ABSTRACT

This project is initiated to optimize the spray drier unit used in the manufacturing of spark plug insulator.

The insulator manufacturing process involves many stages with different variable control parameters. This

project deals with the improvement action in order to obtain maximum output from the spray drier.

Basically insulator is of ceramic material mainly with Calcined alumina milled with other fluxes to

improve mechanical and electrical properties. The milled material is compressed under controlled pressure

to form the required shape and dimension. Then it is sintered in the furnace at high temperature.

The spray drier uses hot air from the air heater to remove the moisture content in the blunged ceramic

slurry. It maintains a negative pressure inside the chamber in order to have an efficient exhaust system of

the hot air and the finest of the ceramic particles.

Initially the process was been studied, monitored and compared with standard manufacturing procedure.

Number of trials have been tried out to with the alterations in the major parameters such as pressure and

temperatures inside the spray drier unit. Care is taken to prevent deviation from the standard procedure

and the quality parameters.