Research and Development

Keramicalia has undertaken about 1000 development projects over the whole spectrum of refractories technologies.   We therefore have a wider range of technologies than the large refractories companies.   We have a very sophisticated and well maintained system of technology records.   We can therefore produce a refractory material appropriate to your application “off the shelf”, and refine it to your ideal properties within days.

Compliance Control

Many corporate refractories consumers do not have adequate in house expertise to do quality control on their refractories. In this situation, they suffer a number of problems;

Suppliers offer the wrong materials.

The client gives the wrong requirements.

The supplier offers a high grade material and supplies a low grade material.

The client cannot determine which aspect of his service environment is causing the refractory to fail.

The client is operating his furnace in a manner severely detrimental to refractory performance.

For all these problems, the client needs a part time consultant.

Testing of Binders

We are inundated by requests to help develop binders for different projects. We cannot fulfill all the requests. We therefore have to be selective and only do the ones that are likely to succeed and bring us sales of binders.

The criteria for selection are the following:

  1. Will the product be commercially viable? (What price per ton can be achieved?)
  2. What are the technical requirements for the product? (Waterproof, water resistant, temperature, etc.)
  3. What is the material?
  4. What size are the particles?
  5. Is the process briquetting, extrusion or pelletising?
  6. What is the scale of the project, in tons per hour?
  7. Does the client have the equipment?
  8. Have we got a sample?
  9. Has any work already been done?

If the project looks viable and easy we will do the initial tests free of charge. If it looks unlikely to succeed, we will charge for the initial testing, usually about R6000.00 plus VAT, on the understanding that the results are likely to be negative, but the client will get an idea of WHY it is not feasible.

If you want your product tested, submit a sample, answer questions 1 to 9 and we will quote on initial evaluation.

QUALITY ASSURANCE

Since Keramicalia started 22 years ago we developed a practical in house hands- on quality control and QA system. It differs appreciably from norms like ISO and SABS, which are suitable for large scale manufacture of a fixed range of products. Keramicalia’s QA system is designed to provide the most appropriate material for any given application. We have a huge, cumbersome, heavy maintenance system to enable this. It is much more intense than ISO and SABS systems, with more paperwork, but all in areas appropriate to the nature of our service. Our system is available to anyone in the research and development field, who has the same challenges of retaining technology.