With our plant technology and expertise, we cover almost the entire process chain for manufacturing ceramic products from both silicate ceramic and technical ceramic raw materials. From preparation to qualification of the end product, we focus on the applications and the final properties of the respective product.
powder technology
Grinding
In order to produce high-quality ceramics, the grain size, grain size distribution and grain shape must be optimised using the appropriate grinding units. Due to the variety of grinding units in our technical centre, we are able to grind both hard, brittle and soft, elastic materials. In order to increase the sintering activity, the starting materials are often crushed down to the sub-µm range. The tendency to agglomerate increases with the specific surface area. To counteract this and obtain a finely dispersed powder, we select the appropriate dispersing agents for stabilisation for your application on request.
- Jaw crusher(Fritsch)
- Cross beater mill (Retsch)
- Planetary ball mill (Fritsch)
- Agitator bead mill LMK 4 (Netzsch)
- Agitator bead mill MiniCer (Netzsch)
Homogenisation
In order to achieve the desired product properties and reproducible workability, the prepared working mass must exhibit a uniform and homogeneous structure. As the properties of the ceramic raw materials and therefore also their processing properties differ, it is important to select the appropriate aggregates in each case. The aim is to produce a homogeneous body with a consistent chemical and mineralogical composition.
- Three-roll mill Exakt 80E/0333 (Exakt)
- Eirich mixer RV02-E (Eirich)
- Planetron mixer (Ika)
- Dissolver (Pendraulik)
- Ultra Turax T25, T50 (Ika)
- Double-shaft Z-mixer High-performance kneading mixer (Ika)
- Acoustic Mixer LabRAM II (Resodyn)
- Centrifugal mixer KK-400WE (Kurabo Industries Ltd.)
Granulation
Dry pressing is a widely used moulding process. Granulation can increase the pourability and bulk density of the material and thus improve automated processability. We offer you customised development to produce the optimum granulate for your application. Our systems are available to you for developments on a laboratory and pilot plant scale.
- Pelletising disc TR04 (Eirich)
- Spray dryer (Büchi)
- Spray tower ICF Industrie CIBEC
- Freeze dryer Gamma 2-20 (Christ)
- Micro-jet-reactor (Sythesechemie / Prominent)
shaping
Press moulding
For large quantities and simple geometries, axial dry pressing is the most economical process. More complicated geometries (indentations) can only be realised in the pressing direction. If the production requires machining of the green bodies, cold isostatic pressing is recommended for the production of uniformly compacted blanks. We would be happy to advise you on optimising your pressing process or designing special press dies for the production of your components.
- Hand lever press PW 20 (P.O. Weber)
- Cold isostatic press (EPSI)
Plastic moulding
Plastic moulding processes are suitable for the mass production of complex shaped parts. We have a wealth of experience in the extrusion of ceramic bodies and support the development of both silicate ceramic and technical ceramic components. We also offer you our expertise in the field of thermoplastic moulding. Whether injection moulding at low pressure (hot moulding) or high pressure, we are your cooperation partner from the preparation and characterisation of thermoplastic bodies through to moulding.
- Torque rheometer PolyLab OS (Haake)
- Vacuum extrusion press VAR 50A/50 (ETC Händle)
- Vacuum extrusion press VARQ 50A (ETC Händle)
- Hot casting machine, low-pressure injection moulding, GC-MPIM-2-MAX (Goceram)
- Hot casting machine, low-pressure injection moulding, MIGL 33 (Peltsmann)
- Injection moulding machine Allrounder 270 C (Arburg)
Casting
Casting processes are suitable for the production of samples with complex geometries (hot or injection moulding) or very thin, flat components (film casting). Our expertise ranges from conventional slip casting of silicate ceramic products to hot casting or film casting of technical ceramics. We develop the process for your product and support you from the development of the slip or mass through to the optimised casting process.
- Foil casting plant
- Ceramic slip casting
Additive manufacturing
Additive manufacturing processes are regarded as future-oriented cross-sectional and key technologies for almost all industries. The market potential is estimated to be correspondingly high. A major advantage of these processes is that production can be customised to customer requirements and at the same time be cost-effective.
- Lithography based Ceramic Manufacturing CeraFab Multi 2M30 (Lithoz GmbH)
- Composite Extrusion Modelling ExAM 255 (Aim3D GmbH)
- Material Extrusion Delta WASP 40100 Clay (CSP s.r.l.)
thermal process technology
Drying
Drying ceramics is a fundamental part of the ceramic process. Drying should be controlled in order to ensure homogeneous shrinkage and thus avoid subsequent stresses and cracks in the component. We offer you the plant technology for this and advise you on accompanying analytical measures.
Debinding and sintering
The technical systems include numerous chamber furnaces, high-temperature furnaces and various debinding furnaces, also with thermal post-combustion. In the high-temperature furnaces, temperatures of up to 1950 °C can be realised in different atmospheres (static air, dynamic air, vacuum, argon, hydrogen, nitrogen, mixed gases). We are therefore able to adapt to your individual requirements and wishes and develop the optimum sintering parameters for your product.
- Debinding furnace KS 80/S (Linntherm)
- Debinding furnaces L 9/11 BO, L 40/11 BO (Nabertherm)
- Electric chamber furnaces (Nabertherm)
- Chamber furnace N20/HR (Nabertherm)
- Gradient furnace Labotherm GR 1300/14S (Nabertherm)
- High-temperature furnace FHT 1750 u. 1800 (Ceram Aix)
- High-temperature furnace LHT 04/17 (Nabertherm)
- Elevator furnace ELT 1750 (Ceram Aix)
- Protective gas furnace (Ceram Aix)
- High-temperature vacuum furnace LHTW 150-150/20 2G (Gero)
Hot isostatic pressing (HIP)
With our HIP system, ceramics can be hot isostatically post-compressed at up to 2000 °C and 3000 bar. This process technology is mainly used in the field of technical, medical and optical high-performance ceramics. Pressurisation supports the diffusion processes in the material, enabling ceramics with very high densities, fine-grained structures and isotropic properties to be achieved.
- Hot isostatic press (EPSI)