Kilns get hot! When it comes to kiln safety, using a safety limit controller helps ensure that a kiln automatically shuts off if it exceeds a pre-defined temperature.
Safety Limit Controllers and Safety Redundancy
While advanced process controllers like TAP and TAP II have max temperature safety shutoff, you’re still entrusting the safety of yourself, your household, and your property to a single layer of safety measures.
Watch SDS Industries’ President Scott Shannon explain the pros and cons of different types of relays.
Adding a safety limit controller (like TAP Monitor) to your kiln or oven build, adds a layer of safety redundancy. Wiring a safety limit controller to a redundant safety relay ensures that your kiln safely shuts off even if your primary controller or relay fails.
With the TAP Kiln Control Mobile App, you can monitor kiln temperature, receive push notifications alerts and alarms, and view real-time firing graphs – even if you have to step away from your project.
This is not only extremely convenient, but it adds an additional layer of kiln safety, keeping you immediately informed of any discrepancies in your firing schedule.
Do I Need a Safety Limit Controller?
Safety limit controllers are much more common in industrial kiln and industrial control system (ICS) applications. Most at home and studio kiln and oven builds don’t include a safety limit controller. And this is usually fine most of the time (especially if you use solid state relays and your primary kiln controller includes max temp safety shutoff).
However, like most safety devices, when you need a safety limit controller, you really need one. A small investment in a safety limit controller potentially protects your property, your health, and will save you massive amounts of money in a worst-case scenario.
If you’re still using a manual kiln or an outdated automatic kiln controller (which includes most kiln controllers currently on the market), we strongly encourage you to invest in a safety limit controller that adds max temperature safety shutoff, precise pyrometric monitoring, and remote kiln monitoring.
Adding TAP Monitor Safety Limit Controller & Pyrometer to Your Kiln or Oven Build
SDS Industries, known for creating the most advanced, easy-to-use automatic kiln controllers, is releasing a safety limit controller and digital pyrometer. TAP Monitor, which is releasing in several months, is already available for pre-order.
TAP Monitor is available as a set of DIY components that can be wired directly to a safety relay (starting at $97.50) to act as a combination safety limit controller and digital pyrometer, or as a plug-and-play standalone remote pyrometer that includes a type K thermocouple and a 2.4” capacitive touchscreen (available for $265).
Both configurations improve kiln safety, but they’re also an affordable way to modernize kiln builds that don’t include precise, remote temperature monitoring. TAP Monitor provides a host of benefits (regardless of the type of kiln control method you currently use):
Protect yourself and your family by wiring TAP Monitor to a safety relay to provide redundant safety shutoff.
Have peace of mind by knowing the exact temperature of your kiln, oven, or forge every step of the way (via TAP Kiln Control Mobile).
Save time and effort by knowing the state of your kiln no matter where you are.
Ensure more consistent outcomes and enjoy added convenience by upgrading your existing automatically or manually controlled kiln to include precise, real-time digital temperature readings.
In addition to the TAP Monitor Safety Limit Controller, the TAP Ecosystem includes a variety of programmable kiln controllers that give artists complete control of their kilns. The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, pyrometers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Limit controllers, on the other hand, are currently more commonly used with ICS control systems, industrial kilns, and manual kilns. Also known as high limit or safety limit controllers, limit controllers monitor kiln temperature and ensure that the kiln automatically shuts off if the kiln exceeds a specified temperature.
Process controllers execute process; limit controllers enforce limits. Process controllers are a primary kiln control method. Limit controllers, while not usually suitable to be the primary control method, are an important part of kiln safety and can protect you, your equipment, and your property in the case of relay or system failure.
The TAP II Kiln Controller is an example of a process controller that allows kiln operators to automatically execute full firing schedules.
If I Already Have a Process Controller Why Would I Need a Limit Controller?
If you’re reading this article and you already have a process controller, you might be asking: Why would I need a limit controller?
The answer? Safety.
Even though advanced kiln controllers, such as TAP and TAP II, provide max temperature safety shutoff in case of relay failure, redundancy is the key to safety. Safety limit controllers such as TAP Monitor add an additional layer of safety. When installed and wired to a redundant safety relay, TAP Monitor will automatically shut off your kiln if it exceeds a specified temperature – even if your primary relay fails.
Benefits of TAP Monitor Limit Controller
TAP Monitor is an advanced, user-friendly kiln limit controller and pyrometric device that can be paired with any manual or automatic kiln controller to provide safety shutoff and remote temperature monitoring.
Wire TAP Monitor to a safety relay to provide redundant safety shutoff.
Precisely monitor the temperature of their kiln, oven, or forge via the TAP Kiln Control Mobile App.
View digital pyrometric readouts from any manually controlled kiln, including remote readouts via TAP Kiln Control Mobile when TAP Monitor is connected to a local network.
Easily add precise, real-time digital temperature readings to their manual kiln or oven.
Pair TAP Monitor with their existing automatically or manually controlled kiln for remote monitoring.
In addition to the TAP Monitor Limit Controller, the TAP Ecosystem includes a variety of programmable kiln controllers that give artists complete control of their kilns. The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, pyrometers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
A kiln temperature monitor is a device that monitors kiln firing temperatures. Typically, when people refer to a kiln temperature monitor, they’re referring to a device specifically dedicated to temperature measurement, such as a pyrometer or a limit controller.
In the next section we’ll explain the difference between limit controllers, pyrometers, and process controllers – because all three devices technically monitor kiln temperature. Then, we’ll explain the benefits and use cases of a dedicated kiln temperature monitor.
Understanding the Difference Between Pyrometers, Limit Controllers, and Process Controllers
However, digital kiln controllers are process controllers, meaning their primary role isn’t to monitor temperature but rather to adjust kiln firing temperatures according to the programmed firing schedule.
Pyrometers, on the other hand, are devices whose sole function is to monitor kiln temperature. And limit controllers, or high limit controllers or safety limiters, are pyrometers with additional control functions that allow users to pre-program their electric kiln to automatically shut off if the kiln exceeds a specified temperature.
What’s The Point of a Dedicated Kiln Temperature Monitor?
Okay, but if your primary process controller already lets you monitor kiln temperature, then what’s the point of a dedicated kiln temperature monitor? The answer: kiln safety.
