Recently, we encountered some frustrating problems on the ceramic production floor. The same deflocculant worked perfectly in the backing (standard body) formulation, but completely failed in the surface (decorative layer) formulation.

Meanwhile, deflocculant stored in the warehouse for some time developed a thick layer of sediment at the bottom of the drums — impossible to mix back in.

These two issues may seem independent, but they both point to the same core problem: the application boundary of deflocculants and product stability. Based on our field experience, let's take a deep dive into both issues.

🔴 Symptoms

• Backing (Standard Body Formulation): With the normal dosage of deflocculant, the slurry flows well after ball milling, with a flow time of 35-45 seconds (Ford Cup #4), solid content reaching 68-70% — everything runs smoothly.
• Surface (Decorative Layer Formulation): With the same deflocculant and the same dosage, the slurry came out noticeably thicker, with flow time soaring to over 80 seconds — sometimes even too thick to stir. We had to add more water to reduce viscosity, but that dropped the solid content, increasing spray drying energy consumption.

🔍 Root Cause Analysis

Why does the same deflocculant perform so differently between backing and surface bodies? The core reason lies in the fact that the mineral compositions of the two formulations are completely different:

✅ Solutions

• Run new lab trials: For the surface formulation, test different deflocculant grades (e.g., GOWAY FG-2017, FG-MK03, FG-SL01A) with gradient dosage trials to find the best match and optimal dosage.
• Don't use a one-size-fits-all approach: Prepare and control backing and surface slurries separately, each with its own deflocculant strategy.
• Watch for organics in the surface formulation: If humic acid or other organic impurities are present, they will consume significant amounts of dispersant. Consider increasing the dosage or switching to a deflocculant grade with better resistance to organic interference.

🔴 Symptoms

• Deflocculant stored in the warehouse (especially liquid or semi-liquid forms) develops a noticeable white/gray sediment layer at the bottom of the drums after some time — like a thick layer of "sludge."
• If not thoroughly mixed before use, the upper layer is too dilute and the lower layer is too concentrated. When added to the slurry, the performance is compromised — sometimes it doesn't disperse enough, and sometimes it's overdosed, causing the slurry to become "over-dispersed" or even "re-flocculated."

🔍 Root Cause Analysis

The root cause of deflocculant sedimentation is closely related to its product form and formulation system:

• Limited solubility/dispersibility: The active ingredients of some deflocculants have limited solubility in water or carrier. After prolonged storage, supersaturated portions gradually precipitate and settle.
• Density difference: If the deflocculant is a suspension (rather than a true solution), there is a density difference between the active particles and the carrier liquid. Over time, the heavier particles will naturally settle.
• Temperature changes: In winter, low temperatures reduce the solubility of some deflocculant components, making them more prone to crystallization or precipitation.
• Excessive storage time: Every chemical product has a shelf life. The longer it sits, the greater the risk of sedimentation.

✅ Solutions

• Thorough mixing before use: Liquid deflocculants must be thoroughly shaken or mechanically stirred before use to ensure uniform concentration from top to bottom.
• Choose a more stable product form: Powder/granular deflocculants (such as GOWAY's granular products) have no sedimentation issues. They are more stable in storage and can be simply weighed on a dry basis before use — no stratification concerns.
• Manage inventory turnover: Follow the FIFO (First In, First Out) principle to prevent deflocculant from sitting in the warehouse for too long.
• Winter insulation: During cold seasons, maintain warehouse temperature above 10°C to reduce low-temperature precipitation.