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Vietnam ceramic raw materials case: Helping increase production capacity by 20%
one. Client Background and Core Challenges
Our client, a company located in Dong Nai Province, Vietnam, is a leading manufacturer of high-end ceramics in Southeast Asia. Its products are primarily exported to the European and American markets, and they have extremely stringent requirements for product whiteness and purity.
However, in its powder preparation workshop, trace ferromagnetic impurities introduced from raw materials (feldspar and quartz) and equipment wear resulted in noticeable black spots or iron stains on the surface of fired ceramic bodies. This not only resulted in a defective rate as high as 5%, but also triggered numerous complaints from end customers, seriously threatening its brand reputation and profitability.
The client had previously used a traditional permanent magnetic iron remover, but this required frequent downtime for manual cleaning, resulting in low efficiency and poor removal of micron-sized, weakly magnetic impurities.
two. Our Customized Solution
After an on-site inspection and material sampling tests by our technical engineers, we recommended and installed eight DCZ-300 dry electromagnetic separators for the client and provided the following customized solution:
Processing Material: Ceramic green body powder (primarily composed of feldspar and quartz, with a particle size between 100-400 mesh).
Processing Capacity: The designed maximum processing capacity is 25-30 tons/hour, perfectly matching the customer's existing production line flow rate.
Equipment Configuration:
High-Intensity Electromagnetic System: The dry magnetic separator utilizes water cooling to generate a magnetic field strength of up to 12,000 gauss, ensuring effective adsorption of weakly magnetic impurities down to micron size (<30μm).
Fully Automatic Self-Cleaning: The dry magnetic separator is equipped with a PLC intelligent control system, which automatically adsorbs, removes, and collects impurities during operation, eliminating downtime and enabling unattended operation.
Dust-Proof Design: Special sealing and dust-proofing measures are implemented specifically for the powder room environment to ensure long-term stable operation.
three. Implementation and Outstanding Results
After installation and commissioning at the Dong Nai, Vietnam, plant, the equipment was immediately operational. The results were immediate:
Quality Leap: The iron impurity content of the ceramic powder after magnetic separation was reduced from 200ppm to below 10ppm. The fired ceramic bodies no longer had any iron spot defects, and the product defect rate dropped from 5% to less than 0.3%.
Efficiency Improvement: Fully automated operation replaced manual cleaning every two hours, enabling 24-hour continuous production and increasing overall production capacity by approximately 15%.
Cost Savings: Not only did it reduce scrap losses, but it also prevented wear and tear on downstream precision equipment such as presses caused by impurities, saving the customer over $20,000 in maintenance and labor costs annually.
Customer Feedback: Mr. Nguyen, the company's Production Director, stated, "Hengci's dry electromagnetic separator has completely resolved the quality issues that had plagued us for years. The equipment's stability and automation exceeded our expectations, providing a solid quality assurance system for our expansion into the high-end market."
four. Why Choose Us?
- This company's success is not an isolated case. We specialize in providing the most reliable industrial magnetic separation solutions to customers worldwide:
- Application Expertise: We deeply understand the unique needs of diverse industries, including ceramics, chemicals, and food.
- Customization: We tailor-make the most suitable equipment for your specific needs, from throughput and material characteristics to installation space.
- Global Service Network: Whether you're in Vietnam, the Middle East, or Europe, we offer timely technical support and after-sales service.
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