Reduction of energy consumption and environmental impact in ceramic sanitary ware production through fluxing agents: a case study

Reducing electricity and natural gas consumption is increasingly vital for industrial sustainability, especially in energy-intensive sectors such as ceramic sanitary ware production. This study introduces an innovative method to lower energy use during ceramic firing by optimizing raw material formulations. Specifically, we investigated three approaches for fire clay washbasins and vitreous china toilets: altering existing formula ratios and adding fluxing agents (talc, nepheline, or K-feldspar) to both the bulk and glaze. All products were tested for compliance with UNI 4543 standards. The new formulations achieved a 9.87% reduction in shrinkage, leading to decreased raw material consumption and demonstrated enhanced mechanical properties, notably a higher modulus of rupture. Additionally, the low-temperature-melting glaze improved surface quality without affecting color. Life cycle assessment and cost analysis showed up to 4.6% lower environmental impact and 5.61% reduction in production costs, all without requiring production line modifications. The novelty of this work lies in the dual integration of fluxing agents into both body and glaze, enabling lower firing temperatures and superior product performance. Future research will explore the long-term durability of these formulations and investigate further sustainable additives, paving the way for broader energy-efficient innovations in ceramic manufacturing.