The document summarizes a project called LIFE CERAM that aims to achieve zero waste in ceramic tile manufacturing. The project (1) develops a new ceramic tile made mainly from waste for outdoor use, and (2) designs a sustainable process using dry milling and granulation technologies. Expected results include reducing water and energy usage, CO2 emissions, and waste disposal by at least 30% each during the project period.

1. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
Organizers:
Supporters:
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

2. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
Title of the project and acronym: LIFE CERAM
Zero Waste in Ceramic Tile Manufacture
Organizers:
Funding programme: LIFE +
Call: 2012
Budget: 799,502 €
Supporters:
50 % UE Co-funding
Length: START 01/09/2013
End 30/06/2016
Website of the project: http://www.lifeceram.eu
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

3. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
Consortium:
– Co-ordinator:
• AICE-ITC. R&D centre.
Organizers:
– Partners and roles:
• Asociación Española de fabricantes de azulejos y
Pavimentos Cerámicos (ASCER). Manufacturers
Supporters:
asociation.
• Chumillas & Tarongi. Machinery manufacturer.
• Keros Cerámica. Tile manufacturer.
• Vernis. Frit and glaze manufacturer.
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

4. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Background:
The manufacturing of ceramic tiles generate waste at different
stages of the production process (1.5 million ton/year).
Organizers:
Raw
Supporters: mat erials
M illing
spray drying
Frit residues
Glaze preparat ion
Fco Javier García Ten
Polishing sludge
Manager of the Ceramic Materials and Technologies Area, Project Manager
Pressing
Drying
Glazing
Cerámica Innova 4: From research to market
Green scraps
Glaze sludge
Firing
Fired scraps
Tile

5. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Background:
Organizers:
70 % of the waste are recycled in the current products.
Some waste are difficult to recycle in the current products and
Supporters:
process (changes in the product properties and manufacturing
problems):
 Hard residues (fired scraps)
 Waste with soluble compounds (dust from the kiln filters and
polishing sludge)
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

6. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Objectives:
Organizers:
 To achieve zero-waste in the manufacture of ceramic tiles.
The strategy consists of:
 Developing a new ceramic tile, consisting mainly of
Supporters:
waste, for outdoor applications.
 Designing a sustainable process based on dry milling and
granulation technologies.
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

7. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Action
2013
2014
Action
Name of the action
I
II III IV I
II III IV I
number
A. Preparatory actions
A1. State of the art in ceramic waste management at national &
A.1
European level
A2. Determination of technical and environmental key parameters
A.2
of existing products for urban paving
B. Implementation actions
B1. Characterization of ceramic and non ceramic residues
B.1
B2. Body composition preparation process
B.2
B3. Body and glaze compositions
B.3
B4. Industrial trials
B.4
B5. Technical and environmental assessment of the new product
B.5
C. Monitoring of the impact of the project actions
C1. Effectiveness of the Project actions
C.1
C2. Assessment of the socio-economic impact of the project
C.2
D. Communication and dissemination actions
D1. Project website
D.1
D2. Notice boards and layman´s report
D.2
D3. Beyond the consortium
D.3
E. Project management and monitoring of the project progress
E1. Day-to-day project Ten
E.1 Fco Javier Garcíamanagement
E2. Networking with other projects
E.2 Manager of the Ceramic Materials and Technologies Area, Project Manager
E3. After-LIFE Communication Plan
E.3
Organizers:
Supporters:
Cerámica Innova 4: From research to market
2015
II
III
2016
IV
I
II
III
IV

8. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
PREPARATORY ACTIONS
Actions A1 and A2
B1
Characterization of ceramic and non
ceramic residues
B2
Body composition
preparation process
B3
Body and glaze
compositions
Supporters:
B4
Industrial trials
B5
Technical and environmental
assessment of the new product
MONITORING OF THE IMPACT OF THE PROJECT ACTIONS
Actions C1 and C2
PROJECT MANAGEMENT
Actions E1 to E3
Organizers:
IMPLEMENTATION ACTIONS
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
DISSEMINATION ACTIONS
Actions D1 to D3
Cerámica Innova 4: From research to market

9. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Expected results:
Organizers:
 To demonstrate the feasibility of achieving zero-waste in
ceramic tile manufacture.
 Manufacturing the new tile will provide:
Supporters:
 65% saving in water consumption
 30% saving in energy input
 30% reduction in CO2 emissions
 During the life span of the project:
Fco Javier García Ten
Manager  5%Ceramic Materials and Technologies Area, Project Manager
of the reduction of annually generated waste
 20% reduction in waste disposal at landfills
Cerámica Innova 4: From research to market

10. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Problems detected and obtained experience
Organizers:
 No problems have been detected (until now ..)
 Time goes very fast
Supporters:
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

11. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
DESCRIPTION OF THE PROJECT
Other highlights:
Organizers:
 The first results about the project will be publish in
QUALICER 2014. Comparative study of the bulk and surface
properties of products used in urban paving (concrete,
natural stone and porcelain tiles)
Supporters:
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market

12. 4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS
Organizers:
Supporters:
Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager
Cerámica Innova 4: From research to market