More advanced kiln controllers, such as TAP, provide max temperature safety shutoff in case of relay failure. But even then you’re still relying on a single controller, a single relay, and a single thermocouple to ensure the safety of your kiln, yourself, and your property.
When it comes to safety, especially at high kiln firing temperatures, redundancy is key. A dedicated kiln temperature monitor adds an additional level of safety by acting as a safety redundancy device. When installed and wired to a redundant safety relay, TAP Monitor will automatically shut off your kiln if it exceeds a specified temperature – even if your primary relay fails.
TAP Monitor integrates with your kiln to provide remote kiln temperature monitoring to your smartphone –when installed with a redundant relay, TAP Monitor also provides additional kiln safety.
Introducing TAP Monitor Digital Pyrometer Limit Controller
While previous kiln temperature monitors only added kiln safety shutoff or a temperature readout, TAP Monitor by SDS Industries adds a whole lot more than that!
TAP Monitor is an advanced, user-friendly kiln temperature monitor that gives kiln operators the ability to precisely monitor kiln firing temperatures – remotely! – regardless of their existing kiln control method.
Precisely monitor the temperature of their kiln, oven, or forge via the TAP Kiln Control Mobile App.
View digital pyrometric readouts from any manually controlled kiln, including remote readouts via TAP Kiln Control Mobile when TAP Monitor is connected to a local network.
Easily add precise, real-time digital temperature readings to their manual kiln or oven.
Pair TAP Monitor with their existing automatically controlled kiln for remote monitoring.
For added safety, use TAP Monitor as a standalone or safety relay controller.
In addition to the TAP Monitor Digital Pyrometer, the TAP Ecosystem includes a variety of programmable kiln controllers that give artists complete control of their kilns – without complicated controls or clumsy user interfaces. The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven. We invite you to explore our selection of programmable kiln controllers, pyrometers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Did you know that you can easily program your TAP Controller to track your electric kiln firing cost? And with the latest update to the TAP Kiln Control Mobile App, we’ve made the kiln firing cost calculator function free for all users!
Why is this important?
There are several benefits to being able to accurately track your electric kiln firing cost. If you sell (or plan on selling) your work, knowing kiln costs for each firing schedule, along with materials and labor costs, allows you to accurately price your work. Additionally, knowing your electric kiln firing cost allows you to accurately track cost growth as utility rates rise.
But even if you don’t sell your work, the kiln firing cost calculator function can help you gain insight into whether your kiln is operating as effectively as it did when it was new, helping you stay ahead of possible kiln maintenance needs. Plus, with how easy it is to program cost settings on your TAP Controller, it’s just cool information to know!
How to Use the Kiln Firing Cost Calculator on Your TAP Controller
Setting up your TAP Controller to track your electric kiln firing cost is super easy. For the original TAP Controller, you can input cost settings right from your controller screen or via the TAP Kiln Control Mobile App. For the TAP II Controller, as well as the other kiln controllers in the TAP Ecosystem, you will set up your kiln firing costs via the TAP Kiln Control Mobile App, so you can skip ahead to the next section for instructions!
Steps for Programming Kiln Cost Settings on the Controller UI
From the Home Screen, go to Menu > Settings > Cost.
Enter your kiln’s power rating in watts in the field for ‘Kiln Power.’ If you’re unsure of your kiln’s power rating, you can usually find it on the kiln’s data plate or in your kiln’s user manual. If your kiln’s power rating is in kilowatts, just multiply that number by 1000 to convert the power rating into watts.So, for instance, if your kiln was rated for 2.16 kW, you’d multiply that by 1000, and enter 2160 in the field for ‘Kiln Power.’
Enter your utility provider’s cost per kilowatt hour in the ‘Cost per kWh’ field. You can find this information on your latest electric bill or on the website for your electric utility provider. In the example below, we’ve highlighted the Cost Per kWh (so, for this example, you would enter $0.041 under ‘Cost per kWh):Once you’ve input this information, your TAP Controller will automatically calculate your electric kiln firing cost – so you can ditch the pencil, notebooks, timers, and calculators!
How to Setup Electric Kiln Firing Cost Tracking on the TAP Kiln Control Mobile App
You can also program cost settings for the TAP or TAP II Controller (as well as our upcoming kiln temp controller options) on the TAP Kiln Control Mobile App – and track your electric kiln firing costs on the go!
In the TAP Kiln Control Mobile App, select your kiln from the Summary Screen.
Press Settin gs on the bottom center of your screen.
Scroll down to Cost. Here you will find the field to inp
ut ‘Cost per kWh’ and ‘Kiln Power’ (refer to Steps 2 & 3 from the previous section):
You can download the latest version of the TAP Kiln Control Mobile App, which makes this feature free for all TAP users on the App Store (for iOS) or the Google Play Store (for Android).
As you know, electric kiln firing costs aren’t the only cost of owning (and maintaining a kiln). For additional information about the cost of kiln ownership – from purchase and installation to maintenance costs – check out our definitive guide on kiln costs!
Explore Programmable Digital Kiln Controllers by SDS Industries
When it comes to providing features that make life easier for artists, electric kiln firing cost tracking is just scratching the surface!
The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
For most artists, purchasing a kiln is a pretty big investment. Newer artists, especially, will probably have a lot of questions about what they’re getting into! How much do kilns cost? What about installation and kiln maintenance? Are kilns safe? What type of kiln is right for me? What kind of controller should I use for my kiln?
Don’t worry, we’ve got you covered! You can find our guides on kiln maintenance, kiln safety, types of kilns, and kiln control methods below. And by the end of this article, you’ll have a complete understanding of kiln costs!
Note: For the sake of this article, we’ll be primarily focusing on kiln costs for electric kilns, which are the most common kilns for the hobby kiln and studio kiln market. Gas kilns are typically more expensive, ranging from $3,000 on the extreme low-end to $30,000+ for a high-capacity gas kiln and have their own unique operating and installation costs.
Understanding Kiln Costs
When people think about kiln costs, a lot of the time they only think about the upfront cost of purchasing their kilns. While we’ll be covering purchase costs in depth, there are additional costs to consider. These include installation costs, kiln maintenance costs, material costs, as well as firing costs.
For the hobbyist, understanding these costs will help avoid unforeseen expenses. It will also help determine the most suitable type of kiln and possibly save some money! But for the professional artist, accurately tracking kilns costs can help make sure they’re pricing their wares correctly.
