A practical guide on the correct two-stage method for adding ceramic diluting agents to ensure stable slurry, reduced viscosity, and improved production quality.
A ceramic diluting agent plays an essential role in ceramic production by reducing slurry viscosity and improving dispersion without increasing the water content. To achieve maximum effect, ceramic diluting agents must be added using a proper method. The most widely accepted and technically effective approach is the two-stage addition method.
For basic information about ceramic diluting agents, please see the product introduction page. If you want to understand how these agents disperse ceramic particles, refer to our detailed working principle guide.
1. Why Use the Two-Stage Method?
While some factories add the diluting agent in a single step, this often results in:
- Incomplete dispersion
- Increased dosage requirement
- Slurry instability after storage
- Poor viscosity control
- More defects in production
The two-stage method ensures better interaction between the diluting agent and ceramic particles, improving both dispersion efficiency and long-term stability. It also helps reduce the overall dosage.
2. The Two Stages Explained
Stage 1: Pre-Dispersion During Ball Milling
The first portion of the ceramic diluting agent should be added at the beginning of the ball milling process. This allows the dispersant to coat the surface of ceramic particles while they are being broken down mechanically.
Benefits of Stage 1:
- Promotes early dispersion
- Reduces initial slurry viscosity
- Improves grinding efficiency
- Ensures uniform particle breaking
Stage 2: Adjustment Before Final Slurry Screening
The second portion is added near the end of mixing or milling to fine-tune viscosity and ensure stable slurry behavior before sieving, storage, or application.
Benefits of Stage 2:
- Precise viscosity adjustment
- Improved stability during storage
- Avoids over-dispersion
- Ensures consistent pumpability and casting behavior
3. Recommended Dosage Ratio for the Two-Stage Method
Although actual dosage depends on raw materials and formulations, the typical two-stage ratio is:
| Addition Stage | Percentage of Total Dosage | Purpose |
|---|---|---|
| Stage 1 (Ball Milling) | 60% – 80% | Initial dispersion and grinding support |
| Stage 2 (Final Adjustment) | 20% – 40% | Viscosity control and stability improvement |
Exact values may vary based on clay characteristics, water hardness, grinding duration, and specific casting requirements.
4. Tips for Achieving the Best Results
- Pre-dilute the agent with water for easier dispersion
- Add gradually instead of all at once
- Monitor slurry viscosity throughout milling
- Adjust pH if necessary for optimal performance
- Combine with compatible deflocculants when required (Learn more about deflocculants: Key Features of Deflocculants)
5. Common Problems & How the Two-Stage Method Solves Them
| Common Issue | Cause | Solution with Two-Stage Method |
|---|---|---|
| Slurry thickens after rest | Incomplete dispersion | Add Stage-2 for stability improvement |
| High initial viscosity | Poor early dispersion | Use Stage-1 during ball milling |
| Over-dispersion or segregation | Excessive one-time addition | Split the dosage into two controlled stages |
| Large dosage needed | Inefficient dispersing | Two-stage method reduces total consumption |
6. When Should You Use the Two-Stage Method?
This method is highly recommended when:
- Your slurry has high solid content
- You want to reduce water usage
- Grinding time is long
- You require very stable storage performance
- You need more precise viscosity control
It is widely used in:
- Ceramic tiles
- Porcelain and stoneware
- Sanitary ware
- Glazes and engobes
- High-alumina and zirconium ceramics
7. Summary
The two-stage method is one of the most effective techniques for using ceramic diluting agents. By dividing the dosage into two strategic points—early milling and final adjustment—you achieve:
- Better dispersion
- Lower viscosity
- Higher green body strength
- Reduced additive usage
- Improved production stability
If you need help optimizing your slurry formulation, you can explore our complete ceramic additive product list or see customer application cases. For technical support, feel free to contact our team.