In this article, we explain what technical ceramics are and why they are chosen as wear-resistant solutions for material handling and processing plants. We will cover their properties, advantages (durability, maintenance, operational continuity), and main application configurations (tiles, mosaic, ceramic-rubber, filled resins). We will conclude with SARO's approach to custom design and an FAQ section to guide you in your choice.
Technical ceramics are engineered materials with high hardness used as wear protection in the most stressed parts of industrial equipment. We are talking about oxide-, carbide-, and nitride-based ceramics (e.g., alumina, zirconia, silicon carbide, silicon nitride) used as internal linings for pipes, bends, valves, hoppers, mills, and critical components to increase their service life and stabilize performance over time.
For SARO, technical ceramics are a key technology in wear protection: tile or mosaic coatings, pre-coated components (bends and pipes), hybrid ceramic-rubber solutions, and filled resin systems (resin-ceramics) for repair and protection. The objective is to address the truly critical points: changes in direction, impact points, accumulation zones, with a solution sized for material, speed, impact, and temperature.
Technical ceramics are among the most effective materials against wear due to their high hardness: for technical alumina, values typically reach close to 9 on the Mohs scale (with Vickers hardness values that, depending on quality and formulation, can be in the range of ~1200–1800 HV). This translates to excellent abrasion resistance compared to many unprotected steels.
This hardness, combined with very low porosity, makes it possible to achieve smooth and compact surfaces, characterized by low surface roughness and excellent sliding properties, which reduce adhesion.
Performance depends significantly on the quality of the raw material, granulometric control, and the sintering process: these factors determine compactness, porosity, and microstructure stability. Thermal shock resistance varies depending on the chosen ceramic and the operating cycle (temperature, gradients, fixing, support).
Their chemical inertia makes them ideal for processes involving sludge, corrosive dust, or particularly harsh atmospheres, while their dimensional stability allows for maintain geometries and tolerances even after thousands of hours of continuous use. It is important to consider that technical ceramics exhibit high hardness but brittle behavior, which is why they are often integrated with elastomeric supports capable of absorbing shocks and dynamic stresses.
In bulk material handling, pneumatic conveying, and processing plants (minerals, clinker, cement, wood, RDF, glass, paper), wear is one of the main causes of plant downtime and maintenance costs. The combined action of erosion (progressive removal of material caused by the impact of solid particles transported by a fluid or gaseous flow), abrasion (continuous rubbing of hard particles) and impact (localized shocks, e.g., in direction changes) rapidly damage pipes, bends, augers, valves, hoppers, and mills.
In this context, technical ceramics offer concrete advantages:
In operation, when the lining is correctly designed (material, thickness, geometry, and fastening), the component replacement frequency can be significantly reduced, with direct effects on maintenance costs and downtime.
Technical ceramics, thanks to their hardness and abrasion resistance, significantly extend the service life of surfaces exposed to wear. In applications such as the transport of cement, minerals, ash, or recycled materials, a well-designed ceramic coating can lead to the lifespan of pipes, elbows, or handling components reaching values much higher than those of unprotected steel components.
In practice, a well-dimensioned ceramic coating maintains the component's profile and functionality for longer, preventing rapid thinning and material loss. For this reason, SARO integrates technical ceramics and filled resin systems into its solutions, choosing the technology based on abrasion, erosion, and impact presence.
By concentrating protection in areas actually subject to wear, technical ceramics allow for longer intervals between interventions. This translates into a reduction in downtime for replacements and repairs, but also in more predictable and less “emergency” maintenance.
Hybrid solutions proposed by SARO, such as ceramic-filled epoxy pastes — including RESINALCERAMICS® T250 A&B e SARPOL RP08 — they are mainly chosen when the component presents complex or difficult-to-coat geometries with traditional solutions and when downtime must be minimized.
These resin-ceramic formulations allow for rapid and localized repairs in high-wear areas, extending the component's service life just enough to reach the scheduled shutdown, without needing to replace the entire part.
Typical applications include chutes, ducts, pump casings, and hoppers, where they help reduce abrasion and impact, and keep equipment running until scheduled maintenance.
