A Greek industrial mineral processor specializing in gypsum powder production faced a critical challenge: their existing sınıflandırma system could not consistently deliver the precise particle size distribution required for high-value applications such as self-leveling flooring compounds and high-performance plasters. With growing demand from the construction sector for finer, more uniform gypsum powder, the customer sought a reliable solution that could improve product quality while maintaining cost efficiency.
The Challenge
The customer’s previous equipment suffered from inconsistent cut points, resulting in excessive fines and oversized particles that compromised the performance of their end products. They needed a sınıflandırıcı capable of achieving a sharp top cut with D97 < 32μm while offering flexibility to produce a wide range of particle sizes from 32μm to 250μm. Additionally, the equipment had to handle a processing capacity of 9 tons per hour with stable, uninterrupted operation.
The Solution: Epic Powder’s CTC Air Classifier
After evaluating multiple options, the Greek customer selected Epic Powder’s precision air classifier, a technology derived from mature German engineering. This equipment was specifically designed to meet their stringent requirements:
- Sharp Top Cut Precision: The classifier achieved a D97 of 30μm, ensuring that 97% of the gypsum powder was finer than 30 microns. This level of precision eliminated oversized particles that could cause defects in finished products.
- Wide Particle Size Range: The system allowed seamless adjustment between 32μm and 250μm, enabling the customer to produce multiple product grades with a single machine.
- Optimal Processing Capacity: Operating at 9 tons per hour, the classifier perfectly matched their production line requirements while maintaining consistent performance.
- Durable Construction: Built to handle abrasive materials such as gypsum, quartz sand, and marble, the equipment featured wear-resistant components that ensured long service life even under continuous operation.
Results and Benefits
The implementation of Epic Powder’s precision air classifier delivered measurable improvements:
| Parameter | Before | After |
|---|---|---|
| D97 Cut Point | Inconsistent | 30μm (stable) |
| Production Yield | Variable | 9 t/h |
| Energy Consumption | High | Reduced by 20% |
| Maintenance Frequency | Monthly | Quarterly |
Key outcomes included:
- Improved Product Quality: The sharp cut point at D97 30μm enabled the customer to supply high-value gypsum powder for premium applications, allowing them to command higher market prices.
- Lower Operating Costs: The equipment’s low energy consumption, combined with reduced maintenance requirements, significantly lowered the total cost of ownership. The customer reported a 20% reduction in energy costs compared to their previous system.
- Minimal Footprint: Unlike conventional systems requiring extensive peripheral equipment, Epic Powder’s classifier operated independently with a compact layout, saving valuable floor space in their facility.
- Enhanced Reliability: With mature German-derived design principles, the equipment delivered stable, uninterrupted performance even when processing abrasive gypsum feed.
Customer Feedback
“Destansı Toz‘s air classifier has transformed our gypsum powder production. The precision at D97 30μm is exceptional, and the ability to adjust particle size across such a wide range gives us the flexibility to serve multiple market segments. The low maintenance requirements and energy efficiency have also made a real impact on our bottom line.”
– Production Manager, Greek Mineral Processing Company
For gypsum processors seeking precision classification with reliable performance, Epic Powder’s air classifier offers a proven solution. By combining German engineering heritage with practical design features such as low energy consumption, minimal footprint, and robust construction for abrasive materials, this equipment enables customers to achieve consistent product quality while optimizing operational costs
