The customer is a leading non-metallic mineral processing enterprise in India, specializing in the production of high-quality Ground Calcium Carbonate (GCC). As an important non-metallic filler, GCC is widely used in paper manufacturing, plastics, coatings, and construction materials.
To meet the rapidly growing market demand in India and address increasingly stringent customer requirements for product fineness and surface performance, the company decided to invest in a new high-capacity, highly integrated GCC deep-processing production line. The project faced three major technical challenges:
Combining Ultra-Fineness with High Output
The target was to achieve a product fineness of D97: 800 mesh (≈18 μm) while maintaining a stable 8 t/h production capacity.
Strict Particle Size Distribution Control
A uniform particle size distribution was required, with no over-grinding or coarse particle residue.
Surface Modification Challenges
Ultra-fine calcium carbonate has higher surface activity and is prone to agglomeration. Efficient, uniform surface modification was essential to improve dispersibility and compatibility in polymer and coating systems.
Solution: Epic Powder’s Integrated Three-in-One Ultrafine Powder System
After thorough technical discussions and customized engineering design, Epic Powder tailored a complete “three-in-one” ultrafine GCC processing line solution for the Indian customer. The system integrates three core technologies:
- Energy-efficient Ball Mill
- High-efficiency Air Classifier
- Pin mill Surface Modification Machine
Process Flow:
Raw material → Energy-saving ball mill → Conveying → Air classifier → Coarse powder → Returned to ball mill→Fine powder → Pin mill modifier (with coating agent added) → Final product → Packaging
Results After Implementation
Once successfully commissioned, the production line delivered significant improvements in both output capacity and product competitiveness:
| Key Indicator | Design Target | Actual Performance | Value Delivered |
|---|---|---|---|
| Product Fineness | D97: 800 mesh (≈18 μm) | Stable at 17–19 μm | Fineness fully meets and maintains target |
| Actual Capacity | 8 t/h | Stable at 8.5 t/h | Exceeds expected high-capacity goal |
| Modification Performance | High dispersibility & hydrophobicity | Coating efficiency >98% | Suitable for high-end plastic masterbatch & coatings |
| Operating Cost | Lower energy & maintenance cost | System energy consumption reduced by 10%+ vs. industry average | Higher profitability |