Kaolin & Attapulgite Products for the Ceramics Industry-Refresh

Ceramic Products Portfolio

AMI supplies a portfolio of kaolin and attapulgite products engineered to fill a variety of ceramic manufacturing needs:

  • Fast casting plastic section replacement
  • Coarse kaolin replacement
  • Whiter firing
  • Frit and glaze improvement

CONTACT US

Stone tiles samples isolated on white background

Ceramic Product Portfolio

Acti-Cast ECS Ball Clay Replacement

Acti-Cast ECS Ball Clay Replacement

Acti-Cast® ECS (Engineered Casting System) is a revolutionary new product / technology that allows for faster casting, whiter bodies, and higher purity products in sanitaryware. ECS replaces the plastic section (Ball clay and kaolin) on a traditional slip,

Concept – Utilizing AMI’s expertise in kaolin mining and manufacturing we created a new technology:

Predictable with improved performance

Increases the rate of slip making, casting and drying in existing systems

Reduces customers’ total manufacturing cost

FEATURES AND BENEFITS

  • ECS new technology will result in savings in manufacturing, quality, productivity and logistics costs
  • Reduces the number and sources of raw materials
  • Reduces associated storage and quality control requirements
  • Reduces the variability from the plastics portion of raw materials
  • Ensures long term supply of plastics fraction with consistent quality and performance
  • Increases productivity without re-tooling
  • Positive impact on firing environment

Presentation is Air Floated in Super sacs and bulk

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Acti-Cast CM Premium Coarse Kaolin

Acti-Cast CM Premium Coarse Kaolin

Acti-Cast® CM (Cage Mill & Air Float) is an evolutionary product. Replaces coarse kaolin / fast casting kaolin in traditional slip formulas for Sanitaryware. Acticast CM / AF is a “drop-in” product that can replace or be blended with existing kaolin solutions

Acti-Cast® CM is a white-firing coarse grained semi-dry kaolin specially selected for the Sanitaryware industry and other applications where a fast-casting clay is desired. The product is controlled to surface area so that casting rates remain consistent and predictable.

Acticast CM line of kaolin clays is designed specifically for customers who wish to prepare quality casting slips with semidried, or air-floated raw materials. Providing a unique combination of particle size distribution, rheology, and mineralogy. Acticast CM will improve casting rate and deflocculant response in traditional, automated and pressure cast applications.

FEATURES AND BENEFITS

  • Unique combination of particle size distribution, rheology and mineralogy
  • Low in residue (AF form) and carbon content
  • Suitable for a variety of product sizes and applications
  • High quality casting rate (low surface area ~10.5) coarse kaolin in sanitaryware
  • Presentation is Bulk for semi-dry form and air-floated forms.
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Acti-Min CK Coarse Kaolin

Acti-Min CK Coarse Kaolin

Acti-Cast® CM (Cage Mill & Air Float) is an evolutionary product. Replaces coarse kaolin / fast casting kaolin in traditional slip formulas for Sanitaryware. Acticast CM / AF is a “drop-in” product that can replace or be blended with existing kaolin solutions

Acti-Cast® CM is a white-firing coarse grained semi-dry kaolin specially selected for the Sanitaryware industry and other applications where a fast-casting clay is desired. The product is controlled to surface area so that casting rates remain consistent and predictable.

Acticast CM line of kaolin clays is designed specifically for customers who wish to prepare quality casting slips with semidried, or air-floated raw materials. Providing a unique combination of particle size distribution, rheology, and mineralogy. Acticast CM will improve casting rate and deflocculant response in traditional, automated and pressure cast applications.

FEATURES AND BENEFITS

  • Unique combination of particle size distribution, rheology and mineralogy
  • Low in residue (AF form) and carbon content
  • Suitable for a variety of product sizes and applications
  • High quality casting rate (low surface area ~10.5) coarse kaolin in sanitaryware
  • Presentation is Bulk for semi-dry form and air-floated forms.

Acti-Gel 208 Finishing Additive

Acti-Gel 208 Finishing Additive

Frit Tile Glaze – Acti-Gel® 208 allows a 50% reduction in kaolin and complete removal of Bentone EW & sodium hexametaphosphate.
Rotary Disc Tile Glaze – Acti-Gel® 208 can eliminate the use of Bentonite and STPP and reduce kaolin and CMC by half. Grinding times are lower as well due to less kaolin in the formula.
Let us show you how Acti-Gel® 208 can improve your production with these benefits in glazes:

  • Reduce dry times by up to 75%
  • Smoother, glossier surface finish
  • Reduce blistering or “pop-off’s” and pinholes.
  • Higher glaze-body adhesion
  • Better spray properties
  • Reduce or eliminate CMC, HMS, bentonite, and kaolin while achieving the same density and viscosity.
  • Excellent anti-settling, with reduced segregation and no hard packing
  • Reduce glaze dripping and sagging and eliminate glaze runoff
  • Lower costs
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Acti-Min WC-5 White Firing Kaolin

Acti-Min WC-5 White Firing Kaolin

ActiMin WC5 – AF and CM is a High-performance kaolin for the ceramic tile industry.

