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Tunnel Kilns

TUNNEL KILNS

Transform your production with our top-of-the-line Tunnel Kilns

What is tunnel kilns?

Nutec Bickley offers a wide variety of tunnel kilns fabrication and car handling equipment for high volume ceramic production. The tunnel kilns are designed to meet the customer’s needs as determined by their process and layout requirements.

Tunnel Kilns comprise of a set of kiln cars or trucks passing through a hot tunnel on rails. Product is placed onto the kiln cars usually with setting furniture. The temperature rises towards the middle and then cools towards the end so the temperature profile is created by different temperatures at different sections of the kiln down its length. This type of kiln is suitable for firing big volumes of products with excellent consistency for the products.

NUTEC Bickley's Tunnel Kilns are manufactured for ceramic production at temperatures of up to 1800°C (3270°F). With NUTEC Bickley’s equipment, process variables are under tight control from the beginning to the end of the cycle, assuring superior quality of your finished products. Our Tunnel Kilns count with high levels of control resulting in top quality products and a low energy usage offering lower cost production.

tunnel kiln for first fire

Electric Tunnel Kiln for Powder Products

tunnel kiln for first fire sanitaryware

Tunnel Kiln for First Fire - Technical Ceramics

tunnel kiln for first fire technical ceramics

First Fire Tunnel Kiln - Sanitaryware

tunnel kiln for sanitaryware

First Fire Tunnel Kiln - Technical Ceramics

tunnel kiln for ceramic colors

First Fire Tunnel Kiln - Sanitaryware

tunnel kiln sanitaryware process

Tunnel Kiln - Ceramic Colors

tunnel kiln technical ceramics

First Fire Tunnel Kiln - Sanitaryware

electric tunnel kiln technical ceramics

Tunnel Kiln for Technical Ceramics

tunnel kilns for powder products
Electric Tunnel Kiln for Powder Products
tunnel kilns for powder
Electric Tunnel Kiln for Powder Products
electric tunnel kilns for powder products
Electric Tunnel Kiln for Powder Products

General Specifications

Dimensions
15m³ to 140m³ (50ft³ to 460ft³)
Temperature
Hasta 1,800°C (3,270°F)
Insulation
Fiber construction up to 1600°C (2900°F), insulating refractories up to 1800°C (3270°F)
Power Source
Natural gas, LPG, diesel, kerosene, other liquid fuels. Electric configurations available

Advantages of our Tunnel Kilns

Temperature Uniformity: We offer the most precise temperature uniformity available in the market.
Energy Savings: Fuel consumption up to 50% lower than with shuttle kilns.
Efficiency: Tunnel kiln operation efficiency from 850 kcal/kg of product (Tunnel Kilns for sanitaryware).
Reliability: PLC controlled to make operation simple and reliable.
Technology: SCADA systems available for better process traceability.
Energy Recovery System: Preheated combustion air up to 425°C (800°F)
Firing: Increased internal air movement for a better firing environment.
Productividad: Unidades de producción de alto volumen y consistentes.
Productivity: Consistent, high volume production units
Easy Maintenance: Low maintenance and minimal downtime.
Flexibility: Car handling systems designed to suit plant operation.
Versatility: Modular tunnel kiln design for easy assembly prior to shipment.

Download the resources related to our Tunnel Kilns

Tunnel Kilns data sheet

Download data sheet

Learn about our solutions for the ceramics industry

Download catalogue

Tunnel Kilns for Sanitaryware data sheet

Download data sheet


Why choose Nutec Bickley when buying a tunnel kiln?

The best temperature uniformity in the market
Power Failure Protection System (PFPS) maintains the kiln alight up to 1 minute in case of a power outage
Tunnel kilns can be lined with our long-lasting Jointless® fiber system
Our customers are welcome to our facilities for project follow up of their tunnel kiln
Energy recovery systems to ensure the lowest fuel consumption
All of our projects are customized, based on the customer's needs
Nutec Bickley's shuttle kiln technology excels over other kiln manufacturers

Benefits of our electric tunnel kilns:

Higher energy efficiency compared to batch/periodic kilns.
Reduced maintenance over time.
Increase in sintering consistency, reduced variations compared to batch/periodic kilns.
Ability to integrate automation of loading/unloading more efficiently.
Large volume of production capacity.

Tunnel Kilns: The Benchmark for High-Volume Efficiency

Tunnel kilns represent the pinnacle of continuous kiln technology, offering unmatched efficiency and productivity for high-volume production. These kilns are specifically designed to optimize operations, making them a superior choice compared to traditional batch kilns when a high volume production is required.

Continuous Performance for Maximum Output

Unlike batch kilns, tunnel kilns operate continuously, ensuring a seamless production process with minimal downtime. Their advanced design allows for high efficiency and consistent output, making them ideal for industries that demand large-scale production. With the ability to operate at temperatures ranging from 100°C to 1800°C, tunnel kilns are suitable for a wide variety of applications.

Versatile Fuel Options

Tunnel kilns can be powered by either electricity or gas, providing flexibility to meet specific operational and environmental requirements. This versatility ensures that industries can choose the best energy source for their needs while maintaining optimal performance.

Automation for Modern Operations

Loading and unloading operations can be fully integrated with automation, streamlining the production process and reducing manual labor. This feature not only enhances efficiency but also improves safety and precision, enabling businesses to meet the demands of modern industrial standards.

Engineered for Excellence

Every tunnel kiln is custom-designed to meet the unique specifications of our customers. Whether you require a kiln for ceramics, refractories, or other high-temperature applications, our expert team ensures that each unit is built to deliver outstanding performance, durability, and energy efficiency.

Experience the power and precision of tunnel kilns—a solution that combines continuous operation, high efficiency, and cutting-edge automation to revolutionize your production processes. Contact us today to learn how a tunnel kiln can elevate your operations.

