Bartın Seramik adopts a high-efficiency tunnel kiln

The Turkish sanitaryware manufacturer confirms the excellent results achieved with the kiln equipped with EnerViT technology supplied by Keramischer OFENBAU.

Bartın Seramik, a Turkish manufacturer of vitreous china sanitaryware, embarked in 2023 on a major investment project involving the construction of a new high-efficiency tunnel kiln equipped with EnerViT technology from Keramischer OFENBAU. The aims of the project – which was completed in less than a year - were to expand production capacity, further improve product quality and achieve a substantial reduction in energy consumption, a strategic step towards safeguarding the company’s future competitiveness.

In response to growing demands for energy efficiency and product quality, Bartın Seramik opted for the solution proposed by Keramischer OFENBAU in view of the positive references from within the industry.

The supplied plant and the results achieved

The supplied plant consists of a 111-metre tunnel kiln with an integrated EnerViT system, complemented by a dryer located at the end of the return track. The scope of supply also included 98 kiln cars, a complete transport system and the entire control and automation system. The kiln is designed for a firing temperature of 1230°C, with a loading width of 4 metres and a kiln car length of 1.5 metres. At the heart of the installation is the proven and continuously upgraded EnerViT system. By using pulsed burners and optimising energy use across all kiln zones, the system achieves a substantial reduction in energy demand. In addition, a carefully engineered cooling system minimises the risk of cooling cracks in the ware while enhancing glaze brilliance.

The kiln is currently operating at around 50% of its design capacity, a deliberate choice based on current production requirements. Even at this reduced throughput, energy consumption has already been cut by around 25% compared with full‑capacity operation of the previous kiln. This result came as a pleasant surprise even to plant manager Mustafa Yaman.

At full capacity, both partners expect to see energy savings of more than 35%. The surface quality of the fired products has also improved significantly, a benefit that has been confirmed by key customers and has already led to additional subcontracting orders for Bartın Seramik.

The energy cost savings alone, even at 50% capacity, are expected to pay back the investment in less than six years. Higher yields and improved product quality point to an even more positive outlook once Bartın Seramik is producing at full capacity, not to mention the additional benefits of reduced waste and leaner production processes.