Customer Challenges: Limited Value from Raw Calcium Carbonate

Located in Minya City, Egypt, the customer owned a large deposit of natural calcium carbonate. However, selling unprocessed or coarsely ground material on the market brought only low returns and limited market demand. Without the capability to produce high-grade fine powder, the customer was unable to tap into higher-value downstream industries such as plastics, rubber, coatings, and construction — all of which require finely ground or surface-treated calcium carbonate as functional fillers.

Customer Needs: Upgrade Material, Increase Value
To break out of the commodity trap and increase the profit margin, the customer was seeking a reliable, efficient, and cost-effective grinding solution. The goal was to produce ultra-fine calcium carbonate powder (D97 5–45µm), with part of it coated for applications requiring improved dispersion and surface performance.

Key requirements included:

Stable production of 8–10 micron D97 powder

Surface modification system for added product value

Energy-efficient operation

Easy maintenance and long-term reliability

After evaluating multiple equipment suppliers, the customer connected with Daswell Machinery, attracted by our specialization in non-metallic mineral processing solutions. They appreciated our track record in building turnkey calcium carbonate grinding plants across the Middle East and Asia.

Daswell Solution: Tailored Grinding + Coating System

After careful evaluation of the customer’s material, product goals, and factory layout, Daswell engineers proposed a Grinding Mill and Vortex Mill Coating Machine, capable of producing consistent fine powder with optional surface treatment. The system was designed for high output, minimal downtime, and optimal energy efficiency.

Final Production Line Delivered

The final production line included:

Φ2.2×5.5m Ball Mill – for efficient fine grinding

AMS10003 Air Classifier – for precise particle size control

XMC70-7 Bag Dust Collector – for clean and safe operation

Vortex Mill Coating Machine – for added functionality and product performance

This configuration enables the production of:

D97 10µm powder at 2.8–3.1 tons/hour

D97 8µm powder at 2.2–2.4 tons/hour

Delivery, Installation & Commissioning

Daswell coordinated the entire shipment and installation process, including mechanical setup, electrical wiring, trial runs, and operator training. Our engineers were dispatched to Egypt to ensure smooth commissioning and fine-tuning of the system.

Despite the remote location and multi-stage process, the project was delivered on time and met the performance expectations from the very first test run.

Customer Feedback: “Perfect“

The customer summarized their experience in a single word: “Perfect.”
From equipment quality to on-site service and final product performance, every step matched or exceeded expectations. The new production line has already helped the customer gain access to higher-value clients in filler and polymer-based industries, while boosting their overall profitability.

Why Choose Daswell for Calcium Carbonate Grinding?

Daswell Machinery is a trusted partner in calcium carbonate processing, offering full-line solutions from grinding and classification to coating and packaging.

• Decades of experience in mineral grinding
• Proven cases across Asia, Africa, and Latin America
• Customized system design
• Stable output with narrow particle distribution
• Local service teams and long-term technical support

Looking to Maximize Product Value and Profit?

Whether you’re a mine owner, mineral processor, or chemical producer, turning raw calcium carbonate into fine or coated powder can significantly increase your product’s market value and profit margin.

Daswell offers complete grinding solutions tailored to your needs.

Contact us today to explore how we can help you transform materials into revenue.

Related Products

Ball Mill

Production capacity: 1-500,000 tons/year
Raw materials: calcium carbonate (calcite, marble, limestone, chalk), etc.

Vortex Mill Coating Machine

Max. Capacity(t/h): 2-6
10μm GCC(t/h): 1.4-5

Ring Roller Mill

Feeding size: 0-10mm
Discharging size: 5-45μm

Key requirements of our Tanzanian customer

Precision particle size control: The client needs production of D97 10 micron and 8 micron calcium carbonate powder.

Wide application range: They want to have a production line, which has ability to produce 5-45 micron D97 powder for versatile use in plastic, paints, and coatings.

Required solution: Want to have a fully integrated system from crushing to surface coating. And the production line should make sure consistency and minimal downtime.

Daswell solution and production line Recommendations for Tanzanian Customer

Daswell recommends a calcium carbonate milling and coating plant for our Tanzanian client. This deployed system combines crushing, grinding, classification, and coating technologies to deliver exceptional performance:

Crushing plant: This system can pre-process raw calcium carbonate into optimal feed size for efficient grinding.

Ball mill grinding(2.2*5.5m): The ball mill grinding machine ensures high-capacity fine grinding with low energy consumption.

ASM10003 classifier: It achieves precise particle size distribution(D97 8-45 microns) with high yield and minimal oversize.

XMC70-7 bag dust filter: The dust filter enhances environmental compliance by capturing 99.9% of dust emissions.

UCOAT750 coating plant: This vortex mill coating machine provides uniform surface modification for improving the compatibility in masterbatch applications.

