Reducing kiln energy consumption through digital innovation

La Favorita Italia and Saitek have developed the SCC digital technology for managing the air-gas ratio in ceramic kiln burners. The first company to successfully test it was Laminam.

Close collaboration between La Favorita Italia and Saitek has led to the development of an innovative digital technology for managing the air-gas ratio in ceramic kiln burners. The SCC (Stoichiometric Combustion Control) system makes kiln regulation far more precise, significantly improving energy efficiency, reducing CO₂ emissions and increasing operating flexibility while maintaining the highest standards of production quality.

This patent-pending solution brings together the expertise of two well-established companies in the Italian ceramic district: La Favorita Italia, a specialist in industrial automation, and Saitek, a company with many years’ experience in the design and manufacture of industrial electronic equipment (burner electronics, sensors, control systems and electrical panels). Their shared goal is to develop intelligent, flexible solutions that respond effectively to the needs of a rapidly evolving sector.

The experience of Laminam

The first company to successfully test the new SCC technology was Laminam, a leader in the production of large-format porcelain panels and slabs and a firm that has made environmentally sustainable production processes one of the pillars of its business.

“We were very interested to trial this new solution, which promised to meet our dual goals of reducing gas consumption through better kiln control, and doing so with a digital solution, avoiding the analogue options that have been available for years,” explains Michele Perozzi, Operations Director at Laminam. “In July 2025 we installed SCC on two dual-channel kilns at one of our plants, and I must say that the results have been more than satisfactory. Gas consumption has fallen by more than 10%, a significant reduction that has also enabled us to apply for and obtain “white certificates” [energy-efficiency certificates] from the Ministry. We have also seen an improvement in the kiln’s fine-tuning, achieving better machine control and a more stable production process. In addition to these tangible results, SCC has the merit of being the first digital combustion control solution that can be retrofitted to existing kilns,” concludes Perozzi.

Characteristics and operation of SCC

At the heart of the SCC system is a modulating air-gas valve that automatically adjusts the air pressure supplied to the burner according to the gas pressure while keeping the desired stoichiometric ratio constant. The system consists of certified transducers for measuring air and gas pressures, proportional actuators for continuously adjusting the air valve, an electronic control unit and a digital interface that communicates setpoints and operating parameters to the supervision systems.

With the burner on, operators can adjust the stoichiometric air-gas ratio according to the type of product being fired, setting an oxidising, neutral or reducing atmosphere in the kiln. With the burner off or deactivated, it is possible to set a specific air pressure to be supplied, either preventing unwanted cooling of the process or allowing controlled cooling in proportion to the selected air flow.

SCC detects whether the burner is on or off and controls the actual position of the air valve by means of 4-20 mA industrial signals, both for the input (control) and output (position).

The Optima^® combustion control system from OXYCOMB was also used in the Laminam kiln optimisation project. Combining SCC control units with the Optima^® system results in greater energy savings. The Optima^® system enhances stoichiometric control of SCC control units by continuously measuring atmospheric oxidation. At the same time, it ensures optimal energy balance thanks to continuous monitoring of the pressure inside the kiln chamber and the flow rate at the flue. The two technologies are complementary and represent a major step forward in ceramic kiln management by ensuring more precise control of oxygen in the atmosphere.

A new kiln management system

SCC is not just an energy-saving project but an entirely new automated kiln management system that provides full control over each individual burner. By eliminating manual adjustments, it optimises every stage of the firing process, ensuring consistently high product quality and simplifying the entire production cycle.