Porcelanosa expands its large-format tile production plant

The addition of a new production line and kiln at Plant 4 will double the production capacity for XTONE and XLIGHT to 2,400,000 sqm/year.

Three years after commissioning Plant 4, a facility dedicated entirely to the production of large-format ceramic and porcelain tiles, Porcelanosa has completed a major expansion. This project, which has involved a significant investment for the company, bolsters the industrial vision that began in 2023 with the launch of one of the most highly automated and technologically advanced production complexes in the world.

Doubled capacity and enhanced production flexibility

The expansion of Plant 4 in Villareal involved the installation of a new, complete production line featuring the same advanced technology as the systems installed three years ago. The plant consists of a forming line with a Sacmi PCR 2180 compactor (part of the Continua+ family), a glazing line, an E7P 200 multi-deck dryer, and a second latest-generation Maestro FMA217 kiln.

The expansion effectively doubles the plant’s annual production capacity, increasing it from 1,300,000 sqm to 2,400,000 sqm.

The installation of this third line has increased the total surface area of Plant 4 to over 48,000 sqm. The original 36,000 sqm footprint has been extended by a further 12,000 sqm repurposed from the adjacent warehouse (Logistics Centre 2). Following the renovation, the logistics centre now occupies a space of 8,000 sqm.

In addition to increased volumes, the expansion also ensures greater manufacturing versatility. The combination of three forming and glazing lines with two kilns allows production to be rapidly adapted to any type of project, effectively responding to market trends and specific customer demands. The modular system is capable of handling various formats and thicknesses while maintaining high quality standards and rapid delivery times.

Process automation and optimisation

A key upgrade is the expansion of the raw materials reception and management system. Sixteen new silos have been added to the 24 installed in 2023, bringing the total to 40 silos. This increase means greater process optimisation and further increases the already high level of automation of the industrial complex.

Porcelanosa has also doubled the number of polishing and squaring machines and expanded the sorting line, increasing processing capacity and ensuring that each piece meets the brand’s rigorous quality standards. This upgrade will absorb the increased output without compromising the plant’s operational flow.

Logistics have also improved: by doubling capacity, order response times can be significantly reduced, a strategic advantage in a market increasingly focused on customisation and complex architectural projects.

New products in the XLIGHT and XTONE catalogues

With this investment, Porcelanosa continues to pursue one of its key objectives: the production of large-format porcelain stoneware surfaces for the XTONE and XLIGHT collections aimed specifically at the worlds of interior design and architecture. Since its inauguration in 2023, Plant 4 has served as a strategic asset driving the growth of these products in both the domestic and international markets.

With the third production line now in operation, the range of XLIGHT and XTONE solutions has expanded even further. Notably, the plant can now produce 3 mm-thick surfaces, primarily intended for furniture surfacing, as well as 160x160 cm floor tiles. These new products join the existing range, which includes 6 mm, 12 mm, 20 mm and 30 mm thicknesses and 59.6x120 cm, 120x120 cm, 270x120 cm and 320x160 cm formats.

Utilising cutting-edge machinery and the most advanced 3D design systems, the production process incorporates proprietary Porcelanosa technologies, including Comet, Core, Eclipse, Lumen, Orion and Titan. These solutions achieve hyper-realistic textures by combining selected raw materials with innovative production techniques, an approach that cements the Porcelanosa Group’s position as a leader in ceramic innovation.

Sustainability takes centre stage

The innovations introduced at Plant 4 also confirm the Porcelanosa Group’s environmental commitment, a central plank of its philosophy since its inception. In 2023, the company installed almost 4,500 solar panels covering an area of 12,000 sqm on the factory roof. Generating 2.4 MWp of power, the system fulfils the plant’s own energy requirements. This is complemented by a heat recovery system that channels heat from the kilns to power the dryers, 100% reuse of water via an industrial treatment plant and total recycling of waste back into the manufacturing cycle.

The launch of the new facilities has created jobs for 50 new employees alongside the plant’s existing workforce.