1. PAINPOINT DRIVEN OPENING

Are you managing grinding operations where inconsistent product fineness leads to rejected batches? Are unscheduled maintenance stops for liner changes and bearing failures causing costly production halts? Do your energy costs for milling consume an unsustainable portion of your operational budget? Each hour of unplanned downtime and each percentage point of energy waste directly erodes your plant's profitability. How can you achieve precise particle size control while extending operational campaigns and reducing total cost of ownership? The solution lies in selecting a white label ball mill engineered not just to grind, but to optimize.

2. PRODUCT OVERVIEW

This product is a white label industrial ball mill, a robust piece of mineral processing and grinding equipment designed for continuous or batch operation. Its core function is the reduction of material particle size through impact and attrition.

Operational Workflow:
1. Feed Introduction: Raw or precrushed material is fed into the mill's inlet trunnion.
2. Grinding Chamber Action: The chamber, partially filled with grinding media (steel or ceramic balls), rotates. Lifter bars elevate the media and charge, which then cascade and tumble, fracturing the material.
3. Size Classification & Discharge: Ground material travels through the mill; finer particles exit via discharge grates at the opposite end, while coarser material remains for further comminution.

Application Scope: Ideal for grinding ores, cement clinker, silicates, fertilizers, and other industrial minerals in secondary and tertiary stages. Suitable for both wet and dry grinding processes.

Limitations: Not designed for primary crushing of large feed stock. Optimal efficiency requires proper feed size control and appropriate selection of media type/size.

3. CORE FEATURES

Modular Shell & Liner System | Technical Basis: Bolton, segmented highchrome or manganese steel liners | Operational Benefit: Enables rapid replacement of worn sections during planned maintenance stops, minimizing downtime by up to 40% compared to welded systems. | ROI Impact: Reduces labor costs for liner changes and increases mill availability for production.

Precision Trunnion Bearing Assembly | Technical Basis: Engineered hydrodynamic or roller bearings with integrated sealing solutions | Operational Benefit: Provides reliable support under high dynamic loads, preventing catastrophic failure and reducing vibrationrelated stress on the gearbox. | ROI Impact: Extends bearing service life, cutting replacement part costs and preventing associated production losses.

Variable Frequency Drive (VFD) Integration | Technical Basis: Direct control of motor speed and torque via solidstate power conversion | Operational Benefit: Allows operators to finetune mill speed for optimal cascading action based on charge volume and desired grind, improving specific energy consumption. | ROI Impact: Field data shows potential for 515% energy savings versus fixedspeed drives across variable load conditions.

Optimized Discharge Grate Design | Technical Basis: Computermodeled aperture geometry and wear profile | Operational Benefit: Ensures efficient expulsion of ground material while retaining grinding media, maintaining a consistent charge level and preventing overgrinding. | ROI Impact: Contributes to stable product fineness (P80) and reduces media consumption.

Centralized Lubrication System | Technical Basis: Automated, programmable greasing points for pinion gear and trunnions | Operational Benefit: Delivers precise lubricant amounts at scheduled intervals, eliminating manual greasing errors and ensuring critical surfaces are protected. | ROI Impact: Lowers risk of premature wear on highcost components like girth gears.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | This White Label Ball Mill Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Change Downtime | 2436 hours per full change | 1624 hours with modular system | ~33% faster |
| Specific Energy Consumption (kWh/t) | Baseline = 100% (varies by material)| Optimized via VFD & charge dynamics| Up to 12% reduction achievable |
| Operational Availability (Annual) | ~9294% (including planned stops)| Target >95% through reliability design| 13 percentage point increase |
| Media Consumption (g/t) | Materialdependent baseline| Reduced by controlled discharge & liner profile| 510% improvement typical |

5. TECHNICAL SPECIFICATIONS

Capacity Range: From pilotscale (50L) to industrial production models up to 20,000L effective volume.
Power Requirements: Motor ratings from 15 kW to 2500+ kW, compatible with global voltage standards (380V10kV). VFD is recommended.
Material Specifications:
Shell: Fabricated from rolled mild steel plate.
Liners: Highchrome cast iron (27% Cr), Manganese steel, or rubber options.
Media Options: Forged/highcarbon steel balls; ceramic balls available.
Physical Dimensions: Customengineered per capacity; drive configuration can be central or girth gear & pinion.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dusttight construction available for dry milling applications.

6. APPLICATION SCENARIOS

MidSized Copper Concentrator Plant

Challenge: The existing ball mill circuit produced inconsistent grind size, impacting flotation recovery rates. Energy costs were exceeding forecasts due to inefficient load management.
Solution: Implementation of a white label ball mill with VFD control and optimized discharge grates tailored to the ore's abrasion index.
Results: Achieved a more stable P80 grind size (±5 micron variance), contributing to a 2% increase in copper recovery. The VFD enabled loadbased power adjustment, yielding an 8% reduction in specific energy consumption.

Industrial Minerals Producer Calcium Carbonate

Challenge: Frequent downtime for liner changes in a dry grinding application was disrupting justintime delivery schedules to paint manufacturers.
Solution: Installation of a white label ball mill featuring a quickchange modular liner system designed for abrasive dry materials.
Results: Liner replacement time decreased from 32 hours to 20 hours per event. This increased annual plant availability by approximately 60 hours, allowing fulfillment of tighter delivery windows without expanding inventory holding costs.

7. COMMERCIAL CONSIDERATIONS

Our white label ball mills are offered in clear pricing tiers based on drum diameter, drive power, and material specification:

1. Standard Tier: Core mill assembly with standard liners and bearings.
2. Performance Tier: Includes VFD drive system, upgraded highchrome liners, centralized lubrication.
3. Custom Tier: Engineered solutions with specific dimensions, special coatings/liners (e.g., alumina brick), or fully integrated control systems.

Optional features include advanced condition monitoring sensors (vibration,temperature), automated lubrication systems extended beyond standard points,and custom paint/finish specifications.Service packages range from basic commissioning support to comprehensive multiyear maintenance agreements with guaranteed parts availability.Financing options including leasing structures are available through partners to assist with capital expenditure planning.

8.FAQ

Q1:What level of technical support is provided during commissioning?
A dedicated project engineer will supervise installation alignment provide operational training for your crew,and assist with initial performance tuning against your specified benchmarks

Q2 Can this white label ball mill integrate with our existing PLCbased plant control system?
Yes.The drive system can be configured with standard communication protocols(Profibus Modbus TCP/IP )to allow remote start/stop speed monitoring,and alarm integration into your central control room

Q3 What is the typical lead time from order placement to delivery?
Lead times vary by model complexity.For standard configurations in our Performance Tier lead times typically range from weeks depending on current manufacturing capacity

Q4 How does the operational noise level compare?
With properly maintained girth gear enclosures precisioncut gearing,and stable bearing assemblies industry testing demonstrates external noise levels typically remain below dB(A) at one meter meeting common workplace regulations

Q5 Are performance guarantees offered?
Yes.We provide mechanical performance guarantees covering workmanship materials Additionally we can collaborate on process performance guarantees based on agreedupon feed specifications test conditions

Q6 What are the key factors in determining optimal liner material selection?
The choice between highchrome manganese steel rubber depends primarily on your application's abrasiveness impact characteristics corrosion potential( wet grinding )and desired service life versus initial cost Our engineers will analyze your operating data make a recommendation

Q7 Is operator training included?
Comprehensive training covering safe operation routine maintenance checks troubleshooting common issues basic liner inspection procedures is included as part of every commissioning package Documentation includes detailed operation maintenance manuals