Precision Grinding and Separation Units for Gypsum Plants
Base gypsum that has undergone the calcination (firing) process must be processed to specific micron (fineness) values so that it can be used as end products—such as plaster, satin plaster, or joint filler—in the construction and building chemicals industry. In this stage—which consumes the most energy in the plant and directly determines product quality—smooth surface quality and the correct setting time depend entirely on the proper grinding and classification of the particles.
At IPS Makina, we design Grinding and Separation Units that operate in a closed-loop system, are fully automated, and maximize energy efficiency. Tailored to your required capacity and target particle size distribution (PSD), these units enable you to produce high-quality end products while minimizing your operating costs.
This critical unit, which determines the quality of your facility, consists of three main technological stages that work in perfect harmony:
1. High-Performance Grinding Systems (Grinding)
This is the section that performs the unit’s most labor-intensive work, where material fed in a controlled manner from the calcined gypsum silo is ground to the desired micron size. The grinding process is not merely about breaking down the material, but about achieving the optimal fineness while maintaining the targeted particle structure.
- Heavy-Duty Construction: Depending on the plant’s capacity, pendulum-type or high-speed hammer mill systems are used. The grinding balls, liners, and hammers inside the mill are manufactured from special alloy steel castings that offer extra resistance to the abrasive effects of gypsum.
- Optimal Energy Consumption: Thanks to the special rotor and grinding chamber design, the mechanical energy expended to crush the material is used most efficiently, reducing the electricity cost per metric ton.
- Continuous Feeding Automation: Frequency-controlled (inverter-driven) feed screws adjust the material flow second by second by reading the mill’s instantaneous load status. This prevents the mill from clogging or wasting energy by running idle.
2. Dynamic Separator Systems (Separation )
- Flawless Separation: The dynamic separator operates using the centrifugal force of its internal rotor and the principle of air classification. Light particles of the desired fineness are carried by the airflow into the cyclones, while heavy and coarse particles that have not reached the required fineness are pushed by the rotor and returned to the bottom of the mill for re-grinding.
- One-Touch Product Changeover: The rotation speed of the separator rotor can be adjusted via the PLC automation screen. This allows for a transition—for example, from producing coarse-grained plaster to very fine-grained satin plaster—in a matter of seconds, without stopping the machine or making mechanical adjustments.
- Homogeneous Particle Distribution: By 100% preventing unwanted coarse particles from mixing into the final product, it ensures perfect consistency in your construction chemical formulations.
3. Jet Pulse Filter Systems (Environmental Control and Recovery)
The grinding and separation process is carried out entirely using closed-loop pneumatic (air-conveyed) systems. At this stage, the filter system is the most critical piece of equipment for preventing very fine (micronized) gypsum dust—which cannot be separated from the air—from being released into the environment and for recovering the product.
- Zero Dust Emissions: Bagged jet pulse filters capture and trap even the finest dust particles that escape from separators and cyclones using high suction power. They keep the facility’s emission levels below international environmental standards (CE, ISO).
- 100% Product Recovery: These valuable, fine micron-sized particles, which adhere to the filter bags, are shaken off using pressurized air pulses (jet pulses) and returned directly to the final product line. The facility’s raw material waste is reduced to zero.
- Clean Factory Floor: It creates a clean, safe, and healthy working environment within the factory and prevents other mechanical and electronic equipment from malfunctioning due to dust.
