Maximize Efficiency and Output with the Calisum Bentonite Processing Machine
Engineered for High-Performance Industrial Mineral Processing
Are You Struggling with Inconsistent Bentonite Quality and High Operating Costs?
In mineral processing and industrial manufacturing, inconsistent raw material quality leads to downstream inefficiencies—poor pellet strength, unreliable rheological performance, and unplanned downtime. For operations relying on high-purity bentonite for foundry sands, drilling muds, or pelletizing applications, variability isn’t just a nuisance—it’s a profit killer.
Traditional bentonite processing systems often lack precision in grinding, activation, and drying control. The result? Suboptimal yield, increased energy consumption, and frequent maintenance. Plant managers and engineering contractors need a solution that delivers consistent product quality while reducing total cost of ownership.
Enter the Calisum Bentonite Machine—a fully integrated processing system engineered for reliability, scalability, and superior output quality in demanding industrial environments.
What Is the Calisum Bentonite Machine—and How Does It Work?
The Calisum Bentonite Machine is a modular, turnkey system designed to process raw bentonite ore into high-activity sodium or calcium-activated bentonite powder. Built for continuous operation in mining, construction materials, and metallurgical support industries, it combines crushing, grinding, activation (ion exchange), drying, and classification into one seamless workflow.
Processing Workflow:
- Primary Crushing – Jaw or hammer crusher reduces lump ore (up to 300 mm) to ≤25 mm.
- Grinding & Milling – Vertical roller mill or ball mill achieves fine particle size (D90 ≤45 µm).
- Activation System – Optional sodium carbonate dosing module enables precise ion exchange for enhanced swelling capacity.
- Flash Drying – High-efficiency rotary or pneumatic dryer reduces moisture from ~12% to ≤8%.
- Air Classification – Dual-stage classifier ensures tight particle size distribution.
- Pneumatic Conveying & Packaging – Automated bulk loading or bagging line integration.
All stages are monitored via PLC control with real-time feedback on moisture content, fineness (Blaine), and throughput—ensuring batch-to-batch consistency critical for industrial buyers.
What Sets the Calisum Apart from Conventional Systems?
Unlike fragmented setups requiring multiple vendors and complex integration, the Calisum Bentonite Machine is a purpose-built system optimized for performance metrics that matter most: uptime, energy efficiency, and product specification adherence.
| Feature | Calisum Bentonite Machine | Standard Competitor Systems |
|---|---|---|
| Integrated Design | Fully engineered single-source solution | Multi-vendor components requiring field integration |
| Energy Consumption | 38–42 kWh/ton (average) | 50–65 kWh/ton |
| Activation Precision | ±1.5% Na₂CO₃ dosing accuracy | Manual or open-loop control (±5–8%) |
| Downtime (MTBF) | >700 hours mean time between failures | ~400–500 hours |
| Automation Level | Full SCADA + remote diagnostics | Basic PLC with local HMI only |
| Maintenance Access | Modular panels & quick-release couplings | Fixed housings; longer service intervals |
Backed by finite element analysis (FEA) structural design and corrosion-resistant alloys in high-wear zones (e.g., mill liners, cyclones), the Calisum delivers long-term durability even in abrasive feedstock environments..jpg)
How Does It Perform Under Real-World Conditions?
Technical Specifications
| Parameter | Specification |
|---|---|
| Feed Size | Up to 300 mm lump ore |
| Final Product Size | D90 ≤45 µm (adjustable) |
| Capacity Range | 3–25 TPH (configurable modules) |
| Moisture Reduction | From 12% to ≤8% |
| Power Requirement | 220–1250 kW (depending on model) |
| Activation Option | Sodium carbonate injection system (optional) |
| Control System | Siemens S7-1500 PLC + WinCC SCADA interface |
| Construction Materials | Wear-resistant steel (NM400), stainless steel ducting |
| Emissions Compliance | Meets EU Stage V / EPA Tier 4 standards |
Available in skid-mounted or fully site-assembled configurations. Scalable from pilot plant (3 TPH) to full-scale production lines (25 TPH+)..jpg)
Where Is the Calisum Being Used Successfully?
Case Study: Iron Ore Pelletizing Plant – Northern Sweden
A major European iron ore processor faced inconsistent bentonite performance affecting pellet drop strength and furnace efficiency. Their legacy grinding line produced variable fineness (+/-12%) and required daily recalibration.
After installing a Calisum 12 TPH system:
- Product fineness stabilized at D90 = 42 µm ±3%
- Sodium activation uniformity improved swelling capacity by 18%
- Energy use dropped from 61 kWh/ton to 41 kWh/ton
- Annual maintenance costs reduced by €78K due to predictive monitoring
“The integration was seamless—we were at full production within five days of commissioning.”
— Senior Process Engineer, Mining Division
Case Study: Drilling Mud Supplier – Gulf Coast USA
A contractor supplying bentonite-based drilling fluids needed higher yield per ton of raw ore. The Calisum’s precision drying module reduced over-drying losses while maintaining API fluid loss specs.
Results:
- Yield increased from 86% to 93%
- Customer rejection rate fell from 4% to <0.7%
- Payback achieved in 14 months
What Are Your Investment Options?
We offer flexible acquisition models tailored to capital planning cycles:
| Option | Details |
|---|---|
| Direct Purchase | Fixed-price turnkey delivery; includes installation supervision and commissioning support |
| Lease-to-Own Program | Structured over 36–60 months with fixed rates; includes scheduled maintenance packages |
| Performance-Based Financing* | Payments tied to verified output metrics (e.g., tons processed/month); ideal for EPC contractors |
*Available for qualified buyers with documented project revenue streams.
All systems include:
- Two-year comprehensive warranty
- Remote diagnostics package
- Operator training program
- Spare parts kit (first year recommended inventory)
Frequently Asked Questions
Can the Calisum process both sodium and calcium bentonite?
Yes. The machine is configured at build stage for either natural calcium-bentonite upgrading or sodium-bentonite enhancement via controlled soda ash dosing. Conversion between types requires reprogramming only—no hardware changes.
How much space does it require?
Footprint varies by capacity:
- 3–6 TPH: ~25 m × 8 m
- 10–15 TPH: ~38 m × 12 m
- 20–25 TPH: ~50 m × 14 m
Modular design allows phased installation if space is constrained.
Is operator training included?
Yes. Each order includes an on-site five-day training program covering safety protocols, routine maintenance, troubleshooting trees, and SCADA navigation. Training materials are provided in English with optional translation upon request.
What kind of after-sales support do you offer?
Global technical support via dedicated service portal with:
- Real-time alarm monitoring
- Digital twin simulation for fault diagnosis
- Priority spare parts dispatch network (>95% availability)
Support available in English, Spanish, Russian, Mandarin, and Arabic.
Can it integrate with existing plant control systems?
Yes. Standard communication protocols include Modbus TCP/IP, Profibus DP, and OPC UA compatibility for integration into central DCS or MES platforms.
The Calisum Bentonite Machine isn’t just another grinder—it’s a complete industrial solution built for predictability, performance, and partnership longevity. Whether you’re upgrading an aging line or commissioning a greenfield mineral processing facility, this system delivers measurable ROI through tighter specs, lower OPEX, and higher-grade output.
Engineered where precision meets productivity—designed for those who demand consistency at scale.