Doubling Calcium Carbonate Screening Capacity in Malaysia with the Sivtek Roto Sifter 1350

One of the major calcium carbonate manufacturers in Malaysia was experiencing an ordinary production dilemma; how can fine and high-quality screening be obtained without compromising throughput. The product required a consistent particle size with an 80# (mesh) designation, and the existing method could not provide sufficient output to meet rising demand.

This challenge and its solution provide valuable insights for any operation facing difficulties with fine powder screening on a larger scale.

Challenge

The customer used a two-stage screening by an inline sifter:

1. First stage: Screening was done for material at 30# mesh at about 2TPH.
2. Second stage: The 30# screened output was then passed through an 80# mesh, again producing only 2 TPH.

To achieve the necessary 80# quality, the company had no option but to screen the same material twice. This caused three significant problems:

• Low throughput: At 2 TPH, meeting production targets required longer operating hours.
• Higher operating cost: Two separate screening steps increased energy use and labor requirements.
• Extended processing time: Double handling proficiency would decline downstream.

Management needed a way to achieve 80# screening in a single pass without compromising product quality.

Galaxy Sivtek’s Solution

Galaxy Sivtek introduced the Sivtek Roto Sifter 1350, a powerful centrifugal sifter crafted for handling fine, low-density powders like calcium carbonate. The Roto Sifter uses a rotating paddle inside a cylindrical screen basket to gently but effectively push material through the mesh. This arrangement allowed for a high throughput at a stage compromising the integrity of the particles.

The most important part of the machine proposed was a type of heavy-duty sieve basket. Unlike ordinary baskets that will wear, or tear under continuous use, this design is able to endure excessive use without monitoring damage which significantly reduces unplanned operational downtime.

Implementation and Results

The Sivtek Roto Sifter 1350 was installed in the customer’s production line to replace the two-step inline sifter arrangement. From installation, you could see an improvement:

• Single-pass 80# screening: The Roto Sifter achieved the fine 80# cut directly—no pre-screening at 30# was needed.
• More than double the throughput: The machine achieved an average of 5 TPH, which is much higher than the former 2 TPH output.
• Reduced processing time: By eliminating the second screening stage, total cycle time was shortened, and material flow became simpler.
• Lower labor and operating cost: There was one step of screening thus reducing by almost half the necessity of other operators and the energy.
• Improved reliability: The strong basket configuration reduced the wear and tear and thus minimized the downtimes of maintenance of the production.

Business Impact

The upgrade transformed the calcium carbonate producer’s operation:

• Productivity gains: Throughput more than doubled while maintaining strict 80# quality standards.
• Cost efficiency: The reduced number of steps within the process and downtime minimized the cost of labor and maintenance.
• Operational simplicity: with a single-pass system, the workflow was further simplified, increasing scheduling flexibility.

Conclusion

By adding a single Sivtek Roto Sifter 1350 replacing the two stages of inline sifter setup; the Malaysian manufacturer resolved the capacity and maintenance issues. Direct 80# screening at 5 tons per hour eliminated an entire processing step, cut labor costs, and improved equipment reliability thanks to the machine’s durable basket.

This case demonstrates how a centrifugal sifter can deliver both high efficiency and consistent quality for fine calcium carbonate applications proving that the right screening technology can unlock significant gains in productivity and cost savings.