Ball Mills Section

 Type of grinder used to grind and blend materials

 Slurry is stored in large tanks fitted with paddle mixer for
continuous stirring
 Weighted raw materials 50% are mixed with water 50%
 Continuous process duration of (17+3) hours .
 1st Feldsper and quartz is mixed with water for 17 hours
 2nd Clay is mixed for next 03 hours
 Fine particle size (10-12 microns) ceramic slurry / slip is prepared

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Filtering Process of Slurry
 To remove unwanted particles from slurry
 Slurry is passed through a Vibrating screen
 Threads of plastic bags, wooden piece etc re moved
 Slurry is then filtered by Magnetic Ferro Filtering system
 Both Electrical magnetic and permanent magnet are employed
to remove ion particles mainly iron
 The scrap material at this stage is recycled for future use

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Dewatering using Filter Press
 Filtered slurry is pumped into filter press
 High pressure filter pressers are installed for cake preparation.
 High pressure is applied by compressing them from both sides
 In this process 80% of the water is removed from the slip

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High Vacuum Pug Mills
 Using conveyor belts cake is then transferred to pug mill
 It is a de-airing operation under vacuum.
 Trapped air bubbles from the cake are removed
 Presence of air results in.
 Presence of any air pockets is not desired because it will disturb
homogeneity and results voids in fired insulator.
 Homogenous pugs in cylinder form are cut automatically in
required length

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Shaping of insulators
 Pugs are fed into Jiggering machines
 At first go impart initial shape of insulator shells.
 The secondary die gives the final shape shells.
 To avoid sticking mixture of Kerosene oil and Coconut oil is used
as Lubricant between die and the mould
 These green stage shells are dried in CD (Chain-dryer).
 Turning process for preparation of cylindrical shapes of
insulators) like transformer bushes LV and HV etc
 Remaining raw material after jiggering and turning pr is re-cycled

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Drying Process
 Shaped insulators are slowly air dried.
 In drying process at temperature is set 45°C for 01 to 1.5 hours
 Moisture content is reduced from 18%-19 to below 01%
 After drying insulator are kept for 24 hours before final
machining is done
 First checked and defective insulators are discarded
 Extra mass is removed without affecting insulators formation.
 Finally smooth surface is achieved by smoothening plate

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Oil Inspection
 After drying oil inspection is done
 It’s a routine process
 Every insulators is visually inspected regardless of size of
insulator and time to find
 Defective and cracked insulators and separated
 This process saves resources also helps to achieve desired quality

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Glazing Unit
 Insulators are dipped into slurry of glaze.
 Color coding brown, white and green (customer’s choice).
 Gives coating of 0.3mm to 0.5mm of thickness
 Gives color for identification to different types of insulators
 Make the surface smooth
 Reduces leakage current , if we use high resistance glaze
 Improves mechanical strength
 Disc shrinks on glazing
 Prevents Environment impacts dust, moist and rays
 Thermal expansion of glaze is lesser that of ceramic portion

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Glazing Unit cont…
 Good Insulators are glazed in Automatic glazing machine (AGM)
 Specific gravity, Viscosity and thickness are maintained to
enhance the glaze impact on the insulators.
 Sanding is done on pin portion and head portion of insulators
 Gives better grip between cement and metal parts and improves
Mechanical characteristics of the insulators.
 Stamping identification made on the insulators based on the
customer requirement and standards

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FIRING UNIT
 Firing is most critical part of the manufacturing of insulators in
EMCO
 Natural Gas firing maximum temperature of 1230°C
 It consists of three zones namely Pre-heating, Firing and cooling
 Two types of Kilns in EMCO
 Shuttle kiln (England) batch by batch firing
 Tunnel kiln 100 meter long (Germany) continuous Firing
 Firing process completes in 03 days

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Assembly of Insulators
 Zinc coated insulator cap and pin are used to corrosion
 Cement mortar is poured inside the cap portion as well as shell
portion.
 A suitable cork is place to insert the ball-pin. The pin is placed
manually.
 The shell is assembled in the cap and is pressed manually. The is
twisted while pressing to eliminate entrapped air.
 The insulator is lifted and placed on the pre-curing chamber
without disturbing alignment of the components.

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Curing Tanks
 As Concrete which is moist cured for 7 days is about 50%
stronger than uncured concrete.
 The assembled insulator are also dipped in curing tanks to get
maximum mechanical strength of interconnection between cap-
shell- pin to handle designated overall mechanical stress and
load.

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