The Cost of Buying a Kiln
For most artists, purchasing a kiln is by far the most expensive part of kiln ownership. Kiln costs vary tremendously, ranging from around $700 for compact kilns to $20,000+ for large, higher powered, industrial grade kilns. There is also a robust used kiln market on Craigslist, eBay, Facebook Marketplace, and other online markets, where pre-owned kilns range from $275 to $3,000+ dollars.
Factors that influence kiln costs include:
Size: Generally speaking, the bigger the kiln, the more expensive – both at the time of purchase and in terms of potential installation, maintenance, and power costs.
Power Rating: Larger kilns and hotter kilns typically require more power and are generally more expensive.
Maximum Temperature: Generally, kilns with a higher maximum temperature are more expensive than comparable kilns with lower maximum temperatures.
Materials Fired: Glass kilns, ceramic kilns, knife kilns, and metal clay kilns (for jewelry) have different price ranges (which we’ll be covering more in-depth below).
Temperature Controller Method: The type of kiln controller that comes included with your kiln will impact its price by up to several hundred dollars – but your controller will have a major impact on your kiln firing experience and the functionality of your kiln.
Shipping Costs: As a larger item, shipping costs for kilns can add a substantial amount to your purchase price. When comparing prices between kiln suppliers, check to see whether shipping costs are included with the purchase of your kiln.
Whew, that may seem like a lot of factors to keep in mind! Don’t worry, we’ll be covering each of these considerations more in-depth. To help narrow your focus when purchasing a new kiln, it’s important to ask yourself the following questions:
How will I be using my kiln? What types of kiln firing schedules will I need to be able to execute?
Based on the media and techniques I use, what kiln firing temperatures and element placement will I need for my projects?
How big does my kiln need to be? How much space do I have to install the kiln at my home or studio?
The more specifically you can answer those types of questions, the easier it will be to determine which features you need to shop for and the kiln costs you should budget for.
Kiln Size Price Ranges
When it comes to buying a kiln, how big does your kiln need to be? Well, that depends…how big are the projects you’ll be firing? If you only need your kiln for slumping glass or firing jewelry or other small objects, chances are you’ll be able to save a lot of money on upfront costs and installation by purchasing a compact kiln.
However, if you’re firing large ceramic pieces – or firing multiple projects at a time – you’ll probably need to spring for a larger kiln.
Below are the average and median prices for kilns based on size (kiln prices throughout this article are based on aggregate price data from Kiln Frog).*
Compact Kilns: Under 15”
Price Range: $924.00 – $3318.54
Average Price: $1594.83
Median Price: $1474.16
Medium Kilns: 13” – 18”
Price Range: $916.00 – $4623.86
Average Price: $2028.56
Median Price: $1921.81
Large Kilns: 17” – 24”
Price Range: $1558.00 – $6889.54
Average Price: $3240.21
Median Price: $3139.00
X-Large Kilns: Over 24”
Price Range: $2416.00 – $25328.55
Average Price: $6669.63
Median Price: $4582.80
As you can see, the size of the kiln makes a big difference in price!
*Price data in this article includes current promotions – prices may vary.
Kiln Costs Based on Power Rating
Another factor that can influence kiln costs – for purchase, installation, and your electric bill – is the power rating of your kiln. When it comes to power rating, there are three ratings you need to understand: voltage, amperage, and wattage.
Voltage is the electric potential of a circuit. Comparing electricity to plumbing, voltage could be considered the pressure in a pipe. In the U.S., kilns typically come in two different voltage configurations: 120V and 240V, which correspond with the electric grid. 120V kilns are typically less expensive and match the voltage of a standard residential wall outlet; however, kilns exceeding 15 amps will need to be installed on a dedicated circuit.
A 240V kiln, on the other hand, needs a special wall outlet (other large appliances, such as wall ovens, AC units, and dryers use 240V outlets). Chances are, you will need the help of an electrician to run a new outlet in order to install your kiln. According to HomeGuide, this will cost anywhere from $250 – $800.
Amperage is the units of electrical current in a circuit. Extending the plumbing analogy, current is similar to the capacity of a pipe: the wider the pipe, the more water that flows. Kilns range from 13 amps to 80 amps. 120V kilns typically only go up to 30 amps, while 240V kilns can range anywhere from 30 amps to 80. At 48 amps or higher, a kiln will have to be wired directly into your power supply – another additional expense!
Watts measure the rate of power flow, calculated by multiplying voltage by amperage. Smaller 120V kilns typically draw between 1500 and 1800 watts, while a large 240V kiln can draw up to 11000 watts. TAP Kiln Controllers by SDS Industries allow you to enter your kiln’s watt rating, as well as the cost per kilowatt hour from your electric bill to automatically calculate your cost per firing.
The TAP Kiln Controller by SDS Industries allows artists to easily track their cost per fire on their electric kiln.
Kiln Costs by Maximum Temperature
Different kilns are capable of reaching different maximum temperatures. Generally, the hotter the kiln, the higher the kiln costs! If you need to fire Cone 14 porcelain, expect to spend more money than if you only need to fire Cone 06 ceramics. Reviewing these firing schedules for glass, ceramic, and metal heat treat can help you figure out which temperatures you’ll need your kiln to be able to reach based on the media and techniques you use.
Kiln Costs by Materials Fired
Speaking of media, when shopping for a new kiln, you’ll find that there are different kilns designed specifically for glass, ceramics, metal heat treat (for objects such as blades and knives), and metal clay (for jewelry and small metal trinkets). How do the materials you fire impact kiln costs?
Kilns have different dimensions and maximum temperatures based on the materials they’re designed to fire. Generally, metal clay kilns will be smaller than glass kilns, which will be smaller than knife kilns. Ceramic kilns tend to be larger and cylindrical, since you can stack pottery during fire. You can expect the price of the kiln to scale accordingly.
Additionally, ceramic kilns and heat treat kilns will typically need to be capable of reaching higher temperatures than metal clay kilns or glass kilns.
Broadly speaking, metal clay kilns will be the least expensive, and ceramic kilns will be the most expensive. Glass kilns and metal heat treat ovens often fall somewhere in between.
