Ceramics

Our solutions support quality and reliable production of high-performance building and industrial materials by streamlining blending, agglomeration, and drying processes. Refractory materials, ceramic tile compounds, and patching formulations are precisely agglomerated for improved consistency and strength, while binders and fibers are expertly blended to create durable ceiling panels, pipe insulation, and fire doors. The ability to agglomerate and dry aluminas, ferrites, glass, and oxides ensures enhanced material properties, better handling, and greater stability. By optimizing the drying of agglomerated ceramic formulations, manufacturers benefit from superior product quality, reduced waste, and more efficient processing, ultimately delivering stronger, longer-lasting end products.

Product Solutions

Solids Processor

Blend, dry, and agglomerate dry ceramic formulations, glass, and alumina products in a single processing unit.

Twin Shell Blender

Efficient blending and agglomeration of refractory materials and ingredients for ceramic patching and tile products.

Zig-Zag Continuous Blender

Rapid blending with minimal product degradation of binders and fibers for a variety of ceramic products.

Slant Cone Shell Blender

Able to handle extremely delicate to heavy abrasive materials in the opposed simple cylinders.

Continuous Dryer

Flighted tubes for maximum product contact with heated surfaces for uniform drying of agglomerated ceramic formulations.

Tubular Vacuum Dryer

Larger heat transfer surface versus traditional vacuum dryers for uniform drying of ceramic materials.

Engineered for the Precision & Consistency Demands of Ceramic Processing

Ceramic manufacturing requires precise control over particle distribution, moisture content, and material consistency to achieve reliable forming, firing, and final product quality. Patterson Kelley (PK) provides precision blending, drying, and powder-processing solutions engineered for the unique demands of ceramic materials processing.

PK Blenders are purpose-built to handle ceramic powders, oxides, clays, pigments, binders, and specialty materials with equipment designed to maintain blend integrity, improve flowability, and deliver repeatable results from R&D through production scale. Our systems support demanding applications, including technical ceramics, refractories, advanced ceramics, and traditional ceramic manufacturing.

Ceramic Processing Pain Points We Solve

Poor blend uniformity affecting final product consistency

Segregation of fine and coarse ceramic particles

Moisture variability impacting pressing and forming

Dust generation and material handling concerns

Scale-up inefficiencies from lab to production

Inconsistent feed to kilns, presses, or extrusion systems

Equipment wear from abrasive ceramic materials

Optimize Your Ceramic Processing Line

We help ceramic manufacturers achieve consistent, high-quality output while improving efficiency and reducing variability.

PK engineers work directly with R&D and production teams to design systems tailored to:

Material density and particle size distribution

Required blend uniformity targets

Moisture and temperature control requirements

Throughput and production rate goals

Scale-up from lab or pilot testing

Facility layout and integration requirements

Engineered for Ceramic Powder Processing

Integrated Drying & Conditioning

PK drying solutions like the Solids Processor (SP), Tubular Vacuum Dryers, and Continuous Tubular Vacuum Dryers provide controlled moisture removal and conditioning to improve powder flow, compaction properties, and downstream forming performance.

Scalable Systems

Ceramic manufacturers benefit from PK’s ability to support every phase of product development. From lab-scale testing with the Blend Master and bench-top units to full-scale production systems with rugged, industrial construction for abrasive materials.

High-Uniformity Powder Blending

PK’s blending technologies, including Twin Shell, Double Cone, Cross-Flow®, Slant Cone®, and Zig-Zag® Continuous Blenders, are engineered to deliver exceptional blend homogeneity across ceramic powders, oxides, binders, pigments, and specialty formulations.

Why Choose Patterson Kelley

Ceramic Manufacturers Need:

Consistent blending of ceramic powders and additives

Controlled drying for moisture-sensitive materials

Robust equipment for abrasive powder handling

Scalable systems from R&D to production

Improved feed consistency for pressing and forming

Solutions that support dust containment and process reliability

PK Benefits

Consistent blend uniformity across ceramic formulations

Reduced segregation between fine and coarse particles

Energy-efficient drying and blending options

Custom-engineered systems for ceramic processing challenges

Reduced downtime and maintenance

Long equipment life in abrasive environments

Proven performance with advanced and traditional ceramics

Technical Advantages

Repeatable blending with optimized vessel geometry

Wear-resistant and industrial-grade construction options

Precision control of speed and fill levels

Vacuum drying for moisture-sensitive ceramic materials

Dust-tight design and containment options

Easy-maintain and CIP-ready configurations

Batch data capture and process monitoring

Custom engineering for abrasive ceramic applications

Scalable Systems From R&D to Production

Ceramic manufacturers benefit from PK’s ability to support every stage of product development. From lab-scale testing with Blend Master and bench-top units, and pilot-scale trials to validate blend uniformity and moisture control, to full-scale production systems with rugged industrial features, PK ensures performance at every step.

Our lab testing service allows you to bring your ceramic material formulation to PK and validate blending and drying methods before investing in equipment.

Applications Across Ceramic Manufacturing

PK supports a broad range of ceramic processing applications:

Advanced ceramic powder blending
Refractory material processing
Oxide and mineral blending
Pigment and additive incorporation
Moisture removal and powder conditioning
Preparation for pressing and extrusion
Technical ceramic formulation blending
Batch or continuous powder processing

System Integration Capabilities

PK equipment integrates seamlessly into ceramic production environments, including:

Material transfer and conveying systems
Dust collection and containment controls
Sifters and classifiers
Vacuum transfer and pneumatic conveying
PLC-based recipe and batch management
Kiln feed and downstream processing integration

Ceramic Processing FAQs

How do PK blenders improve ceramic powder consistency?

PK blenders use optimized vessel geometry and controlled mixing action to evenly distribute powders and additives while minimizing segregation.

Why is moisture control important in ceramic processing?

Moisture directly impacts powder flow, compaction, forming consistency, and final fired product quality. Controlled drying improves repeatability and downstream performance.

Can PK equipment handle abrasive ceramic materials?

Yes. PK systems can be engineered with wear-resistant materials and rugged construction to safely process abrasive ceramic powders and minerals.

Is lab testing available before investing in production equipment?

Absolutely. PK’s lab services allow ceramic manufacturers to validate blend uniformity, drying performance, and scalability using their own materials.

Can PK systems integrate into existing ceramic manufacturing lines?

Yes. Our engineers design systems that integrate seamlessly with conveying, dust collection, kilns, presses, and automation systems already in your facility.

We Have The Solution For Your Process.

Regardless of the processing industry, PK has been providing solutions to processors for more than a century.