At the Ranong kaolin site, once the topsoil and overburden have been removed and the layers of clay are exposed, the Imerys Ceramics production process begins with selective mining at the pit. With the use of an excavator the pit is dug in blocks of 10m by 10m by 20m. The extracted kaolin is transferred to a stockpile. A quality analysis takes place followed by blending if necessary. In order to separate the stone and gravel from the kaolin, the mixture is:

• Washed with water under pressure
• Placed over a grizzle bar to sieve some stones and gravel
• Passed through a Trommel for further separation
• Finally, it is passed through a group of spiral classifiers to filters out the coarse sand

The resulting kaolin is then collected in a thickening tank. Further refining using hydro-cyclones allows classification by particle size. The kaolin is then dried in two stages to bring the moisture level down to 15%. The first stage involves filter presses with square polypropylene plates; then the second stage involves the kaolin being shredded and passed through a dryer. The kaolin is then stockpiled to await distribution.

Imerys Ceramics' Ranong kaolin is of consistent high quality and constitutes the largest kaolin operation for ceramics in southeast Asia. This, combined with our leading market share for sanitaryware demonstrates the strength of Imerys Ceramics' position in the region.

Imerys Ceramics' ball clay production process in Lampang, Thailand, starts with selective extraction at the pit. A thorough knowledge of the deposit allows for accurate selection of component clays. In a primary crusher the lump clays are broken down to a maximum size of 150mm. A secondary crusher then shreds the ball clay lumps down to 25mm or less. The shredded ball clay is then stockpiled for dispatch or is processed further in a blending hopper and a paddle mixer. Additional refining may take place if required prior to storage.

We supply a full range of ball clays for sanitaryware:

• Shredded & blended
• Refined
• Semi-refined ball clays

Our Thai ball clays are recognised for their consistency and high quality. As the owner of a large reserve and as the market share leader in the Thai market we are able to offer our customers a secure and affordable supply. Imerys Ceramics' ball clay operation in Lampang is ISO certified and is supported by laboratory services which runs 24 hours a day.

The Asian hub consists of industrial sites in China, India, New Zealand and Thailand. This hub has developed from the acquisitions of MRD / MRD-ECC, NZCC and most recently of Jumbo Mining in 2007. Imerys Ceramics has a well-established commercial structure in the region and we support our customers with a local team of experienced technical and sales staff. Asia represents a key objective for Imerys Ceramics and we will continue to strengthen our position to better serve this long-term growth area.

Thailand

In Ranong, Imerys Ceramics has facilities for the production of kaolin. This plant opened in 1992 and is the only modern processing plant in the country. The kaolin produced here is of consistent high quality and constitutes the largest kaolin operation for ceramics in Southeast Asia. This, combined with our 90% market share of Sanitaryware production demonstrates the strength of our position in the region.

Imerys Ceramics produces ball clay in Lampang in north Thailand. We have a strong portfolio of both shredded and blended, as well as refined and semi-refined ball clays. Quality control is of critical importance and we can offer customers the assurance of ISO certification for both our ball clay and kaolin operations. We also conduct casting tests after every 15 tons produced.

Imerys Ceramics entered the Thai market with the acquisition of MRD and MRD-ECC which became part of the Imerys group in 2002. We supply our Thai raw materials to the following markets: Sanitaryware, Tableware, Tiles, Electrical Porcelain and Fiberglass.

Further information

Imerys Ceramics production sites