Temperature Controller Costs
Finally, an extremely important consideration when buying a kiln is deciding which brand and model of kiln controller to purchase with your kiln. After all, the kiln controller will be your primary interface with your kiln and will largely determine your user experience. Your kiln control method will determine the accuracy of your kiln firing, as well as what you can program the kiln to do.
Upgrading to a fully featured touchscreen programmable digital kiln controller will add a few hundred dollars to your kiln costs compared to a rudimentary 3-key model. Is it worth it?
In our opinion, yes. Definitively. An advanced, easy-to-use kiln controller like the TAP Kiln Controller gives you the ability to:
Name, save, and edit unlimited firing schedules with an unlimited number of steps per schedule.
Easily find and select the right schedule with alpha-numeric, full text displays.
Integrate your controller with the TAP Kiln Control Mobile App so that you can remotely monitor your kiln and create, modify, and execute firing schedules from your mobile device.
Enjoy peace-of-mind with push notification alerts and alarms to keep you informed of your firing status, notify you when it’s time for preventative maintenance, or let you know when unexpected conditions occur.
Additionally, SDS Industries is working on a lineup of more cost-accessible controller options that contain many of the advanced functions of TAP at a lower price point, with all kiln controller inputs performed via your smartphone.
In addition to kiln costs at point of purchase and installation, there are also longer-term costs to keep in mind.
We mentioned installation costs earlier. You should plan on budgeting up to $800 if you will need the help of an electrician in installing your kiln. Additionally, if you’re purchasing a ceramic kiln, you may need to buy and install a ventilation system which can run another $200 to upwards of $800.
For kiln maintenance, you will have to replace thermocouples, elements, and mechanical relays at regular intervals. Depending on how frequently you use your kiln and the temperatures you fire to, you should plan on budgeting at least $100 to $200 dollars every year or two to replace these components.
And, finally, you will have to budget for materials. Material costs can vary greatly per artist, but you should plan accordingly!
Conclusion
There you have it! Hopefully, this article has given you a full understanding of the true cost of owning a kiln. However, you should look at kiln costs as a long-term investment. If you take care of your kiln, it could last you for decades and give you countless hours of enjoyment and self-expression – so it’s hard to put a price tag on that! But it’s also important to know what you’re getting into and budget accordingly.
Explore Programmable Digital Kiln Controllers by SDS Industries
If you’re buying a new kiln, you’ll want to make sure it’s coming with the right controller. Ask your kiln supplier about TAP! The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Maybe you’re shopping for a new kiln or maybe you’re exploring options for upgrading your current kiln controller. Either way, you’ll find that there are multiple temperature controller manufacturers that make controllers for kilns, furnaces and heat treat ovens.
A few of the temperature control unit manufacturers you’re likely to come across include Orton, Bartlett, Skutt,* and of course TAP by SDS Industries.
*Skutt-branded controllers are technically private label Bartlett controllers, but their touchscreen controller has a proprietary interface, so we’re including them in this comparison.
Comparison Criteria for Temperature Controller Manufacturers
Choosing the right temperature controller for your kiln is a major consideration! After all, your kiln controller will provide the primary interface through which you use your kiln. So how do you decide which kiln temperature controller manufacturer is right for you?
Different temperature control unit manufacturers have different feature sets and different design philosophies. For the sake of this comparison, we’ll be analyzing temperature controller manufacturers by the following criteria:
Accessibility & Ease-of-Use: How easy is it to get started using the controller and to access all of its features?
Input Method & User Interface: Does the controller use keys (analog buttons) or touchscreen controls to program the kiln? How easy is menu navigation? Is the display easy to read and visually pleasing?
Reliability & Support: Does the temperature control unit manufacturer support its products with warranties and customer support? How reliable are their controllers?
Precision: Do these controllers allow for precise execution of your kiln firing schedules?
Schedule Creation & Management: How easy is it to create, edit, and execute kiln firing schedules? Does the controller limit how many schedules and segments for schedules you can save to your controller?
WiFi & Mobile App Integration: Will you be able to remotely manage your kiln firings from your smartphone or tablet?
Kiln Compatibility: Does the temperature controller manufacturer make controllers that are compatible with your kiln or oven build?
Price & Availability: What is the cost range of their product line? How available are their controllers?
TAP Kiln Controllers
When it comes to temperature controller manufacturers, SDS Industries were the new kids on the block when they launched the TAP Kiln Controller in 2015, which revolutionized the kiln controller industry. At the time other temperature control unit manufacturers were still using analog buttons, tiny displays, and complicated menus. SDS Industries introduced responsive touchscreen controls, attractive graphical UIs, intuitive, easy-to-use menus, and mobile app integration to the temperature control industry.
The TAP Kiln Control Ecosystem includes a variety of controller options, ranging from $147.50-$199 for controllers that are exclusively controlled via the TAP Kiln Control Mobile App to $489-$650 for the most advanced, easy-to-use touchscreen controllers (which also include mobile app integration!). SDS Industries manufactures a wide variety of conversion kits and standalone controllers, allowing for easy replacement of existing temperature controllers as well as compatibility with any relay-controlled kiln or oven.
TAP Comparison Summary
Price: $147.50-$650
Input Methods: touchscreen and TAP Kiln Control Mobile App
Reliability: The mainline TAP Controllers include an industry-best 3-year warranty. SDS Industries is known for their high-quality components, controller reliability, customer service, and supporting their controllers with updates to controller software and their mobile app to add new features and improve functionality.
Ease-of-Use: TAP Kiln Controllers are the most user friendly programmable digital kiln controllers on the market today, with touchscreen controls, easy-to-read displays, and intuitive, logical menus.
Schedule Management: TAP Kiln Controllers allow users to easily create, edit, save, and name an unlimited number of firing schedules with an unlimited number of steps.
Remote Control: With both free and premium options, the TAP Kiln Control Mobile App allows users to obtain basic to full control and monitoring of their kiln from their smart phone or tablet (including remote start and the ability to create and adjust firing schedules on the fly). The TAP Kiln Control Mobile App has significantly higher ratings on the App Store than mobile apps by any other temperature controller manufacturer.
Orton Kiln Controllers
Founded in Westerville, Ohio in 1896, Orton was originally a manufacturer of pyrometric cones. Today, Orton manufactures a variety of kiln products, including the Autofire Temperature Controllers.