Production capacity: Produce D97, 10 Micron about 2.8-3.1ton/hour and 8 micron with 2.2-2.4ton/hour.

Key advantages of Daswell calcium carbonate milling and coating plant

Daswell calcium carbonate milling and coating plant helps the client establish a future-proof production line successfully. Our client can produce high-quality calcium carbonate fillers. And it also caters to global masterbatch and polymer industries. This milling and coating plant gets a good reputation from our customer. If you want to get a milling and coating line, send an inquiry to us.

Related Products

Ball Mill

Production capacity: 1-500,000 tons/year
Raw materials: calcium carbonate (calcite, marble, limestone, chalk), etc.

Vortex Mill Coating Machine

Max. Capacity(t/h): 2-6
10μm GCC(t/h): 1.4-5

Daswell technical experts designed a production line for them. The production line includes ball milling, classifier, dust collector and coating equipment.

Ball mill grinding system: 2.2*5.5m ball mill machine. It is applicable for efficient raw material crushing.

High-precision classifier: The AMS10003 classifier ensures accurate particle size separation.

Dust control: XMC70-7 bag dust filter maintains a clean working environment.

Coating plant: We utilize vortex mill coating machine for enhancing product quality for various industrial uses.

Key advantages of Daswell calcium carbonate grinding and coating plant

Daswell sent our engineer to the working site in Minya, Egypt, helping our customer install the machines. And we have trained their workers for operating the whole production line safely and smoothly. Meanwhile, we also provided some tips for maintenance. Our customer said that our production line is perfect for their calcium carbonate processing. They confirmed the system delivers exceptional output, precise particle control, and smooth operation. It is an ideal solution for calcium carbonate processing in Egypt.

If you are looking for a set of ultra-fine calcium carbonate powder production plant with high-yield, low consumption, and environmental compliance, contact Daswell now for getting your own solution!

Related Products

Ball Mill

Production capacity: 1-500,000 tons/year
Raw materials: calcium carbonate (calcite, marble, limestone, chalk), etc.

Vortex Mill Coating Machine

Max. Capacity(t/h): 2-6
10μm GCC(t/h): 1.4-5

What machines did our Egypt customer purchase for the second silica and feldspar powder making plant?

It mainly includes:

Ball mill machine: 2.4x8m ball mill grinding machine

Classifier: ASS830 single wheel classifier, which is 400mm diameter

Dust Collector: SMC70-6 bag dust collector

Production Capacity: It can produce 38 micron about 3.2 tons per hour, 45 micron 3.8 tons per hour, 100 micron 5.8 tons per hour.

This system ensures high-precision classifications and consistent output quality, making it ideal for ceramic and industrial applications.

Why did our Egyptian customer choose Daswell again?

Choosing Daswell Machinery, our customer get stable production and high efficiency. It ensured a reliable supply for their ceramic factory clients. Meanwhile, the high efficiency and high quality of Daswell quartz processing plant, reduced the energy waste and maintenance costs.

If you have interests on Daswell powder grinding plant, please contact our team now! We can offer you professional solutions as you required.

Related Products

Ball Mill

Production capacity: 1-500,000 tons/year
Raw materials: calcium carbonate (calcite, marble, limestone, chalk), etc.

Poor classifier design: The classifier wheel has been worn because of inadequate protection against abrasive silica powder.

Low productivity: The system layout was inefficient. The classifier and dust collector were misaligned, wasting energy and reducing capacity.

Frequent downtime: The processing machines had poor quality, so they should repair the machine constantly.

Daswell Solutions: Engineered for Durability and Efficiency

After evaluating Daswell’s proven track record in recent years, our customer decided to partner with us for upgrading their production line. Our technical experts designed a new plant for their manufacturing. The main equipment included:

Ball Mill Grinding Machine: 2.2*7.5m Ball mill plant

Classifier: ASS630 classifier

Dust Collector: XMC60-4 dust collector

What are the advantages of Daswell ball mill grinding plant?

Daswell delivered and installed the whole grinding line in Egypt in August 2013. Using Daswell ball mill grinding plant with classifier for silica and feldspar powder, the production capacity is 200% higher. They can produce 150 micron powders 6.5 tons per hour. Moreover, the high-quality classifier reduces 70% the maintenance costs. And the streamlined design also reduces power waste, saving more energy.

As China’s leading grinding solution provider for silica and feldspar, Daswell can offer proven designs, end-to-end customization, and premium components. We have installed lots of grinding lines all over the world. For your different powder applications, we can customize your own grinding machines and plants configurations. And the durability components ensure your production efficiency and reduce your maintenance costs.

Contact Daswell team for getting your own powder grinding plant now!

Related Products

Ball Mill

Production capacity: 1-500,000 tons/year
Raw materials: calcium carbonate (calcite, marble, limestone, chalk), etc.