Energy-saving package NewGen ESP – Saving energy and costs

Are you looking for a kiln that is not only powerful but also energy-efficient? We have the perfect solution for you: the new energy saving package KITTEC NewGen ESP: This innovative option for kilns offers numerous advantages which will be explained in more detail in this article.

What is new about the energy saving package KITTEC NewGen ESP?

With our KITTEC NewGen ESP energy-saving package we use a completely new type of refractory lining with innovative foam ceramic bricks in addition to the usual high-quality multi-layer premium insulation and an insulating plate installed underneath the bottom.

What are the advantages of NewGen ESP for you?

Due to the higher-quality insulation in combination with the novel, energy-saving ceramic foam brick, the power requirement is considerably reduced, as are the heating and cooling times (cycle times). The heating elements therefore do not have to “work” as much to reach and maintain the desired temperature in the kiln. In the long run, this is much less stressful for the heating elements and the power consumption is also drastically reduced.

In general, you as a kiln operator not only save an astonishing amount of electricity with the help of the NewGen ESP, the shortened heating and cooling times (cycle times) also allow more firings to be carried out in a shorter time. Thanks to NewGen ESP, the wear of the heating elements is also greatly decelerated and the service life is thus considerably extended.

Is NewGen ESP recommended for every kiln?

According to our experience, NewGen ESP pays off with every kiln, because the additional costs for this energy-saving package are amortised in a very short time.

We have noticed considerable electricity savings in all kilns with NewGen ESP. The advantage of longer heating element life also provides a significant payback over the years because of the much lower spare parts and service costs.

How much electricity can I save with the NewGen ESP?

The exact savings potential you can achieve with NewGen ESP depends, of course, on various factors (quantity/load in the kiln, firing curve and firing temperature, size and power of the kiln, power supply, etc.). However, the savings are particularly significant when firing at relatively high temperatures and when the kiln is used very frequently.

To illustrate this, here are the firing curves of our CB 95 S models in direct comparison for a 1,250°C firing with SKIP (fastest heat-up):

• You can see that the CB 95 S NewGen ESP reached the 1,250°C already after 3:04h, and thus exactly 0:43h faster than the CB 95 S with normal ESP with light refractory bricks, and even 1:13h faster compared to the standard CB 95 S.
• The electricity savings in this case were 5 kWh and 8.5 kWh respectively. Assuming an electricity price of 40 ct/kWh, this is a whole 2 EUR or even 3.40 EUR per firing!

What is the difference between the tried and tested lightweight refractory bricks and the innovative ceramic foam bricks?

Foam ceramic bricks are a completely new development, based on the basic idea of producing a high-temperature brick that is as energy-saving as possible but still has very good insulating properties.

This worldwide unique, patented ceramic foam brick of Central European production was developed especially for the thermal insulation of kilns. It combines the advantages of the tried and tested, robust lightweight refractory bricks with those of energy-saving ceramic fibres that absorb and store very little heat.

If ceramic foam bricks are installed in kilns as heat-insulating kiln linings, the energy requirement is considerably reduced, as are the heating and cooling times (cycle times).

Why does a kiln with ceramic foam bricks heat up and cool down so much faster?

Compared to lightweight refractory bricks, ceramic foam bricks are characterized by a particularly low density (i.e. they are also much lighter). For this reason, they absorb less heat and much less energy is stored within the brick. This leads to much shorter heating and cooling times (cycle time) compared to an identically insulated kiln with lightweight refractory bricks.

Let’s take another look at the firing curves of our CB 95 S models to illustrate this:

You can see that the entire firing cycle from the start of the program until the natural cooling down to 200°C was more than 5 hours shorter for the CB 95 S NewGen ESP than for the conventional ESP version with lightweight refractory bricks. And it was even 47 minutes faster than the (significantly less insulated) standard CB 95 S.

How much lighter are kilns with NewGen ESP ceramic foam bricks?

Top-loading kilns with ceramic foam bricks are about 30% lighter than top-loading kilns with lightweight refractory bricks. Front-loaders are about 20% lighter. This makes the kiln much easier to set up.

Are ceramic foam bricks harmless to health?

As there are no harmful (fibre) components, the ceramic foam brick is absolutely harmless to health and can even be recycled.

Can the ceramic foam bricks be repaired or replaced in the same way as lightweight refractory bricks?

Yes, the bricks can be repaired, glued, repaired, remodeled, or replaced in a comparable way.

The reason for choosing a KITTEC kiln with the energy saving package NewGen ESP:

You now have found out about the advantages of the energy saving package NewGen ESP, that facilitates energy as well as costs savings and helps to protect the environment. By choosing a KITTEC kiln with NewGen ESP, you are investing in the future of your creativity. Contact us to learn more and get help from our experts. We are happy to answer your questions!

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