Perlite-Based Plaster Production Facility

Low Density. High Homogeneity. Consistent Performance

Expanded perlite gives lightweight plaster its characteristic low density and thermal performance, but its porous and fragile structure makes material handling and mixing especially demanding. Excessive impact, high shear or unsuitable transfer equipment can break down the particles, change bulk density and influence the consistency of the final dry plaster. VOLDE develops complete production lines for perlite-based dry plaster — from raw material intake and batch dosing to elevator feeding, gentle mixing, valve-bag filling, robotic palletizing and stretch wrapping. Each system is engineered around the perlite characteristics, formulation, batch size and required production capacity, with particular attention to preserving particle structure while achieving a homogeneous final blend

| Raw Material Dosing & Mixer Feeding

Perlite-based plaster formulations combine expanded perlite with binders, mineral fillers and low-dose chemical additives that differ significantly in density, flow behavior and dosing range. Each ingredient therefore requires a feeding and weighing method suited to its own physical characteristics.

VOLDE integrates silos, big bag discharge stations, bag dumping units, gravimetric weighing and suitable screw or vibratory feeders into a recipe-controlled batch dosing system. Cement, calcite and other major components can be weighed in dedicated hoppers, while polymer powders and specialty additives can be prepared through automatic or manual micro-dosing systems.

Once the batch is complete, the weighed materials are transferred to the mixer through an elevator-based feeding arrangement. The transfer route is designed to limit unnecessary mechanical impact on expanded perlite while providing reliable and repeatable mixer charging.

• Silo, big bag and bagged raw material intake
• Gravimetric batch weighing
• Major, minor and micro-ingredient dosing
• Recipe-controlled material preparation
• Elevator feeding to the mixer
• Dust extraction at transfer and dosing points
• Batch and raw material consumption records

| Gentle Mixing for Expanded Perlite

The mixer is one of the most critical elements of the complete process. Expanded perlite must be distributed uniformly throughout the plaster formulation without subjecting the particles to excessive shear or impact.

VOLDE selects and configures the mixer around the low density and fragile structure of expanded perlite. Mixer geometry, usable volume, rotor speed, mixing tools and cycle time are considered together so that binders, fillers and chemical additives can be distributed throughout the batch while limiting unnecessary perlite degradation.

The objective is not simply to achieve a visually mixed product, but to obtain consistent distribution of all formulation components throughout the complete batch while maintaining the lightweight character of the plaster.

Depending on the formulation and production capacity, the system can incorporate.

• Low-shear mixing configuration
• High usable mixer volume
• Controlled mixer filling sequence
• Recipe-specific mixing time and speed
• Gentle addition of expanded perlite
• Automatic discharge to the packaging buffer

Modern dry-mortar plants similarly treat mixing quality and dosing accuracy as central elements of consistent product manufacture, with mixer parameters configured around the material being processed.

| Valve-Bag Filling, Robotic Palletizing & Stretch Wrapping

After mixing, the finished dry plaster is transferred to the packaging section through a controlled buffer system. The complete downstream line can be configured for automatic filling of kraft valve bags, followed by bag handling, robotic palletizing and stretch wrapping.

Valve-bag filling technology is selected according to the low bulk density and flow characteristics of the perlite-based product. Filling parameters are adjusted to provide stable bag weights while limiting unnecessary product aeration and dust release.

The complete packaging line can include

• Kraft valve-bag filling machines
• Typical 10–25 kg bag formats
• Automatic bag discharge and conveying
• Weight checking and production records
• Bag coding or labeling
• Robotic palletizing
• Automatic stretch wrapping
• Pallet discharge conveyors

From raw material dosing to the finished wrapped pallet, the complete line can be coordinated through a common PLC/SCADA architecture with recipe management, production monitoring and batch traceability.

VOLDE combines dosing, elevator feeding, gentle mixing and fully automatic packaging into one integrated production line developed specifically for perlite-based dry plaster.