Acti-Min® WC-5 AF is a clean, low iron, very white-firing air-float kaolin specially selected for the whitewares segment of the ceramic industry, or other applications where low iron is required. Acti-Min® WC-5 AF has a low residue and intermediate to coarse particle size with good plasticity.

ActiMin WC5 is mainly Used on ceramic coatings and ceramic tiles – Engobe – base layer before glazing / final finish.

  • Replaces Imported and low quality local kaolins.
  • Presentation is Bulk for Semi-dry form and Air Floated versions.
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Kosse Clay High Plasticity Ceramic Clay

Kosse Clay High Plasticity Ceramic Clay

Kosse Kaolin Clay is a low-cost kaolin product that can be utilized in certain tile applications

  • Ceramic Clay with high plasticity and low Carbon content – potential for ceramic tile industry
  • Presentation is Bulk – semi dry material
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  • Acti-Cast ECS Ball Clay Replacement
  • Acti-Cast CM Premium Coarse Kaolin
  • Acti-Min CK Coarse Kaolin
  • Acti-Gel 208 Finishing Additive
  • Acti-Min WC-5 White Firing Kaolin
  • Kosse Clay High Plasticity Ceramic Clay

Acti-Cast ECS Ball Clay Replacement

Acti-Cast® ECS (Engineered Casting System) is a revolutionary new product / technology that allows for faster casting, whiter bodies, and higher purity products in sanitaryware. ECS replaces the plastic section (Ball clay and kaolin) on a traditional slip,

Concept – Utilizing AMI’s expertise in kaolin mining and manufacturing we created a new technology:

Predictable with improved performance

Increases the rate of slip making, casting and drying in existing systems

Reduces customers’ total manufacturing cost

FEATURES AND BENEFITS

  • ECS new technology will result in savings in manufacturing, quality, productivity and logistics costs
  • Reduces the number and sources of raw materials
  • Reduces associated storage and quality control requirements
  • Reduces the variability from the plastics portion of raw materials
  • Ensures long term supply of plastics fraction with consistent quality and performance
  • Increases productivity without re-tooling
  • Positive impact on firing environment

Presentation is Air Floated in Super sacs and bulk

Acti-Cast CM Premium Coarse Kaolin

Acti-Cast® CM (Cage Mill & Air Float) is an evolutionary product. Replaces coarse kaolin / fast casting kaolin in traditional slip formulas for Sanitaryware. Acticast CM / AF is a “drop-in” product that can replace or be blended with existing kaolin solutions

Acti-Cast® CM is a white-firing coarse grained semi-dry kaolin specially selected for the Sanitaryware industry and other applications where a fast-casting clay is desired. The product is controlled to surface area so that casting rates remain consistent and predictable.

Acticast CM line of kaolin clays is designed specifically for customers who wish to prepare quality casting slips with semidried, or air-floated raw materials. Providing a unique combination of particle size distribution, rheology, and mineralogy. Acticast CM will improve casting rate and deflocculant response in traditional, automated and pressure cast applications.

FEATURES AND BENEFITS

  • Unique combination of particle size distribution, rheology and mineralogy
  • Low in residue (AF form) and carbon content
  • Suitable for a variety of product sizes and applications
  • High quality casting rate (low surface area ~10.5) coarse kaolin in sanitaryware
  • Presentation is Bulk for semi-dry form and air-floated forms.

Acti-Min CK Coarse Kaolin

Acti-Cast® CM (Cage Mill & Air Float) is an evolutionary product. Replaces coarse kaolin / fast casting kaolin in traditional slip formulas for Sanitaryware. Acticast CM / AF is a “drop-in” product that can replace or be blended with existing kaolin solutions

Acti-Cast® CM is a white-firing coarse grained semi-dry kaolin specially selected for the Sanitaryware industry and other applications where a fast-casting clay is desired. The product is controlled to surface area so that casting rates remain consistent and predictable.

Acticast CM line of kaolin clays is designed specifically for customers who wish to prepare quality casting slips with semidried, or air-floated raw materials. Providing a unique combination of particle size distribution, rheology, and mineralogy. Acticast CM will improve casting rate and deflocculant response in traditional, automated and pressure cast applications.

FEATURES AND BENEFITS

  • Unique combination of particle size distribution, rheology and mineralogy
  • Low in residue (AF form) and carbon content
  • Suitable for a variety of product sizes and applications
  • High quality casting rate (low surface area ~10.5) coarse kaolin in sanitaryware
  • Presentation is Bulk for semi-dry form and air-floated forms.

