Complete Turnkey Calcium Carbonate Powder Production Lines – From Limestone to Ultra-Fine GCC Specialized engineering solutions for calcium carbonate grinding plants from 30,000 to 500,000 TPY. Our integrated closed-circuit ball mill or vertical roller mill systems with high-efficiency air classifiers deliver D97 from 45 µm down to 5 µm, with specific energy consumption starting as low as 35 kW·h/t for D97=10µm GCC. Whether you are building a new GCC plant or upgrading an existing facility, we provide full EPC services from raw material testing to packaged powder dispatch — trusted by carbonate filler and coating pigment producers worldwide.
Our calcium carbonate grinding plant is a complete, integrated production facility engineered to produce high-quality GCC powder from limestone, marble, or calcite. We deliver the entire plant as a single-source EPC project.
System Scope of Supply
Core Process Equipment:
· Jaw crusher & hammer crusher for primary reduction (≤25 mm feed into mill)
· Calcium carbonate ball mill or vertical roller mill (closed circuit, ceramic-lined)
· High-efficiency turbo or cage-rotor air classifier (multiple stages for ultra-fine grades)
· High-gradient magnetic separator (HGMS) for iron removal
· Surface modification machine (stirred mill or continuous coater with stearic acid dosing, optional)
· Automatic weighing, batching and bag packing system (25/50 kg bags) plus bulk loading
· Integrated baghouse dust collectors for entire plant (emission <10 mg/Nm³)
· Full PLC/DCS central control system with online particle size & brightness monitoring
Product Grades We Can Produce:
· Coarse filler: D97=45-75 µm, for asphalt, carpet backing, putty
· Medium filler: D97=15-25 µm, for paper, PVC pipes, rubber
· Fine filler: D97=5-10 µm, for paints, coatings, adhesives, sealants
· Ultra-fine coating pigment: D97=2-5 µm, for high-gloss paper coating, masterbatch
· Surface-treated GCC (with stearic acid or titanate coupling): for plastic films, breathable film
Raw Material Flexibility:
· Limestone / Calcite / Marble (CaCO₃ >96%, whiteness >90%)
· Chalk (high purity, soft, for specialized fine powders)
· Dolomite (CaMg(CO₃)₂) for glass and filler applications
Not sure about your optimal plant configuration? Tell us your raw material hardness, target product fineness (D97), and annual capacity. Our process engineers will design a complete solution from quarry stone to bagged powder.
From Quarry Stone to Ultra-Fine Calcium Carbonate Powder: How Your Plant Works
Raw Stone Crushing & Storage – Raw limestone or marble (≤600mm) is crushed in a jaw crusher to <50mm and then a hammer crusher to ≤10mm. The granulated material is stored in silos or covered stockpile for buffer.
Precise Dosing & Mill Feeding – The crushed stone is fed into the grinding mill via a weighing belt and screw conveyor. The feed rate is automatically controlled to maintain the optimal mill load and classifier current.
Closed-Circuit Grinding & Classification – The ball mill (with ceramic lining) grinds the material to a fine powder. The mill discharge is air-conveyed to the turbo classifier. On-spec powder passes through; coarse tailings return to the mill for re-grinding. A multi-stage classification system is used for D97 <5 µm products.
Iron Removal & Brightness Protection – Following the classifier, the fine powder passes through a high-gradient magnetic separator to remove any trace iron from the raw material, ensuring final brightness remains high.
Surface Treatment (Optional) – For coated GCC, the fine powder enters a continuous surface modifier where molten stearic acid is atomized and mixed intensively, producing hydrophobic, dispersible powder for plastics.
Packaging & Dispatch – Finished GCC powder is stored in product silos, then extracted and packed into 25/50 kg bags via automatic packers, or loaded in bulk into trucks. A central PLC controls the entire process from stone feed to final product.
