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.
The best fuel consumption in the world of sanitaryware production – usually less than 1,000 Kcals/kg of fired product – makes us the most efficient tunnel kiln manufacturer in the market for firing ceramic whitewares, as well as clay bricks, vitrified roof tiles, abrasives, refractories, etc. Wide variety of tunnel kilns for ceramics in high volume production for temperatures up to 1800°C (3270°F) and car handling equipment to suit the application.
By integrating our combustion and energy recovery systems we ensure the lowest fuel consumption possible in ceramic firing and excellent Energy Efficiency. In a wide range of capacities and with a choice of door, combustion system, and control designs. With SCADA systems for product quality management and Car handling systems.
Nutec Bickley developed this concept and has delivered over 500 Carbell® Kilns to a variety of companies manufacturing ceramics worldwide. Better known as “Top hat kilns”, Carbells have no doors and incorporate an efficient seal design for a low maintenance design. The integrated combustion and control system varies the atmosphere inside these industrial kilns for ceramics, using excess air only when the product requires it, making it very efficient.
The Elevator design offers a very efficient seal between the car and the ceramic kiln reducing to a minimum maintenance issues created by heat leakage while firing ceramics at high temperatures, resulting in a low maintenance system. Available with updraft or downdraft exhaust designs and are ideally suited for high temperature firing of small batches. Used extensively in the technical ceramics industry and for pilot production of refractories and specialty ceramics.
Our Roller Kilns for ceramics offers the manufacturer a fuel efficient solution where cycles are fast and products require a very tight temperature uniformity. With a Power Failure Protection System and our exclusive Jointless® fiber system.
NUTEC Bickley's Rotary Kilns offer a very efficient way to clean activated carbon so that it can be reused.
With SCADA systems for product quality management and best fuel consumption in Sanitaryware production and ceramic industry in general. The greatest flexibility in a wide range of capacities and with a choice of door, combustion system, and control designs.
We are committed to offer not only quality products, but also quality service that exceeds expectations.
Fuel Savings
All of our industrial kilns include features that make our kilns some of the most efficient in the world, by using the latest technology with IMPS, preheated combustion air, self recuperative and regenerative technology, we can achieve this.
Improved Product Quality
With Nutec Bickley Kilns, firing rejects are almost entirely eliminated due high precision in temperature uniformity and reproducibility of the process.
Complete Process Control
All the key factors influencing kiln performance such as air fuel ratio, temperature in various parts of the kiln, product feed time, energy recovery, atmosphere, kiln pressure, and rates of heating and cooling are controllable and programmable with our control and supervisory systems.
Our industrial kilns comply with all worldwide safety recommendations, standards and regulations, most notably these:
NFPA-86 Standard for Ovens and Furnaces (recognized internationally)
CSA B149.3-15 Code for the field approval of fuel-related components on appliances and equipment (Canada)
EN746-2 Safety requirements for combustion and fuel handling systems (Europe)
We are members of the IHEA (Industrial Heating Equipment Association), an organization that continuously participates in the development of improvements in safety and regulatory standards. Compliance with these standards allows our customers to avoid explosion risks and danger risks to personnel and equipment, resulting in an operation that is as safe as it is efficient. At Nutec Bickley we are experts in industrial safety, so we make sure our kilns and furnaces are, at the very least, fully compliant with all current regulations.
Our industrial kilns are specially designed to optimize energy efficiency by various means, one of the main opportunities being the recuperation of heat normally lost through the exhaust flue during the combustion process. With the goal of taking this a step forward – increasing the potential for the use and transfer of process heat – we have developed new technologies for our energy recovery systems (ERS).
The energy that is introduced into the kiln via the burners is typically used to heat the following:
Heating the kiln walls
Heating the product
Heating the kiln furniture
Heating the kiln cars
What our heat recuperation systems seek to achieve is the reuse of the energy carried by the gases that normally exit through the flue, in order to reduce gas consumption in a typical industrial heating process.
More information here
Custom kilns. Specifically designed around a certain application or product manufacturing process.
Standard equipment. Being mass produced, these furnaces are created to cover a broad spectrum of general purpose applications.
Custom kilns. Designed according to standards and international requirements for the heat source, combustion system, components, etc.
Standard equipment. These furnaces carry preset features with fewer adjustment options, which limits their flexibility and adaptability compared to custom furnaces.
Custom kilns. Due to the nature of their design, engineering, and manufacturing process, they may require longer lead times.
Standard equipment. By being standardized, the delivery time is usually faster.
Custom kilns. These offer superior performance due to specific design, engineering, and manufacturing processes.
Standard equipment. Although their standardized design fits a broader spectrum of applications, they can offer reliable performance.
Industrial kilns are used generally for ceramic processes where the product may require sintering, oxidation, calcination, vitrification, glazing, decorating, curing, and others. NUTEC Bickley can offer a wide range of kiln designs to suit your specific needs.
Tunnel kilns
Shuttle Kilns
Carbell Kilns
Industrial kilns can use both electricity and fossil fuels as an energy source.
In the industry, shuttle kilns are most used as they are suited for a high flexibility in production and can range in sizes from 1m³ to 500m³. Shuttle kilns can be both electric and gas fired.
Industrial kilns can fire up to 1800°C (3200°F) in conventional processes. Depending on the type of product, NUTEC Bickley can offer a wide range of products to suit your production needs.
Continuous kilns are more efficient than batch kilns. There are multiple technologies that can improve efficiency like heat exchanger systems, heat storage, ECOmbustion, etc. NUTEC Bickley can offer a wide range of solutions for your heat recovery needs.
Industrial kilns can last for decades if taken care of correctly. Frequent maintenance procedures are important to keep your kilns in top shape. NUTEC Bickley can offer retrofits or refurbishments to repair insulation systems, update obsolete control systems, and replace old combustion systems.
The cost of an industrial kiln can vary from hundreds of thousands of dollars to millions of dollars depending on the size and its use. Speak to NUTEC Bickley’s engineers and we can gladly give you a budget that would suit your requirements.
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.
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.
Explore NUTEC Bickley's latest innovative project, a highly flexible, energy-efficient shuttle kiln for the European sanitaryware sector.
Industry leading manufacturer, specializing in rotary forging, metal spinning, and the flow forming of aluminum and other alloys into complex shapes.
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.