Acti-Gel 208 Finishing Additive

Frit Tile Glaze – Acti-Gel® 208 allows a 50% reduction in kaolin and complete removal of Bentone EW & sodium hexametaphosphate.
Rotary Disc Tile Glaze – Acti-Gel® 208 can eliminate the use of Bentonite and STPP and reduce kaolin and CMC by half. Grinding times are lower as well due to less kaolin in the formula.
Let us show you how Acti-Gel® 208 can improve your production with these benefits in glazes:

  • Reduce dry times by up to 75%
  • Smoother, glossier surface finish
  • Reduce blistering or “pop-off’s” and pinholes.
  • Higher glaze-body adhesion
  • Better spray properties
  • Reduce or eliminate CMC, HMS, bentonite, and kaolin while achieving the same density and viscosity.
  • Excellent anti-settling, with reduced segregation and no hard packing
  • Reduce glaze dripping and sagging and eliminate glaze runoff
  • Lower costs

Acti-Min WC-5 White Firing Kaolin

ActiMin WC5 – AF and CM is a High-performance kaolin for the ceramic tile industry.

Acti-Min® WC-5 AF is a clean, low iron, very white-firing air-float kaolin specially selected for the whitewares segment of the ceramic industry, or other applications where low iron is required. Acti-Min® WC-5 AF has a low residue and intermediate to coarse particle size with good plasticity.

ActiMin WC5 is mainly Used on ceramic coatings and ceramic tiles – Engobe – base layer before glazing / final finish.

  • Replaces Imported and low quality local kaolins.
  • Presentation is Bulk for Semi-dry form and Air Floated versions.

Kosse Clay High Plasticity Ceramic Clay

Kosse Kaolin Clay is a low-cost kaolin product that can be utilized in certain tile applications

  • Ceramic Clay with high plasticity and low Carbon content – potential for ceramic tile industry
  • Presentation is Bulk – semi dry material
Ceramic toilet products, in a workshop production line

Sanitary Casting

In a solid cast mold, ceramic objects are surrounded by plaster on all sides with a reservoir for slip. For a hollow cast mold, once the plaster has absorbed most of the liquid from the outside layer of clay the remaining slip is poured off for later use. The cast piece is removed from the mold, trimmed and allowed to dry. This produces a greenware piece which is then dried before firing. The technique is suited to the production of complex shapes, and is commonly used for sanitary ware, such as toilets and basins.

Tile

Stone tiles samples isolated on white background
Stone tiles samples isolated on white

Kaolin clay (commonly called China clay) is a primary source of clay used in sanitaryware and tiles for its whiteness, chemical inertness, fine uniform particle size, plasticity and absence of coarse impurities. AMI is a global supplier to this market with it’s Acti-Min® WC-5 product. It is shipped in bulk bags, bulk rail and export shipping container deliveries from its Gordon, Georgia processing plant.

Frits and Glazes

A technically advanced product for sanitaryware is Acti-Cast® ECS Engineered Casting System. It is a complete plastic slip component for simplified, predictable and faster sanitaryware casting with reduced cost.

Reliable casting slip performance requires excellent control of oxides, particles size and plasticity… all are designed into Acti-Cast ECS Engineered Casting System for sanitaryware. This kaolin-based engineered product simplifies slip formulations and preparation by minimizing variability through complete replacement of ball clay and all other plastic components. Acti-Cast ECS-based slips have more predictable and faster casting with improved performance leading to higher yields and lower operating costs. This system is especially well-suited for pressure casting.

Request Acti-Min Data Sheet

MORE INFORMATION Acti-Cast ECS

 

Ceramic Bodies

Acti-Gel® 208 additive improves the overall quality of finished glaze with improved smoothness and gloss without pinholes and pop-offs, while increasing glaze-body adhesion. In addition Acti-Gel 208 has demonstrated process advantages like reduced dry times, overspray, settling, glaze dripping and sagging. It eliminates glaze runoff and hard-packing. Acti-Gel 208 offers greater formulating latitude to replace other ingredients that are known to create certain quality problems, like pinholes, as well as reduce costs. For example, kaolin and CMC can be reduces by as much as 50%, and Bentone EW & sodium hexametaphosphate can be completely removed. The reduction of kaolin can directly reduce the grinding times.

In many different types of glazes Acti-Gel® 208 has demonstrated improvements in processing, raw material reduction and, most importantly, the finished quality of the glazed piece. Acti-Gel® 208 offers greater formulating latitude to replace other ingredients that are known to create certain quality problems, like pinholes.

Some examples are:
Frit Tile Glaze – Acti-Gel® 208 allows a 50% reduction in kaolin and complete removal of Bentone EW & sodium hexametaphosphate.
Rotary Disc Tile Glaze – Acti-Gel® 208 can eliminate the use of Bentonite and STPP and reduce kaolin and CMC by half. Grinding times are lower as well due to less kaolin in the formula.
Let us show you how Acti-Gel® 208 can improve your production with these benefits in glazes:

  • Reduce dry times by up to 75%
  • Smoother, glossier surface finish
  • Reduce blistering or “pop-off’s” and pinholes.
  • Higher glaze-body adhesion
  • Better spray properties
  • Reduce or eliminate CMC, HMS, bentonite, and kaolin while achieving the same density and viscosity.
  • Excellent anti-settling, with reduced segregation and no hard packing
  • Reduce glaze dripping and sagging and eliminate glaze runoff
  • Lower costs

CONTACT US

Ceramic toilet products, in a workshop production line

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