More Information



Tunnel kiln benefiting from the best technology

With our SCADA systems, the tunnel kilns operators are able to have complete control of their firing process, enhancing efficiency and productivity. Our latest Industry 4.0 developments integrate the latest technology for tunnel kilns to not only monitor the process, but also to keep the kiln operating at peak performance.

All the data generated during the firing process is stored in our SCADA system, which is then used to generate reports, graphs and intelligence data, to help customers in their decision making process.

Technology

SCADA

SCADA

With our SCADA systems, kilns operators are able to have complete control of their firing process, enhancing efficiency and productivity.

Learn more about SCADA

ECOmbustion™

NUTEC Bickley’s proprietary ECOmbustion™ system is an innovative control methodology designed to achieve fuel savings in gas-fired kilns, bringing operating costs down and reducing carbon footprint.

Learn more about ECOmbustion™

Jointless® Insulation

NUTEC Bickley’s patented ceramic fiber Jointless® modules provides for minimal maintenance, enhanced fuel economy and extended service life.

Learn more about Jointless® Insulation
Industries where our tunnel kilns are used
Sanitaryware
Porcelain Insulators
Refractories
Technical Ceramics
Ceramic Colors
Abrasives

Brick firing

Vitrified Clay Pipe
Tableware

Advanced Materials (Rare Earth)

Processes where our tunnel kilns are used

First Fire

Glazing

Biscuit Firing

Glost Firing

Decoration Firing

Debinding

Binder Burnout

Oxidizing

Calcining

Powder Firing Kilns

Related Services

Spare Parts

NUTEC Bickley provides the best Spare Parts brands for industrial furnaces, kilns and other equipment, with the highest quality components in the combustion and control areas.

Learn more about our Spare Parts catalog
Refacciones

Maintenance Policies

NUTEC Bickley provides Maintenance Policies for industrial furnaces all over the world. Our commitment is to keep your combustion systems in the best possible operating condition with periodic reviews and a process of continuous improvement.

Learn more about our Maintenance Policies

Gas flow dynamics in tunnel kilns

A tunnel kiln is basically a long rectangular chamber, lined with refractory material or ceramic fiber, through which the products to be processed pass on some type of platform (usually an insulated kiln car), while the products of combustion and cooling air move in the opposite direction, as we can see in Fig. 1.

Fig. 2 shows how the movement of gases inside the kiln comes from the cooling end to the products of combustion exhaust fan (POC) at the front end of the kiln.

More information here

Related Resources

Ceramic Industry

(E-book)
Date Added: 02/14/2023
Download E-Book

Ceramic Industry
Tunnel Kilns

(PDS)
Date Added: 04/27/2023
Download PDS

Ceramic Industry
Tunnel Kilns for Sanitaryware

(PDS)
Date Added: 04/27/2023
Download PDS

Related Resources

Gas flow Control in Tunnel Kilns for greater Operational Efficiency
Added: 01/22/2020
Learn more

Frequently asked questions about our tunnel kilns

What is a tunnel kiln?

A tunnel kiln is a highly efficient continuous firing kiln through which a product or ware moves on top of a train of insulated cars.

What are the advantages of a tunnel kiln?

The advantages of a tunnel kiln compared to a shuttle or batch kiln are mainly in fuel efficiency and overall equipment efficiency. A tunnel kiln can offer less than half the fuel consumption per unit of ware compared to a batch kiln. It can also offer high production volumes and faster cycle times compared to intermittent processes.

What is the difference between a tunnel kiln and shuttle kiln?

A tunnel kiln is designed for a continuous process as compared to a shuttle kiln, where the ware is fired in batches. Tunnel kilns are ideal for high production volumes of same or similar products.

What is the temperature of a tunnel kiln?

Tunnel kilns can fire at up to 1800°C. The higher the temperature it is fired at, the more efficient it is compared to a batch process.

What is the difference between a roller kiln and a tunnel kiln?

Tunnel kilns use a train of cars pushed through a tunnel, as compared to a roller kiln where the product is placed on a roller conveyor that moves the product through a tunnel. Tunnel kilns can offer higher production volumes compared to roller kilns. Roller kilns can offer higher efficiency with faster firing cycles.

What is the capacity of a tunnel kiln?

The capacity of a tunnel kiln will depend on the type of product that is being fired and the size of the kiln. tunnel kilns can be up to 150m in length. In sanitaryware, a tunnel kiln can fire up to 100,000 pieces per month.

This is Nutec  Bickley

Providing Thermal Equipment Solutions that go beyond expectations

We serve multiple industries through the design, building and installation of combustion systems, thermal insulation and highly specialized industrial furnaces, kilns and ovens. We are focused on understanding our customers’ needs and supplying the best equipment at the most competitive price. 

Read our latest success stories

Advanced Combustion for Advanced Ceramics

In a major, high-value project – the second at this particular plant in Mexico – NUTEC Bickley will supply a 125m-long tunnel kiln to one of the world’s leading advanced ceramics manufacturers.

VIEW MORE

NUTEC Bickley’s Latest Sanitaryware Kiln: A Byword for Flexibility

Explore NUTEC Bickley's latest innovative project, a highly flexible, energy-efficient shuttle kiln for the European sanitaryware sector.

VIEW MORE

Aluminum Heat Treatment

Industry leading manufacturer, specializing in rotary forging, metal spinning, and the flow forming of aluminum and other alloys into complex shapes.

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Do you want advice to select the ideal furnace or spare part for your project?

We offer specialized technical support and advice to ensure that you choose the solution that best suits your needs. Fill out this form or contact us to talk to us now.

Call us +52 (81) 8151-0800

Send us an email sales@nutec.com

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