IBV and ITC develop innovative solutions to drive the ceramic sector’s transition towards Industry 5.0
The ceramic sector, which is of particular importance to the economy of the Valencian Community, is facing a pivotal moment. This energy-intensive sector is confronted with the challenge of moving towards more sustainable and resilient production, while also adapting to the principles of Industry 5.0, in which the well-being of workers is a priority. Exposure to contaminants in the production environment and the risk of musculoskeletal disorders arising from factors such as the high physical demands of tasks and rigid work organisation are among the issues currently faced by companies in the sector.
In response to these needs, Instituto de Biomecánica (IBV) and the Ceramic Technology Institute (ITC) have joined forces through the I5CER project, whose aim is to develop innovative techniques and technologies that will drive the ceramic sector’s transition towards Industry 5.0, improving workers’ health and well-being while increasing company productivity.
People’s well-being at the heart of the factory of the future
The two main areas on which I5CER’s research has focused are the reduction of ergonomic risks and the monitoring and control of indoor air quality (IAQ) in the production environment.
As a benchmark in the ergonomic improvement of working environments, IBV has identified the main needs in the field of ergonomic risk prevention, incorporating the approach and principles of Industry 5.0. In response to the needs identified, solutions have been developed to monitor and ergonomically analyse workstations based on artificial intelligence and inertial sensors, together with an organisational methodology to optimise task rotation and workload distribution, thereby helping to reduce workers’ physical strain.
For its part, the Ceramic Technology Institute has led the project strand focused on monitoring and controlling indoor air quality (IAQ) in the production environment. The technical team has implemented an advanced infrastructure based on a network of low-cost sensors, specifically selected to record in real time the presence of particulate matter, as well as temperature conditions, CO2 levels and air humidity across the different working areas.
This technology is integrated with spatial positioning devices that make it possible to geolocate workers within the factory. The analysis and combination of all the data collected make it possible to determine each individual’s exposure levels, generating dynamic risk maps of the plant. In this way, the system not only detects environmental anomalies, but also enables the management of early warnings and personalised recommendations, ensuring a healthier working environment aligned with the principles of Industry 5.0.
Collaboration with leading companies
I5CER has benefited from the collaboration of leading companies in the ceramic sector and occupational risk prevention services, making it possible to validate the solutions developed in real-world environments and ensuring the direct transfer of the research results to the sector.
These include Tejas Borja, with a history spanning more than 100 years, specialising in high-quality ceramic roof tiles and systems for pitched roofs; Marazzi, an international leader in the production of ceramic tiles; Euroarce-Grupo SAMCA, a European benchmark in ceramic raw materials; Unimat Prevención, specialising in occupational risk prevention services; Logística General de la Plana, specialising in the storage, handling, administration, management and distribution of goods; and Cerámica Nulense, dedicated to the manufacture of ceramic products for flooring and wall coverings.
Towards a more sustainable and people-centred sector
The solutions developed within I5CER will make it possible to reduce occupational risks, increase productivity and ensure healthier working environments, supporting progress towards a ceramic sector that is more competitive, sustainable and people-centred.
Finally, the I5CER project is supported by the Conselleria of Industry, Tourism, Innovation and Trade of the Generalitat Valenciana, through IVACE+i, with funding from the European Union through the ERDF Programme Comunitat Valenciana 2021-2027 (IMDEEA/2025/64 and IMDEEA/2025/38).
