A major quartz sand processor in Southeast Asia, supplying high-quality material to the glass manufacturing industry, was struggling with their outdated classification system.
Their existing classifier delivered inconsistent results, with D97 values fluctuating wildly between 85μm and 120μm. This variability led to frequent product rejections from demanding glass industry customers. In addition, the highly abrasive nature of quartz (Mohs hardness 7) caused rapid wear on classifier components, requiring replacements every 800 operating hours. Worst of all, the maximum capacity was limited to just 4.5 t/h — far below the growing demand from their expanding customer base.
The company needed a robust, reliable solution that could consistently achieve D97 75μm at a stable 6 t/h while significantly reducing maintenance costs and downtime.
The Solution: Epic Powder MBS-3 Air Classifier
Epic Powder recommended and installed the MBS-3 Air Classifier in a closed-circuit system with the customer’s existing ball mill.
Designed specifically for abrasive materials, the MBS-3 features advanced wear-resistant construction and a precision hierarchical rotor structure that ensures sharp cut points even under challenging conditions.
Key Technical Parameters:
| Parameter | Value |
|---|---|
| Model | MBS-3 |
| Target Fineness | D97 75μm |
| Capacity | 6 t/h |
| Drive Power | 15 kW |
| Airflow | 8,600 m³/h |
Impressive Results After Six Months
The MBS-3 exceeded expectations and delivered transformative improvements across all critical metrics:
| Metric | Before | After (MBS-3) | Improvement |
|---|---|---|---|
| D97 Consistency | 85–120μm (unstable) | 73–78μm (highly stable) | Dramatically improved |
| Oversize Particles (>100μm) | 12–18% | <2% | ~90% reduction |
| Production Capacity | 4.5 t/h | 6.0 t/h | +33% |
| Wear Parts Service Life | 800 hours | 3,200 hours | 4× longer |
| Classifier Power Consumption | 22 kW | 15 kW | 32% lower |
Product rejection rate dropped from 8% to less than 1%. Thanks to the higher throughput and dramatically reduced maintenance, the MBS-3 achieved a return on investment in just two months.
Customer Feedback
“The MBS-3 has completely transformed our production line. We can now consistently deliver glass-grade quartz sand with stable D97 at 75μm. The machine runs reliably 24/7 with minimal wear. We are so satisfied that we have already placed an order for a second unit.”
— Plant Manager, Southeast Asian Quartz Sand Processor
Conclusion
The Epic Powder MBS-3 Air Classifier proves that advanced classification technology can solve the toughest challenges in processing abrasive minerals like quartz sand. It offers stable ultra-fine classification at higher capacity, significantly longer wear life, and lower energy consumption compared to conventional equipment.
If you are facing similar challenges with particle size control, capacity, or maintenance costs in quartz sand, silica, or other abrasive materials, Epic Powder can help.
Contact us today for a free material test, detailed quotation, or technical consultation.
Material: Quartz Sand
Particle Size: 78μm
Output: 6 t/h