Orton Autofire Controllers are available in a variety of configurations. Their prices range from $154 for a 3-key controller, $210 for a 12-key controller, and up to $400 for their touchscreen controller. Orton makes temperature controllers that are compatible with a wide variety of electric kilns, including standalone controllers for upgrading manual kilns.
Orton Comparison Summary
Price: $154-$400
Input Methods: 3-key, 12-key, or touchscreen
Reliability: Orton has a solid reputation. Their controllers are backed by a 2-year warranty.
Ease-of-Use: Their 3-key and 12-key controllers have a steep learning curve for kiln operators, requiring multiple button presses to create a firing schedule. Their touchscreen controller’s menu navigation requires multiple screens to program each step of a firing schedule and isn’t as streamlined as other options.
Schedule Management: Orton’s flagship controller allows users to save a maximum of 35 firing schedules with a maximum of 20 segments per schedule.
Remote Control: Orton has a detachable handheld controller option. They have kiln monitoring software for Windows (that doesn’t include schedule creation, editing, or execution) but no mobile app support and no true option for remote kiln control.
The user interface on the Orton Autofire Slide requires multiple windows for editing each step of a firing schedule, making it less intuitive than other touchscreen temperature controllers.
Bartlett Temperature Controllers
Bartlett Instrument Company, founded in 1946 in Burlington, Iowa is a temperature control unit manufacturer whose controllers are the entry-level option for many kilns on the market.
Their temperature controller lineup includes 3-key, 12-key, and 24-key kiln controllers, as well as a touchscreen option. Their controllers range in price from $248-$398. At this time, Bartlett doesn’t have any options for standalone controllers.
Bartlett Comparison Summary
Price: $248-$398
Input Methods: 3-key, 12-key, 24-key, or touchscreen
Reliability: Bartlett has a solid reputation among temperature controller manufacturers. Their controllers include a 1-year warranty for failure from material or workmanship. Repairs are available from Bartlett for $150.
Ease-of-Use: Bartlett’s 3-key, 12-key, and 24-key controller options require multiple button presses to change settings or edit schedules. Displays for these controllers are small, making menu navigation a challenge for inexperienced kiln operators. Bartlett’s touchscreen controllers are fairly intuitive; however, the display is much smaller than other touchscreens which can diminish the user experience.
Schedule Management: Bartlett’s top-of-the-line temperature controller allows for users to create 30 custom firing schedules of up to 32 steps. The Bartlett V6-CF Controller (their 24-key controller) allows users to create up to 6 firing schedules with 8 steps.
Remote Control: The Bartlett Genesis 2.0 has the KilnAid App which allows users to monitor kiln firings but doesn’t provide options for remote control. You can read reviews of the Android app here and iOS app here. The Bartlett V6-CF Controller, as well as Bartlett’s other key-based controllers don’t have mobile app integration.
The small screen on the Bartlett Genesis Controllers makes them difficult to read and don’t allow for full title displays for kiln firing schedules.
Skutt Temperature Controllers
Founded in Olympia, Washington in 1953, Skutt manufactures kilns. Technically, they aren’t a temperature controller manufacturer; but they do sell proprietary controllers manufactured by Bartlett, which is why they’re included in this comparison.
Skutt offers a 24-key controller, as well as a touchscreen option. Their prices range from $570 to $675 for key-based controllers and touchscreen controllers, respectively. Skutt also provides a 24-key standalone to upgrade manual kilns for $930.
Skutt Comparison Summary
Price: $570-$675
Input Methods: 24-key or touchscreen
Reliability: Skutt has a good reputation in the kiln industry. Their controller is backed by a 2-year warranty.
Ease-of-Use: Skutt’s 24-key controller presents users with the same challenges and inconveniences as key-based controllers by other temperature controller manufacturers. Their touchscreen controller is slightly more intuitive but has small text and a lot of menu layers.
Schedule Management: Skutt’s temperature controllers allow users to create 12 schedules of up to 32 steps.
Remote Control: Skutt supports their controller with the KilnLink App, which allows for remote viewing and diagnostics but doesn’t allow users any remote control or schedule creation features. You can read user reviews of their mobile Android app here and iOS app here.
The Skutt Touchscreen Controller has more complicated menus than other touchscreen kiln controller options.
Paragon Controllers and L&L Temperature Controllers
When shopping for temperature controllers, you may come across Paragon Controllers and L&L Controllers. However, neither of these companies are technically temperature controller manufacturers. Instead, they sell rebranded controllers manufactured by Bartlett and Orton.
Explore Temperature Controllers by SDS Industries
The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use temperature controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Kiln controls are the interface you use to program the temperature of your kiln. There are a wide variety of kiln control methods, so how do you know which one is right for you? Well, that depends on the type of kiln you’re using and the types of kiln firing schedules you frequently use.
For instance, for heat treating knives you may only need a single setpoint controller, whereas for executing firing schedules for glass or ceramics you may need a programmable digital kiln controller that’s capable of automatically executing multiple segments with different setpoints and ramp rates.
Today, we’ll be exploring the different options for kiln controls, as well as different categories of kiln controllers.
What Is a Kiln Controller?
Before getting into different kiln control methods, it’s important to understand the role of a kiln controller. A kiln controller is a device that manages the temperature and tempo of a kiln according to user inputs. Kiln controllers work by cycling the relays to a kiln’s heating elements to adjust the temperature of the kiln. Thermocouples connect the controller to the interior of the kiln to allow the controller to monitor kiln temperature and adjust power to the kiln accordingly.
The TAP Kiln Controller provides users with simple, precise kiln controls via an easy-to-use touchscreen.
Types of Kiln Controls
When it comes to kiln controls, there are different categories of kiln controllers. However, please note that these categories are broad. A single kiln controller may fall into more than one category. For instance, the TAP Kiln Controller by SDS Industries is an automatic controller, a process controller, a multi-setpoint controller, a multi-zone controller, and provides users with remote kiln control through the TAP Kiln Control Mobile App.
Manual Controllers vs Automatic Controllers
When it comes to kiln control methods for controlling temperature to an electric kiln, the biggest distinction is between manual controllers and automatic controllers. With manual controllers, kiln operators must adjust kiln controls by hand, in real-time throughout the firing process using analog control knobs, dials, and switches. While kiln sitters can be used to ensure the kiln eventually shuts off once it reaches a pre-defined temperature, manual kiln controllers require constant user oversight and input in order to make any adjustments to a firing schedule.
