Porcelanosa has strengthened its position as a global leader in ceramic innovation with the expansion of its fourth production plant, doubling its large-format porcelain output to 2.4 million m² per year.
© Porcelanosa
Kiln area of Porcelanosa's fourth production plant.
Located at the group's headquarters in Vila-real and inaugurated in 2023, Plant 4 is dedicated exclusively to the manufacture of large-format porcelain tiles for the XTONE and XLIGHT collections. The latest expansion adds a new complete production line, including a press, glazing line and a state-of-the-art kiln, matching the advanced technology introduced during the plant's original launch.
Doubling capacity with greater flexibility
With the addition of this new line, Plant 4 now operates three press and glazing lines and two kilns, increasing annual output from 1.3 million m² to 2.4 million m². The modular production system enables Porcelanosa to adapt quickly to market demand while supporting a wide variety of formats, thicknesses and project requirements, without compromising on quality or delivery times.
The expansion also significantly improves operational versatility, allowing production to be adjusted in real time to meet evolving architectural and interior design trends.
© Porcelanosa
The three production lines at Porcelanosa's fourth plant.
Increased automation and logistics efficiency
Automation has been further enhanced with the expansion of the raw materials management system. An additional 16 silos have been installed, bringing the total to 40, optimising material flow and reinforcing the plant's high level of industrial automation.
Polishing and grinding machinery has been doubled, alongside the reclassification system, ensuring increased processing capacity while maintaining Porcelanosa's strict quality standards.
The expansion extends into Logistics Centre 2, housed in an adjacent warehouse. The reconfigured logistics area now totals 8,000 m², complementing the 36,000 m² already in operation and bringing the entire complex to more than 48,000 m² dedicated to large-format ceramic and porcelain production.
New formats and technical possibilities
The new kiln unlocks additional technical capabilities, including the introduction of two new formats:
- 3 mm thickness, ideal for furniture and bespoke applications
- 160 × 160 cm floor tiles
- These join Porcelanosa's existing large-format offering, which includes thicknesses of 6, 12, 20 and 30 mm, and formats up to 320 × 160 cm.
This expansion reinforces Porcelanosa's specialisation in large-format porcelain while broadening design solutions for architecture and interior projects across residential, commercial and contract sectors.
© Porcelanosa
Receipt of raw materials at Porcelanosa's Plant 4, which has a total of 40 silos.
Faster lead times for high-specification projects
With production capacity doubled, delivery times have been significantly reduced, a key advantage for complex, highly customised projects where speed and precision are critical.
Advanced in-house technologies
Plant 4 continues to operate using Porcelanosa's proprietary surface technologies — Comet, Core, Eclipse, Lumen, Orion and Titan, enabling hyper-realistic textures and finishes through advanced 3D design systems and carefully selected raw materials. These innovations place PORCELANOSA Group at the forefront of ceramic manufacturing technology.
Sustainability at the core
Sustainability remains integral to the plant's operation. The facility is powered in part by 4,500 solar panels covering 12,000 m², generating 2.4 MWp for energy self-consumption.
Additional sustainability measures include:
- Heat recovery from kilns for drying processes
- 100% water reuse via an on-site treatment system
- Full recycling of production waste back into manufacturing
- To support the expansion, 50 new employees have joined the workforce at Plant 4.
More information:
Porcelanosa
[email protected]
www.porcelanosa.com
