Pathway towards a High Recycling Content in Traditional Ceramics

The present work shows the path towards the industrial production of ceramic tiles containing a high amount of recycling materials in the substitution of natural raw materials. Starting from the applied research at laboratory scale, which is able to demonstrate the work feasibility, other important milestones consist of pilot scale production until the proper industrial production. Finally, when all these steps are positively achieved, the practice is consolidated and it is possible to reach the concrete sustainability benefits (social, environmental and economic). The results of an industry driven project that aimed to produce porcelain stoneware tiles containing 85% of recycled materials were selected to show this path. This innovative ceramic product—containing soda-lime scrap glass from urban-separated collection (post-consumer waste) and unfired scrap tiles from industrial ceramic process (pre-consumer waste)—was sintered about 200 °C lower than a traditional porcelain stoneware tile. It maintains high technical performances belonging to class BIa of the International Standard of ceramic tile classification (EN ISO 14411). Moreover, this product fulfils the standard requirements for dry-pressed ceramic tiles with low water absorption (≤0.5%), and it obtained the certification UNI Keymark. The LCA study was also performed and the results showed a significantly lower environmental impact of this innovative product compared to a traditional porcelain stoneware tile.