Automatic kiln controllers (also known as digital kiln controllers), on the other hand, are capable of executing kiln controls for an entire firing schedule without user input. With automatic controllers, users preprogram their entire firing schedule into the controller in advance. Once they press ‘Start,’ the controller automatically adjusts kiln temperature, ramp rates, and hold times until the firing schedule reaches completion. Automatic kiln controllers significantly streamline the firing process. Their added convenience and precision make them the preferred kiln control method for many artists and industrial kiln operators.
Limit Controllers vs Process Controllers
Another difference to consider when it comes to kiln controls is the difference between limit controllers and process controllers. Limit controllers, also known as high limit controllers or safety limiters, allow users to pre-program their electric kiln to automatically shut off if the kiln exceeds a specified temperature. While limit controllers usually aren’t suited to be the primary control method on an electric kiln, they are an important part of kiln safety and can protect you, your equipment, and your property in the case of relay or system failure.
Process controllers, on the other hand, monitor temperature throughout the firing process, automatically adjusting output to ensure that the kiln stays within a preset range. Process controllers are used to execute firing schedules with added precision.
Multi-Setpoint Controllers vs Single Setpoint Controllers
Another distinction between kiln control methods is whether a controller is multi-setpoint or single setpoint. A multi-setpoint controller is capable of automatically reaching multiple setpoints (pre-defined temperatures) in succession according to a firing schedule. By comparison, single setpoint controllers are only capable of bringing the kiln to a single setpoint over the course of a firing program.
Multi-Zone Controllers vs Single Zone Controllers
Kiln controls also vary according to whether they are able to deliver uniform temperature throughout different areas – or zones – of the kiln. A multi-zone controller is capable of independently heating multiple zones of the kiln to maintain uniformity throughout the firing chamber. Multi-zone kilns and ovens are usually very large and can see significant temperature differences from one section to another. Single zone controllers can heat the entire kiln to a single temperature.
The TAP II Controller is a cutting-edge single zone kiln controller.
Touchscreen Controllers vs Key-Based Controllers
Another distinction between kiln control methods is how users interface with the controller. Up until fairly recently, automatic kiln controllers could only be programmed using keys (or analog buttons). Due to a limited number of keys, this kiln control method requires users to press each button multiple times and navigate complex, multi-layered menus.
In 2015, SDS Industries revolutionized the kiln control industry by introducing touchscreen kiln controls. Touchscreen kiln controllers brought users added convenience, precision, and ease-of-use, allowing them to easily adjust settings and completely program their kiln with minimal finger presses. Additionally, the touchscreen allowed for a larger display, making controller navigation significantly easier, with alpha-numeric, full text displays of kiln firing schedule names to make it easy for operators to access, edit, and execute the right firing schedule.
Remote Kiln Controls
Another major advancement in kiln control came in 2016 with the release of the TAP Kiln Control Mobile App. Whereas earlier kiln control methods required users to be physically present by their controller in order to input kiln controls, the TAP Kiln Controllers allowed users to monitor and make adjustments to their kiln remotely from their smartphone or tablet. The TAP Kiln Control Mobile App allows users to:
Monitor their kiln remotely with real-time updates.
Remote start, skip firing steps, or abort firings.
Receive real-time firing updates via push notifications.
Create and modify schedules.
Update kiln settings.
And more!
The TAP Kiln Control Mobile App provides remote kiln controls from your smartphone or tablet.
Explore Kiln Controls by SDS Industries
The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use kiln controls on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Similar to other industries, the mid-1980s brought major advancements to kiln control technology. Manual kilns and kiln sitters gave way to programmable digital kiln controllers. Kiln operators no longer had to manually adjust their kilns for each segment of their kiln firing schedule. Instead, they could use programmable kiln controllers to input their entire firing program in advance, and the controller would carry out the program automatically!
Also known as electronic or automatic kiln controllers, programmable digital kiln controllers are computerized controllers that automatically cycle the relays to a kiln’s heating elements on and off in accordance to predefined ramp rates, setpoints and hold times.
Compared to manual controllers, programmable kiln controllers significantly streamline the firing process, reducing the possibility of user error and ensuring consistently repeatable firing conditions.
Programmable Digital Kiln Controller Input Methods
When it comes to programmable digital kiln controllers, there are two primary input methods: keys and touchscreen.
Key-Based Controls
Early programmable kiln controllers all used keys, or analog buttons, in order to program the controller. Many kiln controllers today still use this input method. Common configurations are 3-key controllers and 12-key controllers, but some kiln controllers use as many as 24 keys!
However, regardless of how many keys a controller has, this control method presents several inconveniences:
Keys must be pressed multiple times to increase setpoints, cycle through preprogrammed schedules, or control other inputs.
Key-based controllers often have small, hard-to-read screens that make it impossible to see all the relevant information about a firing schedule.
These controllers have multi-layered menus that can be extremely difficult to navigate.
Good luck using these controllers without constantly having to consult the user manual and press a LOT of buttons!
Touchscreen Controls
In 2015, SDS Industries revolutionized the kiln control industry, by replacing keys and alarm-clock-like screens with intuitive, responsive touchscreen controls and an easy-to-read graphical UI. The TAP Controller, and later the TAP II Controller, allows kiln operators to quickly and easily program their kiln with just a few presses of their finger on the controller or their via their smartphone with the TAP Kiln Control Mobile App.
When it comes to programmable digital controllers, touchscreen controls present several major advantages:
Intuitive, user-friendly menus that are designed for complete navigation with minimal finger presses.
Alpha-numeric, full text displays of kiln firing schedules to make it easy for operators to access, edit, and execute the right firing schedule.
The ability to create a theoretically unlimited number of kiln firing schedules, each containing a theoretically unlimited number of steps, so users don’t have to relegate schedules to their firing notebook when they run out of storage.
Integration with the TAP Kiln Control Mobile App to allow users to create, modify, and execute kiln firing schedules from their mobile device when their kiln controller is connected to Wi-Fi.
Additionally, TAP Digital Kiln Controllers include PID-driven precision, advanced diagnostics, complete firing logs, and preventative maintenance alerts, and more, to ensure that the controller and kiln maintain optimum performance.