Standard GCC Grinding Plant Configurations (Ball Mill + Air Classifier System)
| Plant Capacity (TPY) | Main Mill Model | Classifier Type | Product D97 (µm) | Specific Power (kW·h/t, D97=10µm) | Site Area (m², approx.) |
|---|---|---|---|---|---|
| 30,000 | Φ2.2×7m Ball Mill | Single Turbo | 10–45 | 45–50 | 5,000–8,000 |
| 60,000 | Φ2.4×8m Ball Mill | Single Turbo | 5–45 | 40–45 | 8,000–12,000 |
| 100,000 | Φ2.4×13m Ball Mill | Multi-stage Turbo | 5–45 | 35–40 | 12,000–18,000 |
| 200,000 | 2×Φ2.4m or 1×Φ3.2m | Multi-stage Turbo | 2–45 | 32–38 | 20,000–30,000 |
| 500,000 | VRM or 2×Φ4.2m Ball Mill | Multi-stage Turbo | 5–45 | 28–35 | 40,000+ |
*Note: Specific power depends on raw material hardness and target fineness. Plants producing D97 <5 µm will require multi-stage classification and surface treatment options, and energy consumption will be higher.*
Key Performance Guarantees
| Parameter | Guaranteed Value |
|---|---|
| Product D97 top cut | Target ±1 µm |
| Product ISO brightness (after HGMS) | ≥95% |
| Iron content (Fe₂O₃) | <0.02% (200 ppm) |
| Dust emission | <10 mg/Nm³ |
| Plant availability | >85% (annual) |
| Specific power consumption | As per contractual test guarantee |
EPC Project Scope Options:
· Full EPC (Turnkey): Complete plant from raw stone crushing to bagged/bulk dispatch, including civil, steel structure, ceramic lining, electrical, automation, and operator training.
· EP (Engineering & Equipment Supply): Design plus supply of all core equipment. Local civil works and erection by others, with our supervision.
· Standalone Grinding & Classifying System: Supply of the ball mill, classifier, and dust collection system only.
Tell us your target annual output, feed material specifications, and required product fineness (D97). We will prepare a complete calcium carbonate grinding plant proposal with flow sheet, equipment list, and firm price.
Proven Performance: Global Calcium Carbonate Plant Projects
Case 1: 100,000 TPY GCC Grinding Plant, Southeast Asia
· Scope: Full EPC (Quarry stone receiving to bagged powder)
· Configuration: Φ2.4×13m closed-circuit ball mill + single turbo classifier + stearic acid coating
· Product: Coated & uncoated GCC, D97=10µm for PVC pipes and masterbatch
· Result: Commissioned in 12 months. Uncoated powder specific power 38 kW·h/t, ISO brightness 96%. Coated product activation rate >98%. The plant became the local market leader in PVC filler within 6 months.
Case 2: 60,000 TPY Ultra-Fine Coating Grade GCC Line, Africa
· Scope: Full EPC
· Configuration: Φ2.4×8m ceramic-lined ball mill + two-stage turbo classifier + HGMS
· Product: Paper coating GCC, D97 <5 µm, ISO brightness 97%, Fe₂O₃ <0.015%
· Result: Successfully replaced imported European GCC. Specific power 55 kW·h/t for D97=5 µm. Customer won a long-term contract with a major paper mill.
Case 3: Plant Retrofit: From 15µm to 5µm Product, South Asia
· Scope: Retrofit (replaced old separator with multi-stage classifier, added ceramic lining & HGMS)
· Original product: D97=15 µm filler for putty; Output: 3 TPH
· New product: D97=5 µm coating pigment for paints; Output: 4 TPH
· Result: Product upgrade doubled the selling price. Payback period on retrofit: 1.5 years.
Ready to Build Your World-Class Calcium Carbonate Plant?
Send an inquiry. You will receive:
A complete GCC plant proposal tailored to your stone type, capacity, and target D97.
A process flow sheet, equipment list, and firm EPC price.
A detailed project schedule from design to commissioning.
Optional: Free grinding test on your limestone sample with full particle size and whiteness analysis.
Your raw material details and business plan are held in strict confidence.
Kolev Equipment Technology Co., Ltd. is a large-scale private technology enterprise specializing in the research, development, production, and sales of mining and metal ore processing equipment. With over 20 years of experience in ultra-fine grinding, industrial drying, and crushing sand making industries, we provide intelligent solutions and mature supporting products worldwide.
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