Relevant case studies

Blog post: 18/09/2025 10:04 am

Author: Spark Team

Luxury Ceramic Tile Manufacturing: Digital SOP Systems for Dust & Heat Safety

Luxury ceramic tiles demand beautiful glazes, tight calibration, and durable performance. Yet the production environment—spray-drying, pressing, glazing, and kilns—exposes workers to respirable crystalline silica (RCS), high heat, and heavy materials handling. Regulators and clients now expect digital proof that HSE controls are embedded in daily routines. A cohesive system of VR/AR training and AI oversight standardises safe behaviour and preserves premium quality.

Standards & Obligations

• RCS controls (COSHH): Local exhaust ventilation, housekeeping, and fit-tested RPE.
• Thermal risk management: Kiln loading/unloading, refractory handling, heat stress monitoring.
• Machinery safety: Guarding and lock-out/tag-out (LOTO) on presses, conveyors, and cutters.

Where Safety Breaks Down

• Inconsistent practices: Housekeeping standards drift across shifts.
• Heat complacency: Shortcuts during kiln turnaround cause injuries.
• Paper SOPs: Lack of real-time feedback and weak audit evidence.

Digital SOPs That Drive Behaviour

• VR Hazard Modules: Train operators on RCS hotspots, LOTO sequences, emergency responses, and safe lifting in a risk-free environment.
• AR On-Station Prompts: Visual cues for vacuuming vs. dry sweeping, glaze booth checks, and kiln door protocols, with time-stamped photo evidence.
• AI Avatars: Ask for confirmations at high-risk steps (e.g., RPE fit and filter checks), flagging non-compliance instantly.

Quality & Safety Go Together

Cleaner processes improve glaze adhesion and reduce contamination defects. Standardised kiln practices stabilise firing curves, lowering scrap on top-end decorative ranges.

Commercial Benefits

1. Reduced incidents: Fewer RCS exposures and heat injuries.
2. Consistent output: Lower scrap and rework from contamination or firing errors.
3. Audit confidence: Digital evidence packs for regulators and luxury clients.
4. Workforce retention: Safer, smarter work reduces turnover.

Why Spark Emerging Technologies

Spark designs tile-plant VR training, AR SOP execution, and AI coaching that plug into your QMS/LMS and EHS systems—giving leaders a live view of compliance and performance.

Call to Action

Want measurable dust and heat safety without compromising luxury finish? Partner with Spark Emerging Technologies to implement digital SOP systems across your lines.

© 2025 All Rights Reserved | Company Reg No. 05327622 | Spark Emerging Technologies Limited

Privacy Policy | Terms and Conditions