When Wade Ceramics Ltd, based in Burslem, Stoke-on-Trent and one of the UK's longest established ceramic companies, was looking for a unique and cost-effective solution to continuous firing, the company turned to Consultant Gas Engineers (CGE) Limited of Skelmersdale, UK. CGE had recently pioneered the innovative design of the new CGE Fast Track kiln for the rapid firing of product to temperatures as high as 1550 [degrees] C. Such a kiln was installed for the glost firing of ceramic whisky decanters.

At Wade Ceramics the electric version of the Fast Track kiln fires to an operating temperature of 1200 [degrees] C and has been used successfully for both biscuit and glost firings. The kiln incorporates a segmented refractory hearth that moves continuously through a heating and cooling tunnel. The hearth consists of heat sealing modular sections that move by means of a heavy conveyor chain. Each hearth module comprises a stainless can lined with a ceramic fiber blanket. When required, the modules can be maintained or replaced without switching off the kiln through movable roof sections that facilitate rapid access to the kiln interior.

According to Mike Farmer, manufacturing manager at Wade Ceramics, productivity has increased on first-fire yields by an average of 10%, while a decrease in firing time (33% more ware fired than the existing tunnel kiln) and a reduction in handling faults have resulted since the introduction of this new kiln. "We have also introduced a 24-hour, seven-day-a-week glost selection system direct from the kiln, thus greatly reducing our work in progress. This was only possible because ware is delivered direct from the kiln to our glost selectors in single layers."

Excellent temperature uniformity is achieved across the section of the Fast Track kiln due to its envelope of heat input. A very accurate temperature profile can be achieved down the length of the kiln and multiple zones can create the ideal firing conditions. Control of the kiln is from a single panel that is mounted onto the unit. The electrical input to the kiln is distributed over the roof, side walls and hearth with a digital temperature controller incorporated in the control panel for each of the zones.

The Fast Track kiln can be accommodated into most in-line systems. Should production capacity increase, extra modules can be added to extend the kiln's length. The unique design of the kiln means that a complete seal is created in the hearth enabling kiln pressure to be completely stable.

Such a design, which can be electric or gas fired, has all the advantages of competing designs, such as the roller hearth kiln, and many unique features where rapid firing of multiple products is required. The Fast Track kiln, unlike the roller hearth kiln, has a far greater potential setting width and a high load bearing capacity for product. The kiln also eliminates any relative movement between the product and the hearth.

Compared to other rapid fire tunnel kilns, the Fast Track kiln is less expensive because there are no kiln cars, car transfer and car return systems. The Fast Track kiln is also flexible, particularly in two areas. Due to its low thermal mass, the heat up and cool down times are rapid and, therefore, the kiln can be shut down economically at the end of the shift, day or weekend. Additionally, the conveyor speed and process temperature are variable, which allows for rapid product changeover.

Other benefits of the Fast Track kiln include a rapid cooling system, which minimizes product cooling time and rapid change of operating conditions/cycle times to suit any product requirement. The ratio of refractories to ware is low, thus allowing more product to be fired with the same amount of energy in the kiln.

After the successful installation of the CGE Electric Fast Track kiln at Wade Ceramics, CGE has received a number of recent inquiries for the CGE Fast Track kiln and will be looking to secure further contracts during the coming months. Significant success has already been achieved in other applications such as china, earthenware, hotel-ware, tableware and industrial ceramics.

"At first I was hesitant about CGE's proposals, but I can now see the benefits of the system and the results that it is bringing in terms of increased production and efficiency," says Peter Mellor, works manager at Wade Ceramics.

For further information on the CGE Fast Track kiln, contact Consultant Gas Engineers Limited, Peel Road, West Pimbo, Skelmersdale, Lancashire WN8 9PT, England. Telephone: + 44 (0) 1695 727441. Fax: + 44 (0) 1695 729466.