PROCESS DETAILS

After weighment of raw materials (non-plastic) with some percentage of plastic clay is charged in a Ball Mill lined with silex stone along with flint pebbles and water.

After grinding for about 16-18 hours, the slurry of the ball mill is discharged through Vibrating Seive and permanent magnet to underground blunger. Remaining part of China Clays are being blunged and then transferred to underground blunger.

The slurry from the underground blunger is pumped to Filter Press for removing excess water and to get the slurry as cake form. These cakes after aging for 24 hours put into pug mill for 1st pugging. Purpose of 1st pugging is to have uniform distribution of moisture and to remove partially air from the processed body.
 

These pugged masses are kept further for 24 hours for aging and then pugged through final pugmill in diff. Sizes according to production programme for to remove air completely.

MAKING
These pugged masses are shaped either by machine or by throwing according to requirement. These shaped pieces are kept in open air for 36 to 46 hours for making leather hard for giving final shapes in coping lathe or by hand by skilled workers on Potter’s wheel.

These final shaped insulator are further kept in hot room No.1 whose tem. is about 40-45ºC for 72 hours and then to hot room No.2 at 70-80º C for 72 hors to have a moisture less than 0.5 percent.

GLAZING
These dried insulator are glazed in a glazed solution and then kept in a dryer No.3 for 48 hours for further drying where temperature is about 70-80º C.

LOADING AND FIRING
Glazed insulators after dryer No.3 are loaded in the cars of shuttle kiln and then fired for 32 hours at about 1200ºC.

Cooling of these insulators requires 14 hours and then get it unloaded. Each of these insulator are being checked and sorted out.