Engineered Workflows, Perfected Through Experience
Initial Quality Testing
Incoming raw materials are sent to our in-house laboratory for initial quality assessment, where they are specifically tested for Alumina and Iron content. If the material meets our standards, it proceeds to the next stage. If not, it is returned to the vendor for replacement.
Crushing & Grinding for Castable Making
After a successful chemical assessment, raw materials are conveyed for crushing and grinding, reducing them to the required size for further processing. This process is repeated once again after calcination to ensure uniform particle size and consistency.
Pelletization of Raw Material
The finely ground material is then fed into pelletizing discs, combined with required aggregates as per the desired grade, and converted into uniform pellets to achieve consistent quality and performance.
Rotary Kiln Firing & Air Quenching
The pellets are fired in a rotary kiln at controlled, elevated temperatures for a specified duration to induce the required physical and chemical transformations. After firing, the semi-finished lumps undergo air or inert gas quenching, which cools them rapidly to prepare for the next stage of quality testing.
Second Round Quality Check
A second round of testing is conducted to evaluate Bulk Density (BD), Apparent Porosity, and Setting Time — parameters critical for durability and pressure resistance during application. Once approved, the lumps are crushed and ground again to achieve precise grain sizes and shapes suitable for castable production.
Batch Milling (Homogeneous Mixing) & Packaging
The prepared grains and fines are mixed in exact proportions as required for specific castable formulations. This blend undergoes a third round of quality testing to ensure that chemical and physical properties match the exact specifications provided by our customers. Finally, the material is packed in high-quality HDPE bags with inner liners to prevent moisture contamination and preserve product integrity until use.