3m in funding to help bring the kiln-free, low-energy ceramic-like composite material to market.
Dr Aled Roberts, Founder and CEO of Dekiln, said: "Johnson Tiles' technical expertise, market reach and sustainability focus makes them an ideal partner to support our ambition to scale up and commercialise our technology. This marks an important milestone for Dekiln as we transition from the laboratory to industrial scale manufacturing."
The companies are also exploring the possibility of establishing a pilot or demonstration manufacturing plant in Stoke-on-Trent, the historic heart of the UK's ceramics industry.
Jason Bridges, Procurement Director at Johnson Tiles, said the technology had the potential to be a "real game-changer", combining the performance and aesthetics of traditional ceramic tiles with dramatically lower embodied carbon, while supporting the company's long-term sustainability ambitions.
