Design and Manufacture of Trolleys for Ceramic Kilns
Solutions tailored to the firing cycle, load, and conditions of each facility.
Kiln Cars for Tunnel Kilns: Design, Components and 360° Refractory Technology
For more than 70 years, TEIDE has designed and manufactured kiln cars for the ceramic industry, with more than 400 installations across five continents.
A kiln car is much more than a vehicle that carries products through a tunnel kiln. It is one of the key factors influencing energy consumption, kiln productivity and the service life of the entire installation. This page explains what a kiln car is, its main refractory components, the different design technologies available and how to choose the most suitable solution for your kiln.
What is a kiln car?
A kiln car is the mobile platform that transports ceramic products—bricks, roof tiles, sanitary ware or porcelain—through a tunnel kiln during the firing cycle. It runs on rails by means of a steel chassis with wheels, while its upper structure is built from refractory materials capable of withstanding hundreds of thermal cycles without losing flatness or mechanical strength.
The kiln car design directly affects:
- Thermal mass that must be heated and cooled during each firing cycle, and therefore fuel consumption.
- Load capacity per square metre.
- Maintenance frequency and the number of replacement parts required.
Our engineering team designs every kiln car according to the firing cycle, operating temperature, kiln atmosphere and mechanical load.
Set up kiln car 3d simulation layer per layer
Kiln Car Components
Although every project is customised, most kiln cars are composed of the following elements:
Steel chassis
Steel structure with wheels running on the kiln rails. It supports the complete refractory superstructure.
Levelling refractory concrete
A refractory concrete layer that levels the chassis and provides a stable base for the kiln car structure.
Perimeter supports
Perimeter supports – Refractory side supports protecting the steel chassis and the sand seals from radiant heat while preventing hot gases from reaching the metallic structure.
Support tubes
Rectangular refractory beams that distribute the mechanical load throughout the kiln car.
Deck slabs (platforms)
Cordierite or mullite refractory slabs forming the upper surface where ceramic products are stacked. They can be manufactured using pressed, extruded or mixed technologies.
Drought hole blocks (Viaduct Blocks)
Refractory load-bearing blocks positioned on the deck slabs—or directly on the insulating base in VNT technology. Besides supporting the ceramic load, they allow hot gases to circulate through the kiln car, improving heat distribution and firing uniformity.
Insulating fill
Lightweight insulating material that reduces heat transfer towards the steel chassis, lowers the kiln car thermal mass and contributes to energy savings.
Materials: Cordierite and Mullite
Kiln car components are mainly manufactured from cordierite and mullite because of their low reversible thermal expansion and excellent thermal shock resistance.
TEIDE also develops proprietary refractory formulations through its Phaseteide R&D programme, validated by the Institute of Ceramic Technology (ITC), for demanding kiln operating conditions.
Kiln Cars by Industry
· Structural Ceramics (Bricks, Roof Tiles and Blocks) VTP, VPX, VMX, VEX and VNT technologies.
· Sanitary Ware and Porcelain: VSA and VPO kiln cars combining handcrafted, pressed and extruded cordierite components with different densities to maximise lightness and energy efficiency. densidades de cordierita, priorizando ligereza y ahorro.
Frequently Asked Questions
What is a kiln car called?
The international term is kiln car. In some countries it may also be referred to simply as a kiln wagon, although kiln car is by far the most widely used term in the ceramic industry.
What are the main components of a kiln car?
A kiln car consists of a steel chassis, support tubes, levelling refractory concrete, insulating fill, perimeter supports, drought hole blocks (viaduct blocks) and refractory deck slabs.
What is a drought hole block?
A drought hole block, also known in some ceramic plants as a viaduct block, is a refractory load-bearing component that supports the ceramic products while allowing hot gases to circulate through its internal openings, ensuring uniform heat distribution.
How much load can a kiln car support?
Depending on the technology, TEIDE kiln cars can support between 1,500 kg/m² (VEX and VNT) and 2,500 kg/m² (VTP).
What is the difference between VTP and VNT kiln cars?
VTP is the traditional pressed kiln car, designed for heavy loads and maximum durability. VNT eliminates the deck slabs to minimise thermal mass and reduce energy consumption.
Need to design or upgrade your kiln cars?
Tell us about your kiln, firing cycle and production requirements.
Our engineering team will analyse your process and recommend the most suitable refractory solution.