Process Flow and Equipment for Raymond Mill in Cat Litter Production

Introduction to Cat Litter Production

The production of high-quality cat litter relies heavily on the efficient processing of raw materials, primarily minerals like bentonite, silica gel, or plant-based fibers, into a consistent, absorbent, and low-dust granular product. The grinding stage is arguably the most critical, as it determines the final product’s texture, clumping ability, and dust control properties. Among the various grinding technologies available, Raymond Mill technology, specifically modernized pendulum roller mills and vertical roller mills, has proven to be exceptionally effective for this application. This article delves into the process flow of cat litter production and examines the pivotal role played by advanced milling equipment.

Raw Material Preparation and Initial Crushing

The process begins with the receipt and inspection of raw bulk material, such as bentonite clay lumps. These lumps can vary significantly in size. The first mechanical stage involves primary crushing to reduce the raw material to a manageable size suitable for feeding into the grinding mill. A jaw crusher or a hammer mill is typically employed for this task, reducing the material to a nominal size of ≤30mm.

This pre-crushed material is then conveyed to a raw material storage hopper, which acts as a buffer to ensure a continuous and steady feed to the subsequent grinding mill, a key factor in maintaining stable mill operation and consistent product quality.

The Core Grinding Process: Raymond Mill Technology

The heart of the cat litter production line is the grinding mill. While the term “Raymond Mill” is often used generically, it refers to a class of mills that use pendulum-mounted grinding rollers to crush material against a stationary grinding ring. For modern cat litter production, advanced versions of this technology are essential.

The process within the mill is a combination of impact, compression, and shear forces. Material from the feed hopper is metered into the mill’s grinding chamber by an electronic vibrating feeder. The rotating grinding rollers, suspended from a spider assembly, swing outward due to centrifugal force and roll against the inner surface of the grinding ring. The material is crushed and ground between these components.

A critical integrated component is the dynamic classifier atop the mill. It controls the final product fineness by separating fine particles, which are carried away by the air stream, from coarse particles, which fall back onto the grinding ring for further size reduction. This closed-circuit grinding system is highly efficient.

Recommended Equipment: MTW Series Trapezium Mill

For producers seeking high capacity and reliability for medium-fineness grinding (30-325 mesh), our MTW Series Trapezium Mill is an ideal solution. This advanced iteration of the traditional Raymond mill incorporates numerous engineering improvements specifically beneficial for mineral processing like cat litter production.

Its key advantages include:

• Durable Wear Parts Design: The combination-style shovel blades and curved wear surface design significantly extend the service life of critical wear parts, reducing maintenance frequency and cost.
• Optimized Airflow: The patented curved air duct reduces air flow resistance, enhancing transmission efficiency and reducing energy consumption.
• Efficient Drive System: The use of an integral conical gear transmission delivers power with up to 98% efficiency, ensuring stable operation and lower installed costs due to its compact design.
• High Capacity: With models like the MTW215G offering throughputs of 15-45 tons per hour, it can serve the needs of both large and medium-scale production facilities.

The ability to consistently produce material within the 30-100 mesh range—perfect for clumping litter—makes the MTW Series a cornerstone of efficient production lines.

Post-Grinding Classification and Collection

The fine powder lifted by the air stream from the grinding chamber first enters a high-efficiency cyclone collector. Here, the majority of the product (approximately 80-90%) is separated from the air flow by centrifugal force and discharged through a rotary airlock valve, which prevents air leakage.

The remaining fine dust-laden air is then drawn into a pulse-jet baghouse dust collector. This environmental control equipment is crucial for meeting modern factory emission standards. It filters the exhaust air, capturing the sub-micron dust particles and ensuring that the air released into the atmosphere is clean. The collected ultra-fine dust is also returned to the product stream, maximizing yield.

Final Product Blending, Packaging, and Storage

The ground and collected cat litter base material may then be transferred to a blending system. Here, additives—such as odor control agents (e.g., baking soda, activated charcoal) or fragrance—are uniformly mixed into the bulk material.

The final blended product is conveyed to automated packaging machines, which weigh and fill it into bags, boxes, or jugs. The packaged cat litter is then palletized and moved to the warehouse for storage and distribution. Throughout this process, dust containment systems are vital to maintain a clean plant environment.

Advanced Solution for Ultra-Fine and Specialty Litter

While the MTW Series is excellent for standard grades, the market trend towards low-dust, ultra-absorbent, and lightweight litters sometimes demands even finer grinding. For these premium applications, our SCM Series Ultrafine Mill is the superior choice.

This mill is engineered to achieve fineness levels between 325 and 2500 mesh (D97 ≤5μm), which is far beyond the capability of standard mills. Its technological edge includes:

• Ultra-High Precision Classification: A vertically mounted turbo-classifier ensures extremely sharp particle size cuts, eliminating coarse grit and producing a remarkably uniform and smooth powder. This directly translates to a premium, ultra-low-dust cat litter product.
• Exceptional Energy Efficiency: Despite its ability to produce ultra-fine powder, the SCM Mill is designed for low energy consumption, operating with approximately 30% less energy than traditional jet mills of comparable output.
• High Hygiene and Stability: The innovative no-bearing screw feeder and fully sealed grinding chamber prevent lubricant contamination and ensure stable, leak-free operation—a critical factor for consumer products.

For producers aiming to develop a premium segment product with superior clumping and dust control properties, the SCM Ultrafine Mill provides the necessary technological capability.

Conclusion

The production of high-quality cat litter is a precise engineering process where the selection of grinding equipment is paramount. Modern Raymond Mill-based systems, such as the MTW Series Trapezium Mill for general use and the SCM Series Ultrafine Mill for premium applications, offer the efficiency, control, and reliability required by today’s manufacturers. By integrating this advanced milling technology with proper crushing, classification, and dust collection, producers can achieve optimal product characteristics, maximize yield, minimize energy costs, and operate in an environmentally responsible manner. Investing in the right grinding technology is the foundation for success in the competitive cat litter market.