Henan Hongke Heavy Machinery Co., Ltd. has delivered a ceramsite (expanded clay aggregate) rotary kiln production line to a customer in Indonesia. The line is designed for an annual output of 300,000 cubic meters. This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: Indonesia (South Sumatra region)
Industry: Building materials / lightweight aggregate production
Indonesia's construction sector has grown steadily over the past decade, driving demand for lightweight aggregates used in concrete blocks, structural concrete, and insulation materials. Expanded clay ceramsite is one such material—produced from locally available clay and shale, it offers low density, good thermal insulation, and reliable mechanical strength.
Our customer is a building materials producer in Indonesia. They identified an opportunity to manufacture ceramsite locally, using clay and shale deposits near their site, to serve growing demand from contractors and precast producers in the region.
2. The Original Problem
Before approaching Henan Hongke Machinery, the customer faced several practical challenges:
| Problem | Impact |
|---|---|
| No local ceramsite supply | Contractors relied on imported or distant sources; high cost, long lead times |
| Variable raw material | Local clay and shale varied in moisture, plasticity, and expansion behavior |
| Uncertain process parameters | No established reference for calcination temperature and residence time with local materials |
| Environmental requirements | Dust and emissions had to meet Indonesian regulations |
| Capacity target | 300,000 m³/year required a robust, continuous line |
| Operational reliability | Equipment had to run consistently in tropical conditions—high humidity, high ambient temperature |
The customer needed a complete production line—not just a kiln. Mixing, granulation, calcination, cooling, screening, and dust collection all had to work together.
3. Why the Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected us for specific, practical reasons:
a) Complete line capability, not single-machine supply
Ceramsite production is a chain: raw material preparation → mixing → granulation → calcination → cooling → screening → dust collection. We demonstrated the ability to supply and integrate the full line, so the customer did not have to coordinate multiple vendors.
b) Design based on their actual clay and shale
We requested samples of the customer's raw materials and reviewed their moisture, plasticity, and expansion characteristics before finalizing the kiln design and process parameters. The kiln internal structure and temperature profile were matched to their material.
c) Experience with tropical operating conditions
High ambient temperature and humidity affect equipment cooling, electrical systems, and material handling. We considered these factors in the design—motor sizing, cooling provisions, and moisture control in feed preparation.
d) Factory inspection and reference review
The customer reviewed our manufacturing facility and similar ceramsite projects before signing.
e) Long-term support commitment
The customer wanted a supplier who would remain available for process optimization and spare parts after handover.
4. Equipment Configuration
The line is built around a rotary kiln, with a complete production chain from raw material feed to finished product screening.
| Parameter | Specification |
|---|---|
| Application | Ceramsite (expanded clay aggregate) production |
| Design capacity | 300,000 m³/year |
| Raw materials | Local clay and shale |
| Kiln type | Rotary kiln with refractory lining |
| Operating temperature | Up to 1,200°C (adjustable by zone) |
| Drive system | Heavy-duty gear drive with main and auxiliary motors |
| Sealing | Labyrinth seals with air purge |
| Control | PLC-based with temperature, speed, and feed monitoring |
Scope of supply:
| System | Function |
|---|---|
| Raw material storage and feeding | Clay/shale storage, controlled feed into process |
| Twin-shaft mixer | Crushing and homogenization of raw material |
| Granulator | Formation of green pellets at target size |
| Rotary kiln | Calcination and expansion of pellets |
| Cooler | Quenching of hot product to preserve strength |
| Vibrating screen | Classification of finished product by size |
| Dust collection system | Cyclone + bag filter for emission compliance |
| Conveying equipment | Material transfer between process stages |
| PLC control system | Process monitoring and data logging |
5. Delivery Timeline
| Stage | Status |
|---|---|
| Raw material testing and process design | Completed |
| Manufacturing at Henan Hongke facility | Completed |
| Factory assembly and no-load testing | Completed |
| Shipment to Indonesia | Completed |
| On-site installation | Completed |
| Commissioning and trial production | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Product quality | Ceramsite with uniform size and density, meeting target specifications |
| Kiln temperature control | Stable across operating zones |
| Throughput | Meets design capacity for 300,000 m³/year |
| Expansion behavior | Consistent expansion with local clay/shale |
| Dust emissions | Within regulatory limits |
| Operational stability | Continuous operation achieved |
| Product screening | Consistent size classification |
7. Customer Feedback
"The line has been running well since commissioning. The kiln handles our local clay and shale without the problems we were worried about. Product quality is consistent, and the dust control meets our requirements. The team was responsive during installation and commissioning." — Production Manager, Indonesian ceramsite producer
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| Local ceramsite supply | Shorter lead times, lower cost than imported material |
| Consistent product quality | Stable offtake agreements with contractors |
| Full-line integration | Single point of responsibility |
| Environmental compliance | Meets Indonesian emission requirements |
| Reliable operation | Continuous production in tropical conditions |
| Support for future expansion | Scalable design and ongoing technical support |
9. Building Long-Term Partnerships
Our commitment to the Indonesian customer does not end at handover. We continue to provide:
Technical support on process optimization for different clay and shale sources
Spare parts availability for critical components
Maintenance guidance and preventive maintenance planning
Support for future capacity expansion or process adjustment
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been designing and manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for ceramsite, lime, dolomite, zinc oxide, metallurgy, and mineral calcination
Rotary Dryers – for sludge, sand, gypsum, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We focus on one-stop solutions for mining and materials processing—complete systems, not just individual machines.
Let's Talk About Your Ceramsite Project
If you are planning a ceramsite production line using local clay or shale, we can discuss kiln sizing, process configuration, and expected output based on your raw material data.
Contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Built for Reliability, Backed by Service