Automation of deflocculant application in a discontinuous grinding ceramic industry

Abstract

The ceramic industry constantly seeks efficient processes, focusing on automation and solutions that make production stages agile and standardized. Many factories with older structures face practical challenges in adopting fully automated systems, especially due to physical and layout limitations that make the installation of modern equipment unfeasible. In these situations, part of the production process remains under the responsibility of operators, as is the case with the dosing of additives used in slurry preparation. As a manual activity, this stage is subject to a series of variations, both due to the difficulty of ensuring precision in the dosed amount and the difference in criteria among the professionals involved. This compromises process standardization and results in instability in slurry parameters, such as viscosity, density, and residue content. These fluctuations directly affect the performance of the production process and the final quality of the ceramic product, requiring frequent rework and adjustments. The constant repetition of this task, combined with the inadequate posture required in many situations, favors the emergence of occupational injuries. In this context, the automation of water and deflocculant addition in discontinuous mills represents a promising alternative, applicable even in plants with structural limitations. Automation ensures dosing repeatability, reduces losses caused by manual adjustments, and contributes directly to the consistency of the ceramic suspension. This improvement impacts slurry stability and process efficiency. Investing in automated solutions, even partially, brings gains in quality, productivity, and operational safety, benefiting the entire production system and generating concrete results for the ceramic industry