Transforming traditional industry into a leader: The tile industry in ...

Transforming traditional industry into a leader: The tile industry in Castellon Dr. José Luis Amorós and Dr. Carlos Feliu

The Spanish Ceramic Tile Cluster

Transforming traditional industry into a leader: The tile industry in Castellon

Ceramic Tile Cluster The Ceramic Tile Cluster comprises the group of activities related to ceramic tile manufacturing, from floor and wall tile fabrication, complementary activities such as frit and ceramic colour production, machinery building, and other commercial activities (raw materials supply, manufacture of trims, design studios, etc.) to business support activities (public and private institutions)

OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


Ceramic tile consumption and production Data for 2004 on the major ceramic tile manufacturing countries

Production

2000

Consumption

1500

1000

500

USA

Iran

Thailand

Vietnam

Mexico

Turkey

Indonesia

India

Brazil

Italy

Spain

UE25-It-Sp

Source: ASCER

P.R. China

0



Ceramic Tile Cluster. Geographic concentration Spain

Castellón cluster

Figueroles

Number of companies

300 250 200

L'Alcora

La Pobla

294 Borriol

223 Vila-real

150

Onda

100 Nules

50

Mediterranean Sea

28 26

0

Tiles

Frits and pigments

10 miles Almenara

Source: ITC, ASCER, ANFFECC OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


Ceramic Tile Cluster. Distribution of employment Castellon distribution of employment 2003 > Number of employees: 226,300 Unemployment rate: 5.94%

Number of employees: 36,326 Frits and pigments 9.00%

Machinery 4.10%

Industry 30.9% Ceramic tile Industry 12,7%

Services 49.7%

Tiles 86% Building 11.8%

Agriculture 6.50%

Source: INE. Instituto Nacional de Estadística OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


Ceramic Cluster. Industrial Investments Industrial Investments Ceramic Tile Sector Total %

1997 53,54 373,31 14,3

1998 78,18 435,77 17,9

1999 126,33 557,17 22,7

2000 122,31 535,73 22,8

2001 180,48 861,68 20,9

2002 91,14 520,13 17,5

2003 46,48 411,41 11,3

Million €

Although the investment in 2003 by the ceramic sector was the lowest in the last 7 years, it accounted for 64.5% of the total industrial investment in Castellón province and 11.3% of the entire Valencia Region.

Source: ASCER OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


Ceramic Cluster. Evolution of frit and pigment production

Turnover (million €)

900 750 600 450 300 150

19 93 19 94 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05

0

Year Source: ANFFECC

National

Export



Ceramic Cluster. Evolution of tile production 4000

Turnover (million €)

3500 3000 2500 2000 1500 1000 500 0 93 994 995 996 997 998 999 000 001 002 003 004 005 1 1 1 1 1 1 2 2 2 19 2 2 2 Source: ASCER

National

Year

Export



Ceramic Cluster. Evolution of tile production Evolution of firing processing

Production (million m2)

Total production 700

25.1%

600

1% 3.7%

500

44.1%

400 300 200

64.2%

100

36.9%

9% 1%

04

02

00

98

96

94

92

90

88

86

0

Year 1984

Source: ASCER

1998

Single-fire floor tile

Fast twice-fire wall tile

Single-fire wall tile

Traditional twice-fire wall tile



Main factors contributing to the success of the ceramic sector in Castellón: > > > >

High sectoral cohesion Highly skilled human resources Optimal use of technological resources Existence of public and private institutions supporting sector innovation

Innovation System Model


Local Innovation System Model


Ceramic Tile Cluster. Innovation System Model Innovation and technology development are the result of a complex set of relationships among actors in the system, which includes enterprises, universities, government and research institutes Enterprises

Administration

Infrastructures

Public-Private R&D system

Environment



Ceramic Cluster. Innovation System Model CEVISAMA

Ministry of Commerce

ICEX

Ministry of Industry

Technological Policy

Environment

SEPIVA IVEX

Industry

IMPIVA ASEBEC

Education AAOA

University Jaume I of Castellón County Council

ANFFECC Companies

Regional Government Generalitat Valenciana

ASCER

CDTI / DGpyme

Depts

Public bodies

Town Councils

FP II

ITC ALICER

Chemical Engineering Dept Lab. CSC

QUALICER

IPC Cer. Cer. Technicians’ Technicians’ Ass. Ass.

Chamber of Commerce

Ind. Eng. Eng. Ass. Ass.


The Instituto de Tecnología Cerámica


Structure

Concert Agreement AICE - UJI University Institute for Ceramic 5th November 2001 Technology

“Agustín Escardino”

Ceramic Industry Research Association

Both institutions jointly use the premises, facilities, equipment, material, and staff that make up their research infrastructure OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


ITC general overview Main objective: > “The Instituto de Tecnología Cerámica’s mission is to foster and develop whatever technical activities may contribute to enhancing the competitiveness of the ceramic sector, both in the domestic and international marketplace” Over 30 years’ experience in research and technology development, always working closely with companies to meet industry needs Providing more than 360 companies world-wide (90% of which are SMEs) with scientific and technological services



ITC historical overview 1969: Creation of the Instituto de Química Técnica. University of Valencia 1975: All activities are focused on ceramics 1984: Establishment of the Ceramic Industry Research Association (AICE). Agreement between AICE and Instituto de Química Técnica. 1993: The name changes and becomes Instituto de Tecnología Cerámica (ITC). Integration of ITC at University Jaume I

