Johnson Tiles

Name

Johnson Tiles

Organisation

Johnson Tiles manufactures and supplies ceramic tiles.

Summary

Johnson Tiles is the leading manufacturer and supplier of ceramic tiles in the UK, with a long history of market leadership and industry production development.

The company’s products are used in a wide range of commercial and non commercial projects and they supply ceramic tiles to almost every country in the world.

The company operates a fully automated production facility on a single integrated site in Stoke-on-Trent.  The factory employs over 400 people and produces over 5 million square metres of ceramic tiles for use in the UK and overseas markets.

Johnson Tiles has adopted a culture of resource efficiency on site where the efficient use of all materials, supplies, energy and transport is promoted.

The company were the first ceramics company within the whitewares sector to gain certification to ISO14001 and since then have received several business awards for their environmental achievements. The company has been a member of Staffordshire Business & Environment Network since 1999.

The aim

To uphold their longstanding commitment to environmental management.

The solutions

They have had a formal environmental policy in place since 1992.

A number of energy saving measures have been implemented throughout the plant such as:

  • speeding up kilns
  • changing CRT monitors to flat screens
  • switching from twice fired to once fired production
  • using automatic light sensors to low usage areas
  • re-using kiln exit heat.

 

Other environmental management measures include:

  • Used pallets are utilised within the factory and for deliveries.
  • The company purchases second hand pallets and also repairs damaged pallets where possible.
  • Re-using 90% of the glaze and pigment transportation buckets that are used on site.
  • Each year Johnson Tiles recycle 20,000 tonnes of ceramic waste from their own production processes and those of 14 other local ceramic manufacturers who deliver ceramic waste from their own production plants for re-processing at the Stoke-on-Trent factory.
  • The ceramic waste is ground to a suitable size and added to standard ceramic materials to create tile bodies.  These recycled materials comprise on average 25% of the raw material but can be as high as 36%.
  • 92% of the content of the company’s packaging is from recycled materials and all waste cardboard and plastic wrapping waste is baled on site and sent for recycling.
  • Reuses water in the company’s body preparation area and has removed water from other parts of the production process.

 

The results

  • Energy saving measures have realised significant energy savings of 25% per tonne of ceramic tile produced which equates to 42 million kWh per year.
  • Recycling the 20,000 tonnes of ceramic waste annually diverts 24,000 cubic metres from landfill.
  • 1,250 tonnes of virgin timber saved annually through the re-use of pallets on site
  • 92% of the company’s packaging is from recycled materials and all cardboard and plastic wrapping waste is sent for recycling
  • In the company’s body preparation area 30,000m3 of water is re-used each year.  In addition, the company has also removed water from other parts of the production process which has realised additional savings of 2,100m3 of water.
  • Reusing 90% of the 10,000 plastic glaze buckets in their factory gives a saving of 5 tonnes of plastic per year.
  • In addition, it is estimated that 235,000 miles of HGV journeys per year using 133,750 litres of diesel (360 tonnes of CO2) are saved on the transportation of raw materials by using this recycled material.

 

Learning points

  • Johnson Tiles has recognised the financial and environmental benefits that can be gained through adopting a systematic approach to resource efficiency and is committed to continuously improving its performance going forward.
  • Huge savings can be made by reusing and recycling materials, equipment and water.

SWM comment

Johnson Tiles has demonstrated that  waste can be eliminated by reusing materials and water which is positive for both the environment and the company as it saves on bills and costs for buying new materials.

Contact

For more information on Johnson Tiles please visit the Johnson Tiles website.

The information for this case study was sourced from Staffordshire Business & Environment Network (SBEN). For further information about the SBEN call them on 01785 277 379 or visit the Staffordshire Business & Environment Network website.