Types of Kilns that Use Programmable Kiln Controllers
Today, programmable digital kilns controllers are the standard for industrial kilns and have become increasingly common for hobby and studio kilns. Many programmable kiln controllers include preset firing schedules for glasswork, ceramics, glazes, and heat treat, greatly reducing the learning curve for new artists while still offering veteran artists the ability to completely customize their firing schedules.
Retrofitting Your Kiln with a Programmable Controller
Whether your kiln came equipped with a manual controller or you’re using an outdated programmable controller, retrofitting your kiln with a modern programmable digital kiln controller is easy through the use of standalone controllers or conversion kits. Standalone controllers are a plug-and-play solution for upgrading your manual kiln to automatic controls, while conversion kits enable you to upgrade an existing automatic controller with no (or minimal) modification to your kiln.
Check out our step-by-step guide for installing programmable digital kiln controller standalones and conversion kits!
How to Use a Programmable Digital Kiln Controller
The specifics of how to program your kiln using a digital kiln controller largely depends on the type of controller you’re using. However, generally, upon powering on your kiln you will use the input method on the controller to either select a saved or preset schedule or create your own (you can do this before or after loading your wares). If you’re new to kiln firing, make sure to familiarize yourself with kiln safety guidelines prior to executing your firing schedule.
Once you have selected your firing schedule, press ‘Start’ and your programmable digital controller will automatically execute your firing schedule to completion. Easy as that! While it may be tempting to trust everything to your programmable kiln controller, for safety reasons you should never leave your kiln unattended during firing. While programmable controllers are extremely reliable compared to relying on a kiln sitter, there is always the possibility of relay failure or other technical mishaps (for additional safety, we recommend using an additional limit controller as an added layer of relay redundancy to force safety shutoff if the kiln exceeds certain temperature thresholds).
Programming a TAP II Digital Kiln Controller
While we can’t provide a How-To for using every programmable kiln controller on the market, below we’ll be looking at how to program a TAP II Kiln Controller (the UI for the original TAP Controller is extremely similar):
Step 1: Starting from the ‘Home Screen’
Below is a picture of the home screen on a TAP II Kiln Controller:
To access kiln firing schedules, or create a new one, press ‘Start’ on the right side of the screen.
Step 2: Using the ‘Schedule Selector’ Screen
On the ‘Schedule Selector’ screen, you have the ability to access all of your saved or preset kiln firing schedules by scrolling through the menu on the left side of the screen. To execute an existing schedule, select the schedule from this screen, then press ‘Start’!
If you need to edit a schedule, clicking the ‘Edit Icon’ beside the schedule title allows you to edit that firing schedule. Or, to create a new schedule, click ‘New’ on the right side of the screen.
Step 3: Edit and Add Steps to Your Firing Schedule
Clicking the ‘Edit Icon’ will bring you to the ‘Edit Schedule’ screen:
On this screen, you have the ability to add new steps and edit the Schedule Name, Ramp Rate, Setpoint, and Hold Time for each step. Additionally, you have the ability to set alerts to notify you when your kiln has reached its setpoint or hold time for each specific step. When you’re finished editing your firing schedule, click ‘Save.’
Step 4: Execute Your New Firing Schedule
When you click ‘Save,’ the controller will bring you back to the ‘Schedule Selector’ screen. Select your desired schedule and then press ‘Start.’
From there, your TAP II Controller will automatically execute your new firing schedule. From the ‘Execute’ screen, you’ll be able to monitor exactly where your kiln is in terms of your firing schedule, as well as skip steps, access firing logs, or abort your firing.
Please Note – Most programmable digital kiln controllers are not nearly that easy-to-use or intuitive. A huge part of our focus at SDS Industries is to make using a programmable kiln controller as simple, precise, and straightforward as possible!
Explore Programmable Kiln Controllers by SDS Industries
The TAP and TAP II Controllers by SDS Industries are the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.
We invite you to explore our selection of programmable kiln controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Beyond industrial kilns, ovens, and furnaces, electric temperature controllers are used in a wide variety of industrial processes and applications. Commonly referred to as ICS controllers, electric temperature controllers are used to monitor and regulate temperatures in manufacturing or storage processes where consistent outcomes rely on precise temperature control.
Unfamiliar with the acronym? Don’t worry! Below, we’ll be exploring industrial control systems (ICS) and the role and applications of ICS controllers.
What is an Industrial Control System?
Industrial control systems (ICS) refer to the equipment and software that are used to monitor, regulate, and control the behavior of machinery in automated industrial processes. An industrial control system provides physical or digital means through which humans can interface with machinery, providing inputs (or setpoints) to tell the machinery when and how to act.
Before exploring the role of ICS controllers, there are a few terms that are important to understand:
Localized Control System: In localized control systems, inputs are directly entered into each individual machine via a machine-mounted control panel. In a localized control system, machinery doesn’t communicate with each other, and there is no overall view or centralized process control.
Centralized Control System: More sophisticated industrial control systems use sensors and electronic signals to consolidate control of all machines to a centralized control room.
Distributed Control System (DSC):Distributed control systems are computerized control systems that use a series of sensors and automatic controllers distributed throughout a factory. In a DSC, controllers automatically regulate the behavior of individual machines but are also connected to a centralized network so that an operator can monitor and adjust the overall process. DSCs are more efficient, consistent, and cost effective than localized or centralized control systems.
Process Variables (PVs):Process variables are the actual measured values of a particular part of an industrial process that is being controlled or measured. So, for example, when it comes to temperature control the process variable would be the current temperature of an industrial kiln or oven, as opposed to the desired temperature (or setpoint).
Setpoints (SPs): A setpoint is the desired or target value for a process variable. In terms of temperature control, the setpoint would be the desired temperature of a kiln or oven according to its firing schedule.
Final Control Elements (FCEs):Final control elements are the mechanical devices that physically change a process in response to setpoints within an industrial control system. These include elements, valves, and dampers.
Control Loops: A control loop consists of the process sensor, controller, and final control elements – basically all of the components needed to adjust process variables to match desired setpoints.
Human Machine Interface (HMI): A human machine interface is the user interface or dashboard from where an operator can control a machine, system, or device.
Discrete Controllers: Discrete controllers consist of a single control loop to directly view and interface with a single machine.
