Client background

The client, an established building materials company in Brazil specializing in tile adhesives and other dry mortar products, planned to build a new specialized factory for tile adhesive production.

The client already owned standard mortar production line but lacked experience in specialty mortar products.

Client’s needs

Tile adhesive production rate: 150,000 t / year
The products cover multiple performance classes such as C1 and C2.
Highly-automated production
Sustainable manufacturing meeting environment standards

Challenges

The small quantities (1-5%) of additives (dispersible polymer powder, cellulose ether, etc.) require high-precision dosing.
Fibrous materials have a low relative density and tend to agglomerate, and are difficult to mix and disperse uniformly.
The properties differences in sand and cement from different regions require localized equipment configurations.
Quick product/material changeover leads to contamination.

Solutions

Huangang provided complete turnkey solutions.

For micro-additives, a loss-in-weight micro-dosing system can achieve dosing accuracy of up to ±0.1%.
The mixing system combines ploughshare mixer with high-speed choppers to effectively disperse fibers.
Mixing uniformity (CV) is less than 5%.
Automatic PLC control that supports storage of multiple recipes and one-tap changeover.
The configurations are localized based on material properties; Electric control and HMI are following local standards.
Auxiliary Systems：The product silo features anti-segregation design; The pulse-jet bag filter dust collector ensures minimum dust emission(≤10mg/Nm³) ; automatic valve bag packaging machine

Results

The completed production line achieved production rate of 150,000t/year for tile adhesive production, constantly meeting the market demand in Brazil.
Mixing uniformity( CV):≤5%; All key indicators such as adhesive strength and water retention meet the standards.
The automatic operation only requires 3-4 operators.
Dust emissions meet local standards.
The payback period is expected to end within 2 years.

According to the client’s feedback, Huangang provides more than just standard equipment. Instead, we offers complete solutions tailored to solving real problems, from precise dosing to uniform mixing. We take every step into consideration.