Reducing wear-related failures increases plant availability and reliability, two key elements for overall productivity and efficiency. The use of technical ceramics at the most critical points in the process drastically reduces the probability of breakage, perforation, or malfunctions due to surface degradation, with a direct impact on operational continuity.
Role studies Technical ceramics in plant efficiency also highlight how smooth and durable surfaces improve material flow, helping to reduce local turbulence and increases in head loss due to surface roughness and progressive wear of internal walls.
Comparison of standard components and SARO technical ceramic solutions
| Appearance | Without technical ceramics | With SARO technical ceramics |
| Duration components | Shortened service life, frequent replacements | Much longer useful life in high wear areas |
| Maintenance frequency | Recurring extraordinary maintenance, unplanned shutdowns | More programmable maintenance, fewer urgent interventions |
| Business continuity | Increased risk of breakdowns and unplanned stops | Increased plant availability and production stability |
| High-temperature behavior | Possible deformation and degradation over time | Stability even at high process temperatures (within the limits of support and fastening systems) |
| Chemical resistance | Low resistance to corrosion | High chemical inertness, ideal with sludge and corrosive powders |
For a ceramic coating to work effectively, the material is as important as the method: field survey, reading wear points, choosing the format (tile/mosaic/hybrid), surface preparation, and correct installation. SARO supports clients with technical assistance from the initial diagnosis through installation and performance monitoring.
SARO specializes in wear protection for industrial plants, machinery, and components, with a tailored approach that integrates technical ceramics, polymer resins, and pre-faced plates. The portfolio includes ceramic coatings (tiles and mosaic), ceramic-rubber solutions for impact resistance, pre-coated components for pneumatic conveying, and filled resin systems for localized repairs.
Active since 1994, SARO has developed specific expertise in wear protection for the processing and transport of abrasive materials. Since 2000, the company has been among the first in Italy to offer ceramic-rubber hybrid solutions to combine abrasion resistance and shock absorption. This path has consolidated pioneering know-how in the design of wear-resistant linings and components, now applied on a case-by-case basis according to actual operating conditions.
The method of work can be synthesized in four steps:
An example of a hybrid solution is represented by HEXAGON & TETRAGON HOSE Wear HosesCeramic inserts with hexagonal or square geometry are integrated into the rubber to combine installation flexibility and abrasion resistance, particularly in the pneumatic conveying of abrasive materials.
Transportation lines and material processing sections These are among the areas where the use of technical ceramics yields the most significant results in terms of wear reduction. Pipelines, bends, mills, separators, valves, and hoppers operating in highly abrasive conditions require targeted protection.
Thanks to this experience and a portfolio of technologies combining technical ceramics, polymer resins, and pre-applied metal sheets, it is possible to protect equipment throughout the entire process, from initial handling to the final treatment stages, reducing wear and improving the overall reliability of the lines.
Technical ceramics are used where wear is a process variable: cement plants, mining, steel mills, waste-to-energy/power generation, glass, paper mills, recovery and recycling, as well as many applications involving powders and bulk materials with high abrasive power.
Yes. Interventions are carried out on existing systems with on-site linings or by providing pre-lined components (e.g., elbows and pipes) ready for replacement. The choice depends on accessibility, downtime, availability, and the criticality of wear points.
The choice depends on the material being handled, speed, impacts, temperature, chemical conditions, and geometry. Based on these parameters, the following are defined: type of ceramic, thickness, format (tiles/mosaic), optional elastomeric support (ceramic-rubber), and fastening system.
Yes. In many cases, the best solution is a hybrid: ceramic-rubber where shock absorption is needed, filled resins (resin-ceramics) for restorations or difficult areas, and pre-cladded sheets when the impact load is medium and abrasion is dominant. SARO often works with these combinations, choosing the technology and construction details based on the location in the plant.
If you have premature wear on curves, chutes, slides, valves, or pneumatic conveying lines, the most effective approach is to start with a diagnosis of the critical points and the actual operating conditions (material, flow rate, speed, impacts, temperature). SARO can support you in selecting the most suitable protection among technical ceramics, hybrid systems, and filled resins.
For a technical comparisonPrepare some photos of the wear points and, if available, flow/speed data and maintenance history. This helps to quickly identify the solution that is “closest” to your system, without oversizing.
