Custom Software for Ceramics Manufacturing

From kiln monitoring to glaze recipe management, Bookuvai builds software that reduces defect rates, optimizes firing schedules, and digitizes ceramic production.

Industry: Ceramics

Pain Points

  • Kiln Firing Consistency: Kiln temperature profiles must follow precise curves over hours or days. Manual monitoring leads to inconsistent results, wasted energy, and product defects.
  • Glaze Recipe Management and Reproducibility: Glaze recipes involve complex material chemistry. Without proper version control and batch tracking, reproducing successful glazes across production runs is unreliable.
  • High Defect Rates and Quality Variability: Ceramic production involves many variables (clay body, moisture, forming, drying, firing, glazing). Identifying root causes of defects requires correlating data across all stages.

Solutions

  • Kiln Monitoring and Control Systems: IoT-connected kiln monitoring with real-time temperature curves, firing profile automation, energy consumption tracking, and anomaly alerting.
    • Real-time temperature curve display
    • Firing profile templates and automation
    • Energy consumption tracking per firing
    • Anomaly detection and alerting
  • Glaze Recipe Management: Digital glaze recipe databases with version control, batch scaling, material substitution calculations, and integration with inventory for raw material tracking.
    • Recipe version control and history
    • Batch scaling and material calculations
    • Unity molecular formula analysis
    • Inventory integration for materials
  • Production Quality Tracking: End-to-end production tracking that correlates forming, drying, glazing, and firing parameters with final product quality to identify defect root causes.
    • Batch tracking through all production stages
    • Defect classification and photography
    • Parameter correlation analysis
    • Quality trend dashboards

Use Cases

  • Kiln Monitoring Dashboard — An IoT-connected dashboard displaying real-time kiln temperature curves, firing profiles, and energy usage with SMS alerts for temperature deviations. (80-140, $160-$280, 5-7 weeks)
  • Glaze Recipe Database — A web app for managing glaze recipes with version control, batch scaling, unity formula calculations, and photo documentation of fired test tiles. (60-100, $120-$200, 4-6 weeks)
  • Production Defect Tracker — A quality management system tracking defect rates by production stage, correlating defects with process parameters to identify root causes and reduce waste. (100-160, $200-$320, 6-8 weeks)

Frequently Asked Questions

Can you integrate with our existing kiln controllers?
Yes. We integrate with common kiln controllers via Modbus, OPC-UA, or serial connections to read temperature data and firing profiles without replacing your existing equipment.
Do you support Seger cone or orton cone calculations?
Our glaze management systems include unity molecular formula (UMF) calculations, Seger formula analysis, and thermal expansion coefficient estimation for glaze fit analysis.
Can you build for both industrial and artisan ceramics?
Yes. Our solutions scale from single-studio potters managing glaze recipes to industrial ceramic tile manufacturers tracking production across multiple lines and kilns.
How do you handle the variety of ceramic products?
We build configurable product catalogs that support different ceramic types (tile, tableware, sanitaryware, technical ceramics) with product-specific quality parameters and specifications.