Programmable Logic Controllers (PLCs):Programmable logic controllers are digital controllers that receive data through inputs (such as thermocouples) and uses the internal logic that’s been programmed into it to adjust outputs to matched desired setpoints. TAP Kiln Controllers are examples of programmable logic controllers.
SCADA Systems: SCADA stands for Supervisory Control and Data Acquisition. SCADA systems consist of all hardware and software that are used to control, monitor, and gather data from industrial devices and processes – both remotely and on-site.
Understanding the Role of ICS Controllers
An ICS controller is a device where operators can input setpoints for an industrial control system. The ICS controller receives data from input sensors and adjusts outputs to the final control elements in order for the industrial control system to reach its desired setpoints.
ICS controllers play an important role in ensuring that industrial processes are executed effectively and consistently.
The TAP Controller by SDS Industries includes an advanced feature set for use in industrial control systems.
ICS Controllers for Temperature Control
While there are different types of ICS controllers for managing different process variables throughout an ICS, for the sake of this article we’ll be focusing on ICS controllers for temperature control. Many industrial systems rely on heating, cooling, or maintaining precise temperatures to alter or preserve the physical properties of material.
Industrial kilns, ovens, furnaces, and temperature-controlled drums, freezers, and storage units all rely on ICS kiln controllers to regulate temperature.
ICS controllers can be manual or automatic. Manual ICS controllers rely on constant user input through analog dials and switches to regulate power to final control elements. Automatic ICS controllers, on the other hand, are programmed to reach various setpoints over specific time periods and automatically adjust the final control elements to achieve the desired temperature.
Benefits and Features of TAP ICS Controllers
SDS Industries’ TAP Digital Controllers include a variety of features that make them ideal for industrial control systems, including:
PID (Proportional Integral Derivative) control algorithms to ensure maximum accuracy between temperature input and output.
The ability to create, store, edit and automatically execute an infinite number of firing profiles with an infinite number of steps.
The ability to remotely monitor commercial kilns and edit and execute firing processes through the TAP Kiln Control Mobile App.
Advanced diagnostics and preventative maintenance alerts to ensure peak performance for industrial thermal processes.
High quality components for maximum precision and durability.
Wi-Fi capability to seamlessly integrate TAP Controllers to a distributed control system.
The TAP Kiln Control Mobile App allows operators to remotely monitor and make adjustments to temperature control elements.
Explore ICS Controllers by SDS Industries
The TAP and TAP II Controllers by SDS Industries are the most advanced, precise, and easy-to-use ICS controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled industrial kiln, oven, or furnace to allow you to easily manage control system setpoints.
We invite you to explore our selection of programmable ICS controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
Kilns aren’t just limited to home and studio applications. Industrial kilns, or commercial kilns, are used in a wide variety of industrial processes. From mass producing ceramic tableware to processing plastic, industrial kilns are used to create many of the objects you use in day-to-day life.
Compared to kilns for personal or artistic use, industrial kilns are typically much larger and more powerful, designed to process large quantities of materials in industrial settings. Designed for mass production and commercial use, industrial kilns are often permanently installed and capable of reaching extremely high temperatures.
Industries That Use Commercial Kilns
Industrial kilns, furnaces, and ovens are used across a wide variety of industrial sectors including:
Ceramic: Industrial kilns are used in the ceramic industry to produce tableware, pottery, tile, and other ceramic products.
Glass: Industrial glass kilns, furnaces, and annealers are used in the glass industry to produce windows, sheet glass, drinkware, bottles, mirrors, and more.
Construction and Building Materials Manufacturing: In the construction industry, commercial kilns and heat treat ovens are used to produce brick, tiles, windows, machinery, tools, and other building materials.
Metal Processing and Manufacturing: Industrial heat treat ovens and furnaces are used to process metal for a wide variety of applications including, but not limited to, knifemaking, jewelry production, and silverware manufacturing.
Plastic Processing and Manufacturing: The plastic processing and manufacturing industry uses commercial kilns to heat raw material into finished or semi-finished plastic products.
Food Industry: In the food industry, industrial kilns and commercial ovens are used to dry, cook, and process food.
Waste Management: The waste management industry uses commercial furnaces for incineration, recycling, and energy recovery.
However, these are just a few of the industries that use industrial kilns, furnaces, and ovens. Kilns and ovens are also used in the medical, pharmaceutical, electronic, automotive, military and defense, and aerospace industries (among countless others!).
The Differences Between Industrial Kilns, Furnaces, and Ovens
When it comes to commercial thermal processing equipment, there are three main categories: kilns, furnaces, and ovens. Superficially, all these terms can be used interchangeably. However, typically, each of these terms is used to denote equipment used for specific use-cases or to describe equipment capable of reaching specific temperatures:
Industrial Kiln: More likely to be used to describe thermal processing units used to process ceramics or glass. Typically used to describe units that reach maximum temperatures of approximately 1400° C (2552° F).
Industrial Furnace: More likely to be used to describe thermal processing units used for metal heat treatment and metallurgy. Often used to describe units that reach peak temperatures exceeding 1400° C (2552° F), all the way up to 1750° C (3182° F).
Industrial Oven: More likely to be used to describe thermal processing units used for the food, electronic, medical, and pharmaceutical sectors. Often used to describe units whose processes don’t result in a fundamental phase change (such as drying, moisture reduction, and bakeout).
The TAP Kiln Controller by SDS Industries includes a variety of features and benefits for industrial kiln usage, such as:
PID (Proportional Integral Derivative) control algorithms to ensure maximum accuracy between temperature input and output.
Multizone temperature control to set specific temperatures in up to three different areas of an industrial kiln or oven.
The ability to create, store, edit and execute an infinite number of firing profiles.
The ability to remotely monitor commercial kilns and edit and execute firing processes through the TAP Kiln Control Mobile App.
Advanced diagnostics and preventative maintenance alerts to ensure peak performance for industrial thermal processes.
High quality components for maximum precision and durability.
Read more about the roles and functions of industrial kiln controllers.
Explore Industrial Kiln Controllers by SDS Industries
The TAP and TAP II Controllers by SDS Industries are the most advanced, precise, and easy-to-use industrial kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven to allow you to easily manage and execute your kiln firing schedules.
We invite you to explore our selection of programmable industrial kiln controllers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:
