Enhancing the Ceramic Additive Mixing Process with Vibro Sifters: A Path to Uniformity & Quality

Introduction: Ceramic Industry & Manufacturing Process

The ceramic industry is a major player in the global manufacturing industry, serving applications ranging from construction and sanitaryware to electrical and electronic, tiles, refractories and technical ceramics. Ceramic products manufacturing uses various crucial processes that comprise the raw material preparation, forming, drying, glazing, and firing.

Among these, additive mixing is a vital sub-process during raw material preparation. Ceramic powders are mixed with other processing aids (additives) which include binders, plasticizers, deflocculants and more to help the green strength, plasticity and formability of the mixture. The homogeneity and purity of this mixture has direct effects on the quality of the product, structure strength and surface finish of the desired ceramic product.

Nevertheless, even though it is a necessary part, additive mixing is also associated with certain difficulties, especially, the implementation of homogeneity and the elimination of overlarge or foreign particles in the mix. This is where an advanced screening system like the Sivtek Vibro Separator becomes indispensable.

Challenges in Ceramic Additive Mixing Process

1. Inconsistent Mixture Quality
   Difference of the effective particle size for additives can cause bad dispersion. This leads to inconsistent performance and product qualities of ceramic materials in the molding or pressing stage.
2. Oversized and Contaminant Particles
   Additive materials often include lumps or foreign particles that may damage forming equipment or cause defects in the final product such as cracks or rough surfaces.
3. Clogging and Manual Cleaning in Traditional Sieving Systems
   Traditional screening systems often clog because certain binders and plasticizers carry a stick aspect, requiring more machine downtime and maintenance.
4. Dust Generation and Product Loss
   Excessive dust generation and wastage from handling dry additives in open areas poses health and safety issues.
5. Low Throughput in Manual or Basic Screening Methods
   Using traditional manual sieving or outdated machinery can really slow down the production cycle, making it tough to keep up with large-scale production demands.

Vibro Sifter: A Proven Solution for Ceramic Additive Screening

Galaxy Sivtek provides a solution to these problems with it’s specifically designed screening machine — SIVTEK Vibro Separator, which is one of the high rated devices used for handling extreme screening & separation in ceramic mixing that helps improving production rates.

Key Advantages of Using Sivtek Vibro Separator in Ceramic Additive Processing:

• Achieves High Screening Efficiency
  The machine ensures uniform particle size by separating oversize impurities, agglomerates, and contaminants effectively from additive materials.
• Gentle yet Precise Sieving
  It was developed to work on fine powders, plasticizers, and binders without altering their functional characteristics, by implementing a variable vibratory motion.
• Dust-Free Operation
  The fully enclosed design means no dust is able to escape during the screening process this ensures a clean working environment and prevents any product loss.
• Customizable for Ceramic Applications
  Galaxy Sivtek offers tailor-made solutions with mesh sizes, contact parts, and surface finishes designed specifically for ceramic-grade materials.
• Low Maintenance and Easy Cleaning
  The equipment has possibilities of quick-release clamping, mirror-polished interior, and tool-free assembly, which facilitate the fast cleaning process and support hygienic cycles.
• High Throughput with Reduced Downtime
  The Vibro Sifter has been specially designed to work absolutely uninterrupted under high-volume processing.

How the Screening Process Works

1. Feeding the Additive Mix
   The premixed additives are fed to the Sivtek Vibro Separator either manually or through some automated conveying systems.
2. Vibratory Screening
   The feeder uses circular vibrations which promote sieving. Finer utilizable particles will pass through the mesh screen whilst oversized materials or contaminants will remain above.
3. Separation & Collection
   The fine homogenous additive mix is taken from the bottom outlet to be mixed with either a ceramic body slip or powder, whilst the oversized reject will ensure discharge onto its own.
4. Integration with Conveying Systems
   This machine can be easily integrated into an existing pneumatic or mechanical line of conveyors without problems in continuity of process.

Custom-Built for Ceramic Industry Needs

Galaxy Sivtek understands that every ceramic manufacturing setup is unique. Whether you’re processing ceramic tiles, refractories, or technical ceramics, we offer customized Vibro Sifter solutions engineered for your material characteristics, required mesh sizes, and throughput expectations.

Above all, they are already trusted in the world by major ceramics manufacturers who enjoy the durability of our machines, precision during screening, and the ease of use.

Final Thoughts

In order to ensure consistent quality in your ceramic product, consistent mixing at the additive stage is very important. Oversized particles and uneven blending would rather cause setbacks in production and create product faults. With Galaxy Sivtek’s Sivtek Vibro Separator operating for you, these troubles can be consigned to history with a great boost to the reliability and efficiency of your process.

Whether you’re facing screening issues with binders, plasticizers, or other ceramic additives — we have a solution tailored to your process.

Looking to Optimize Your Ceramic Additive Process?

Get a custom screening solution designed for your process. Contact Galaxy Sivtek Today