Recipe-Based Production with Lightweight Raw Materials

Refractory and insulation blends intended for thermal insulation require low density, high porosity, and stable thermal performance. The perlite, vermiculite, lightweight chamotte, expanded minerals, microsilica, and binder phases used in such products demand far more precise process control than conventional heavy mineral mixtures. VOLDE systems are designed to process these fragile, low-density raw materials without damaging them, producing insulation blends fully compliant with the recipe and homogeneous in structure.

| Recipe-Based Production

This system has 4 dedicated bins for the main fractions used in insulation blends. Each bin is custom-designed for raw materials with different densities and grain structures.

The system operates with;

• Bin level and mass tracking via load cells
• High-resolution dosing screws or vibro feeders on the downstream side
• Custom bin geometry that prevents bridging in low-density products

The quantity taken from each bin according to the recipe is automatically weighed and collected, and verified on a batch basis. This structure ensures that product density and thermal insulation performance remain constant from batch to batch.

| Blending That Preserves Mixture Quality

Lightweight and porous aggregates can easily break or undergo segregation under high shear force and aggressive conveying. For this reason, the system operates on the following logic;

• Low-speed, gentle feeding characteristics
• Transfer geometry that prevents aggregate breakage
• High-precision dosing for fine binders and micro-additives

mantığıyla çalışır.
Once the collected batch is verified via check-weigh, it is directed to the mixer or straight to the filling line. This way, the distribution of the binder phase, the porosity structure, and the stability of the final product are kept under control.

| Advantages

The fine fractions and lightweight aggregates used in insulation blends have a high potential to generate dust. The facility operates integrated with a central dust collection system, and all critical points are controlled as a closed loop.

• Dust-free working environment

• Traceability and Reporting

○ Recipe- and batch-based production tracking

○ Weighing and dosing records

○ Raw material consumption analyses

○ Data sharing with ERP and quality systems