Egyptian Masterbatch Producer Upgrades to High-Capacity PE Pulverizer

A color masterbatch manufacturer in Cairo, Egypt, needed to upgrade from an aging, underpowered pulverizer that was limiting their production capacity. Their expanding customer base in the MENA region required increased output while maintaining the tight particle size control essential for masterbatch quality. Their existing 30 kW machine was producing only 80-100 kg/h and suffering frequent downtime.

Zhiyi Machine provided a ZPM-600 disc-type PE pulverizer with enhanced configuration:

• ZPM-600 disc mill with 55 kW motor — nearly double the capacity of their previous unit
• Precision disc gap control for reproducible 20-40 mesh particle size for masterbatch
• 16-bag pulse dust collector ensuring clean operation in the production hall
• Automatic load-sensing feeding system to prevent overload and ensure consistent output
• Comprehensive spare parts kit included with initial shipment

Remote commissioning was completed via video call with their maintenance team over three sessions.

• Production increase: From 80-100 kg/h to 300-350 kg/h — a 3.5× improvement
• Particle consistency: 20-40 mesh distribution within ±5% variation batch-to-batch
• Downtime: Reduced from 12 hours/month to under 2 hours/month
• Energy per kg: Reduced by 28% due to more efficient grinding and motor sizing
• Customer satisfaction: Enabled them to take on three new major clients within 6 months