Project Overview
November 20, 2025
Date :
Large-Format Porcelain Tile Manufacturer
Client :
Mineral Processing & Beneficiation
Category :
Morbi Industrial Belt, Gujarat
Location :
Ceramic Beneficiation
We began with an exhaustive diagnostic assessment of the slip-house body preparation circuits, logging slip viscosities, particle size curves, and kiln roller speeds. Evaluating incoming crude clay assays against fired tile defects enabled our mineral engineers to isolate free quartz grit and uncalibrated iron oxides as the root defect triggers.
Engineered Solutions & Execution
Hydrocyclone Desliming
Crude run-of-mine kaolin was passed through high-shear log washers and a two-stage battery of 75 mm hydrocyclones, stripping out all free silica particles larger than 20 microns before slip preparation.
Controlled Moisture Dewatering
Beneficiated clay slurry was dewatered through high-pressure recessed plate filter presses, delivering consistent filter cakes with moisture content held strictly below 14% for optimal extrusion.
Air-Swept Dynamic Micronisation
Dewatered material was pulverized in continuous ball mills coupled with rotary air classifiers, yielding an ultra-fine powder with 98.5% passing 300 mesh (45 microns) while capping iron content at 0.65%.
Quantified Operational Impact
8.2% → 1.1%
Kiln Rejection Rate
-6.5% Gas
Thermal Energy Savings
45 Days
Process Continuity
Driving Value Beyond Completion
Our technical support extended far beyond flowsheet installation. We instituted daily rheology calibration protocols, automated sieve tests, and raw lot assay checks at the mine gate before shipment. Ongoing audits ensure clay properties remain tightly aligned with kiln thermal curves as feed sources vary.
The tile manufacturer now operates with predictable slip viscosity, lower thermal energy overhead, and a superior grade of defect-free polished porcelain slabs. This turnaround illustrates how precise mineral beneficiation upstream directly protects end-product margins downstream.