Case Study: Sivtek Tumbler Screen Doubles Quartz Production
Industry Overview: Quartz and Its Applications
Quartz is an essential mineral used across a broad range of industries, from electronics and optics to ceramics and glass production. Its versatility and unique properties, such as high hardness and resistance to chemical wear, make it highly sought after in various fields, including the production of precision instruments, solar panels, and semiconductor devices.
In industries like these, achieving the right particle size of quartz is crucial for ensuring optimal product quality. Manufacturers often face challenges when attempting to sieve quartz with precision, especially when dealing with fine particles.
Challenges
Our client, the largest quartz manufacturer, was facing substantial difficulties with their existing screening system. To achieve the desired particle size distribution between 0.4mm and 0.1mm, they were using 12 separate screening machines, each with a throughput capacity of just 1 ton per hour (TPH).
The sheer number of machines in operation led to high energy consumption, increased maintenance costs, and significant downtime. Despite this considerable effort, the manufacturer still struggled to meet production goals, resulting in inefficiency and operational bottlenecks.
Problem Analysis & Solution Implementation
Galaxy Sivtek’s team carefully analyzed the client’s production line and pinpointed inefficiencies in their screening process. After thorough consideration of the client’s needs and challenges, we recommended the Sivtek Tumbler Screen 2000, which is specifically designed for fine particle separation and high throughput.
Galaxy Sivtek Solution: Sivtek Tumbler Screen 2000
The Sivtek Tumbler Screening Machine was introduced as the ideal solution for the client’s needs. This advanced machine utilizes a three-dimensional elliptical tumbling motion, allowing for efficient particle separation with minimal clogging or downtime. It is particularly effective for fine particles like quartz and is capable of handling high-volume processing with precision.
Results Achieved
After installing the Sivtek Tumbler Screen 2000, the client’s production efficiency skyrocketed. They achieved a remarkable 1 TPH throughput with a single machine, effectively doubling their production capacity while reducing the number of machines from 12 to just one.
Key results from the installation:
- Production increased to 1 TPH with one machine, doubling efficiency.
- Screening accuracy reached 99%, ensuring consistent and high-quality product.
- Significant reduction in machine footprint, leading to savings in operational space.
- The client reported a major decrease in power consumption and maintenance costs.
Client Feedback & Benefits
The client’s maintenance team expressed their satisfaction with the Sivtek Tumbler Screen’s performance, noting its reliability and minimal maintenance needs. Additionally, the advanced design of the tumbler screen reduced energy consumption, leading to significant cost savings. The overall return on investment was substantial, as the client saved both time and money on operational and maintenance expenses.
Conclusion:
By implementing the Sivtek Tumbler Screen, Galaxy Sivtek was able to solve the client’s challenges, enhancing production efficiency and reducing operational costs. The installation led to a 50% increase in production capacity, improved product quality, and substantial energy savings, making this a successful and sustainable solution for the largest quartz manufacturer.
Are you ready to revolutionize your quartz processing operations? Contact us today. Our experts are here to guide you through every step of the way, from initial consultation to after-sales support.
