Powering Progress in the UK Clay Manufacturing Industry
First published in the February 2025 issue of Quarry Management
Sharing knowledge is a cornerstone of innovation and progress, particularly in industries such as the UK clay manufacturing sector, where tradition and modernity cross over. The exchange of ideas, techniques, and research provides a collaborative environment that enhances both individual and collective knowledge. For example, the integration of technological advancements, such as automation and sustainable manufacturing practices, requires open dialogue among industry stakeholders to remain competitive on a global scale.
A study by McKinsey & Company found that effective knowledge-sharing practices can improve workplace productivity by up to 25%, particularly in industries reliant upon collaboration and specialized expertise. This highlights the significant potential for gains in efficiency and innovation when businesses actively embrace an environment where knowledge is freely exchanged.
In the context of the UK clay manufacturing industry, this statistic demonstrates the importance of structured knowledge-sharing initiatives, such as training programmes, industry conferences, and digital platforms, to optimize operations and improve on industry knowledge.
The importance of the clay manufacturing industry
The UK clay manufacturing industry plays a pivotal role in supporting the nation’s construction, infrastructure, and design sectors. Over the past five years from 2019 to 2024, the market size of the industry in the UK alone has increased at a compound and growth rate of 4.2%. Renowned for its production of bricks, tiles, and sanitaryware, the industry is vital in building durable homes, commercial spaces, and public infrastructure. With a heritage stretching back centuries, UK clay products are celebrated for their quality, reliability, and sustainability. The sector also supports a robust supply chain, contributing significantly to the UK economy through employment, exports, and investments in local communities.
Beyond its economic importance, the UK clay manufacturing industry is a leader in adopting environmentally sustainable practices. From utilizing locally sourced materials to innovating low-carbon manufacturing processes, the sector is committed to reducing its environmental footprint.
This commitment aligns with national and global goals for sustainability, making the industry a key player in driving forward the UK’s green agenda. As it bridges tradition and innovation, UK clay manufacturing not only meets the demands of modern construction, but also preserves the craftsmanship and expertise that define its legacy.
Heavy Clay UK
In partnership with the Institute of Quarrying (IQ), the Heavy Clay Technology Association (HCTa) launched the Heavy Clay UK event last November. The event, sponsored by Lingl UK, Borregaard, Craven Fawcett, Keller, Rieter Morando, and Refratechnik, was well received with more than 30 exhibitors showcasing their latest developments to more than 100 attendees. Aimed at employees working in the clay manufacturing industry, the event served as an opportunity for attendees to network, share knowledge, and learn about the latest innovations, guidance, and best practices.
Revolutionizing ceramics firing with hydrogen
One of the presentations featured at the event was by Dr Andrew McDermott, deputy chief executive of Ceramics UK, whose focus was on transforming the UK ceramics sector through hydrogen firing technology. The presentation detailed two phases of hydrogen projects: H2P1, a six-month feasibility study assessing the use of hydrogen in ceramic firing; and H2P2, a two-year demonstration project aimed at implementing hydrogen firing in production kilns.
Digitalization strategy
LINGL SOLEAD GmbH talked about integrating production data evaluation, overall equipment effectiveness (OEE), and digital-twin technology as part of their digitalization strategy aimed at enhancing productivity and efficiency in manufacturing. The digital twin serves as a virtual replica of physical machinery, allowing for real-time monitoring, operation, and troubleshooting.
Transformation of energy systems
This presentation discussed innovative heat-recovery projects led by Reiter Morando and Keller Solutions, highlighting their focus on minimizing primary energy demand through the reutilization of thermal energy generated in industrial processes. Key examples include Refratechnik Cement GmbH’s recovery of waste heat from kiln cooling zones, which contributes approximately 12GWh of energy annually to the municipal heating network in the German city of Göettingen, significantly reducing CO2 emissions.
HCTa Awards
During Heavy Clay UK, the HCTa took the opportunity, with their Awards ceremony, to recognize the hard work and achievements of those who have given meritorious service to the Institute, as well as achievements in the technical academic courses available to the industry.
The Ernest Simpson Award & Lisney Prize was awarded to Ibstock plc’s David Baggaley, deputy chair of the HCTa’s North Staffordshire branch, whilst Forterra kiln manager Martin Petch was awarded both the Clay Drying and Firing Certificate Award and the Keith FR Morton Award.
Reflecting on the event, HCTa chair Paula Wardle commented: ‘It was great to see many of our suppliers to the industry in the exhibition hall interacting with employees from the industry, sharing best practice and new ideas. I was honoured to present our top students awards for their achievements.’
Heavy Clay UK will return later this year, taking place on Thursday 20 November. To express interest in exhibiting at or sponsoring the 2025 event, visit: www.quarrying.org/heavy-clay-2025
Building knowledge brick by brick
The HCTa is committed to advancing heavy clay technology across the UK and internationally. Its mission is to provide people with valuable opportunities to expand their professional expertise, enhance their skills, and gain new qualifications.
In partnership with the Mineral Products Qualifications Council (MPQC), the HCTa offers the ‘Introduction to the Heavy Clay Industry: Level 2’ course with cohorts beginning in March, June, and September 2025. Aimed primarily at employees requiring a basic understanding of heavy clay manufacturing, the course provides basic ‘quarry to lorry’ technical knowledge of the processes involved in making bricks, pavers, tiles, and pipes.
For more information about the level 2 course, visit: www.mpskills.co.uk/preview.php?site_page_id=579
For further information about the HCTa, visit: www.quarrying.org/hcta-home
REFERENCES
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