Evaluating tunnel kiln performance

Process improvements in the production of whitewares provide the potential for substantial savings for manufacturers. A typical whiteware manufacturer incurs an annual defective product loss of {approximately}$20 million when accounting for raw materials, energy, labor and waste disposal. Reduction in defective product loss of 1% could result in a savings in excess of $1 million annually. This study was designed to establish benchmarks for two conventional tunnel kilns used to bisque-fire dinnerware at Buffalo China Inc. (Buffalo, NY). The benchmark was established by assessing the current conditions and variability of the two tunnel kilns as a function of the fracture strength of sample bars that were made from production body. Sample bars were fired in multiple locations in both kilns to assess the conditions and variability of firing within each kiln. Comparison of strength results between the two kilns also was assessed. These comparisons were accomplished through applied statistical analysis, wherein significant statistical variations were identified and isolated for both tunnel kilns. The statistical methods and tools used in this analysis are readily accessible to manufacturers, thus allowing implementation of similar analysis, or benchmarking, in-house.