As India’s industrial sector continues its rapid expansion, the demand for high-quality refractory materials and the equipment to produce them has never been greater. This case study highlights the successful application of the CO-NELE CMP series castable mixer at a leading refractory product manufacturer in Gujarat, India.
The Customer’s Challenge:
Our client, a well-established refractory company in India, faced significant challenges with their existing mixing equipment. Their old mixer struggled with achieving a consistent, homogenous mix for high-grade low-cement and ultra-low-cement castables. Issues included:
* Inconsistent Mix Quality: Leading to variable setting times and compromised end-product strength.
* Material Lumping: Inefficient mixing action caused clay and binder agglomeration.
* High Maintenance Downtime: Frequent breakdowns were disrupting their production schedule.
* Inefficient Operation: The mixing process was time-consuming and labor-intensive.
The CO-NELE Solution:
After a thorough evaluation of several international brands, the customer selected four CO-NELE CMP750 refractory castable mixers. The key deciding factors were:
* Advanced Mixing Principle: The unique combination of a rotating pan and high-speed counter-rotating stars ensures a violent yet precise cutting and shearing action. This is ideal for breaking down lumps and coating every aggregate particle evenly with binders.
* Robust Construction: Built with high-strength steel and wear-resistant linings, the mixer is designed for the tough abrasive nature of refractory materials.
* Programmable Logic Control (PLC): The automated system allows for precise control of mixing time, speed, and sequence, guaranteeing batch-to-batch consistency.
* Ease of Maintenance: The simple yet durable design minimizes wear parts and allows for quick cleaning and servicing.
Results and Benefits:
Since the installation of the CO-NELE CMP mixer, the customer has reported outstanding results:
* Uniform Mix Quality: Every batch is perfectly mixed, resulting in a notable improvement in the density and strength of their cured refractory castables.
* Increased Productivity: Mixing cycles are up to 40% faster, significantly boosting their daily output.
* Reduced Material Waste: The highly efficient mixing action ensures virtually no leftover unmixed material, maximizing yield.
* Low Operational Cost: Reduced energy consumption, minimal maintenance requirements, and no need for constant operator intervention have drastically lowered operating expenses.
* Enhanced Reputation: The ability to reliably produce superior quality refractories has strengthened their market position.
Customer Feedback:
*”We are extremely satisfied with the performance of our CO-NELE mixer. It has become the core of our production line. The mix quality is exceptional and consistent, which directly translates to better products for our clients. The machine is robust, and the support from the CO-NELE team has been excellent.”*
— Production Manager, Indian Refractory Company
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Post time: Aug-23-2025