(UJI) of Castellón. 1993: Establishment of Industrial Ceramic Design Association (ALICER) from ITC Design Department 1997: Official opening of the new ITC building on UJI campus grounds. 2006: Integration of ALICER OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


ITC main facts Highly qualified team – 23 university lecturers, 53 graduates, 27 technicians, and 27 support staff 8000 m2 of laboratories, pilot plant, meeting rooms, offices, lecture rooms, and stores 6 million euro in scientific instruments and equipment 450 analyses and tests relating to ceramic materials or the manufacturing process 600 R&D Projects ∼ Revenue of 12.5 million euro 17 European R&D Projects



Organisation Production

79.2%

22 PhD holders 54 4 or 5 yr degree holders/Engineers 4 3 yr degree holders/Tech. Engin. 23 Vocational training and Arts & Crafts graduates Support

Total Staff: 130

20.8%

2 4 or 5 yr degree holders 8 3 yr degree holders/Tech. Engin. 17 Medium-level qualifications

(Equivalent 108 fullfull-time staff) OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


Organisation 28 Persons engaged in the University

20.7%

3 Full Professors 10 Associate Professors 1 PhD-holding Assist. Prof. 9 Assistant Professors 1 PhD-holding administrative and service staff 4 Administrative and service staff

Total Staff: 130 (Equivalent 108 fullfull-time staff) OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


ITC Number of associated companies Average in the last 10 years: 284 companies No. of associates 400 350 300 250 200 150 100 50 0 1995

year 1996

1997

1998

1999

2000

2001

2002

2003

2004

2005



ITC contribution to Industrial Innovation

Industrial Innovation Novel technology + resources

Qualified human resources

+

Financial resources (capital)


Novel technology resources


ITC activities > R&D+i and technological consultancy > Technology Transfer > Training and educating > Technological service > Design and Architecture > Competitive Intelligence service



Ceramic subsector activity Revenue from ceramic subsectors Euros 2.500.000

Sanitary ware/Artware

2.000.000

Other

Machinery and Consultancy Brick & Roof tiles

1.500.000

Raw materials 1.000.000

Frits and glazes 500.000

Ceramic tiles 0

1991

1992

1993

1994

1995

1996

1997 1998

1999

2000

2001

2002

2003

2004

2005

Year OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


R&D activity Euros

Revenue from R&D projects

2.000.000 1.800.000 1.600.000 1.400.000

Spanish Administration-related R&D

1.200.000 1.000.000

European Union-related R&D

800.000 600.000

Company-related R&D

400.000 200.000 0 1996

1997

1998

1999

2000

Year

2001

2002

2003

2004

2005



Areas of work Number of papers in scientific journals 120

Technical ceramics 100

Energy and Environment 80

Measurement and control techniques 60

Frits and Glazes

40

Manufacturing process 20

Raw materials 0 1972-1976

1977-1981

1982-1986

1987-1991

1992-1996

1997-2001

2002-2006



R&D+i and technological consultancy R&D+i and Technological Consultancy activities are carried out to meet he demands of the ceramic sector



Technology transfer The work involved is aimed at directly applying or, when required, adapting technologies from other industrial branches to the ceramic sector to satisfy specific industrial needs



Technological service Analyses and Tests

accredited laboratories



Design & Architectural applications From this area actions are undertaken to generate new applications of ceramics in architecture, aimed at recovering ceramics as functional and decorative, yet also innovative elements for architects and designers



Competitive Intelligence System Center for Information and documentation generating and coordinating studies, reports, and events concerning the market; industry; consumer; trends in product design in related sectors; technology watch and product development


Qualified Human Resources


Offer in Castellón of specialised training in ceramics (regulated) Vocational training

Industrial ceramics

School of art and design

Ceramic tile design

Schools of ceramics

Diploma in Ceramics

84/85 (Castellón) 00/01 (Onda)

88/89 00/01 (Manises) 05/06 (l´Alcora)

Chem. Degree, specialty in Industrial Chemistry

From 88/89 to 98/99

Chemical Engineering Degree

Since 93/94



University graduates University graduates from UJI with a specialty in ceramic materials technology 800 700

500

Chemical Engineering (400)

400 300 200

Industrial Chemistry (283)

100

20 06

20 05

20 04

20 03

20 02

20 01

20 00

19 99

19 98

19 97

19 96

19 95

19 94

19 93

19 92

19 91

0 19 90

Nr graduates

600

year OECD/IMHE Supporting the contribution of higher education instituttions to regional development. Copenhagen 16-17/10/2006


ITC contribution to the training of qualified technical personnel Attendance by industrial technicians to ongoing training courses 3000

2604 technicians in 174 courses since 1990

2000

1500 1000 500

20 05

20 04

20 03

20 02

20 01

20 00

19 99

19 98

19 97

19 96

19 95

19 94

19 93

19 92

19 91

0

19 90

Number of technicians

2500



ITC contribution to the training of qualified technical personnel 137 technicians with higher education or medium-level qualifications hired by companies, after postgraduate training at ITC 160

No 140 120 100 80 60 40 20

05 20

04 20

03 20

02 20

01 20

00 20

99 19

98 19

97 19

96 19

95 19

94 19

93 19

92 19

91 19

19

90

0



The INSTITUTO DE TECNOLOGIA CERAMICA


DISEÑO Y ARQUITECTURA