Customer: A leading calcium carbonate producer in Shandong, China
Material: Precipitated Light Calcium Carbonate (PCC)
Feed Material: 300 mesh (approx. d97 ≈ 45–50 μm)
Machine Model: Epic Powder HTS200 Turbo Air Classifier (single-rotor version)
Production Date: November 2025
Objective
The customer required precise separation of 300 mesh light calcium carbonate into two products:
- Ultra-fine powder: d97 ≤ 5 μm (for high-end coatings and plastics applications)
- Coarse fraction: d50 ≈ 15 μm (to be sold as a mid-grade filler or returned to the mill)
Solution & Equipment
After on-site testing at Epic Powder’s test center and subsequent factory-scale trial, the customer selected the HTS200 air classifier.
Key Operating Parameters:
- Rotor speed: 4800–5200 rpm (fine adjustment according to real-time PSD)
- Secondary air volume: 15–18%
- System fan frequency: 45 Hz
- Feeding rate: Stable at 120 kg/h
Results Achieved (Third-party laser particle size analysis report)
| Product | d50 (μm) | d97 (μm) | Yield | Remarks |
|---|---|---|---|---|
| Fine Powder | 2.85 | 4.78 | ~58–62% | Excellent whiteness and dispersion |
| Coarse Powder | 15.30 | 38.5 | ~38–42% | Clean cut, minimal fines entrainment |
Particle Size Distribution Highlights:
- Fine powder: d10 = 1.32 μm, d50 = 2.85 μm, d97 = 4.78 μm → Narrow distribution, steep curve
- Coarse powder: Almost zero particles below 6 μm → Extremely low fine powder loss into coarse fraction
Customer Benefits
- Single-pass classification achieved d97 = 4.78 μm at 120 kg/h capacity, exceeding the original target of d97 < 5 μm
- Fine powder yield reached 60% on average, significantly increasing the proportion of high-value sub-5-micron product
- Coarse powder can be directly packaged and sold as 800–1000 mesh grade, creating an additional revenue stream
- Compared with the customer’s previous imported classifier, energy consumption reduced by ≈22% at the same capacity
- System runs stably for 24-hour continuous production with almost no need to clean the rotor
Customer Feedback
“Epic Powder’s HTS200 air classifier perfectly met our requirement of turning ordinary 300 mesh light calcium carbonate into high-value 4–5 μm ultrafine powder. The cut is sharp, the capacity is real (120 kg/h verified), and the fine powder ratio is much higher than our previous equipment. This machine has directly improved our product structure and profitability.”
This successful case has now become one of Epic Powder’s benchmark projects for sub-5-micron light calcium carbonate classification in China.
Epic Powder – Turning Ordinary Calcium into Extraordinary Value
