Background: A Japanese electronic component manufacturer required the screening of alumina ceramic powder (used for MLCC* production) to remove agglomerates and impurities >10μm.
Challenges: Ceramic microparticles tended to agglomerate; conventional screening methods showed low efficiency, and electrostatic adsorption caused frequent screen mesh blockage.
Solutions:
Implemented an ultrasonic vibrating screen with high-frequency micro-vibration (28kHz) to break particle agglomerates and enhance precision.
Used a 316L stainless steel screen mesh with Teflon coating to minimize electrostatic adhesion.
Integrated a nitrogen protection system to prevent powder oxidation.
Results:
Achieved a screening precision of 5μm (equivalent to 2500 mesh), increasing qualified powder yield from 85% to 99.5%.
Screen mesh lifespan tripled, reducing maintenance costs by 40%.
Product certified to IEC 60384-8 standards.
MLCC: Multilayer Ceramic Capacitor
Background: A German specialty ceramic manufacturer needed to classify silicon carbide (SiC) abrasive into three grades: 60-80 mesh, 100-120 mesh, and 200-400 mesh.
Challenges: SiC's extreme hardness (Mohs 9.5) caused rapid wear and frequent replacement of standard screens.
Solutions:
Customized a linear vibrating screen with polyurethane screen meshes coated with tungsten carbide wear-resistant layers, improving impact resistance by 70%.
Dual-layer design: upper layer for coarse particles (60-80 mesh), lower layer for fine powder (200-400 mesh).
Integrated pneumatic pulse cleaning system for automatic mesh cleaning every 30 seconds.
Results:
Screening efficiency reached 8 tons/hour with particle classification accuracy error <±2%.
Screen mesh lifespan extended from 3 days to 45 days, saving €120,000 annually in consumables.
Background: A Chinese refractory material producer required screening of mullite raw materials (0.5-3mm particle size) post high-temperature calcination to remove under-fired clumps.
Challenges: Material temperature reached 200°C, causing traditional sifter bearings to overheat and jam.
Solutions:
Deployed a water-cooled rotary centrifugal sifter with circulating coolant channels in bearings (±5°C temperature control).
Screen drum constructed from heat-resistant Inconel 600 alloy (withstanding 1200°C deformation).
Tapered sieve hole design (5mm inlet → 2mm outlet) for progressive classification.
Results:
Achieved 12-hour continuous operation without failure, increasing screening rate from 78% to 95%.
Reduced scrap re-melting rate by 60%, saving over ¥500,000 annually in fuel costs.
Background: An Italian ceramic glaze supplier needed to remove >45μm (325 mesh) impurities from zirconium silicate glaze.
Challenges: Organic binders in the glaze caused paste-like clogs during wet screening.
Solutions:
Introduced an airflow vortex sifter utilizing the Venturi effect to generate 200m/s high-speed airflow for dry dispersion of viscous particles.
Integrated real-time laser particle size analyzer to dynamically adjust airflow pressure (0.2-0.8MPa).
Full ATEX-certified explosion-proof design for combustible dust environments.
Results:
Achieved 500kg/h efficiency for ultra-fine powder (D50=6.5μm), with residual impurities <0.01%.
Glazed product defect rate dropped from 3% to 0.2%, increasing client’s product premium by 25%.
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