CALES DE LLIERCA

01/12/2025 | Case Studies

Limestone sorting

MEET THE CLIENT | Cales de Llierca, Spanien

Cales de Llierca is a leading manufacturer of high-quality calcium oxide and calcium hydroxide based in Girona, Spain. As part of the Calcinor Group and a sister company of Eurotalc within the Eurominerals Group, the company relies on cutting-edge technology to ensure the quality of its products. A central element of their production process is the sorting of raw materials to produce precipitated calcium carbonate (PCC). The company places a strong emphasis on achieving the highest color quality in its limestone, which was a key factor in their investment in REDWAVE technology.

THE CHALLENGE | Raw Material Preparation

Cales de Llierca, a pioneer in limestone production, has gained a significant competitive advantage by strategically using advanced sorting technology. The challenge was to extract high-quality limestone from raw materials to meet the ever-growing demands of customers.
In response to increasing production requirements, Cales de Llierca reached out to REDWAVE to explore the implementation of a reliable and precise sorting technology. In the summer of 2019, an intensive sorting trial was conducted, providing the crucial proof: The REDWAVE ROX sorting machine, equipped with a state-of-the-art double-camera system, met all expectations of the Spanish company.

THE SOLUTION | REDWAVE 2000 ROX CC Sorting Technology

Based on the successful sorting trials, Cales de Llierca decided to invest in two REDWAVE ROX sorting machines, both equipped with advanced double-camera systems. These sensor-based sorting machines, with a sorting width of 2 meters, allow for precise color-based material separation. This enables efficient removal of dark particles, ensuring the production of limestone with the highest color purity. The 2-meter-wide system can achieve the necessary throughput of 80 tons per hour for the 25-50 mm grain size range and 120 tons per hour for the 50-90 mm range.

Technical Details of the System:

Number of machines: 2 REDWAVE 2000 ROX CC
Sorting width: 2.0 m
Grain size 1: +25 - 50 mm, throughput: 80 t/h
Grain size 2: +50 - 90 mm, throughput: 120 t/h
Sorting criterion: Color-selective sorting to remove dark minerals
Technology: High-resolution RGB cameras and dual-side detection technology for precise color sorting
Commissioning: 2022

The REDWAVE ROX CC technology uses a combination of cutting-edge sensors and intelligent image processing to optimize the quality of the raw material. High-resolution cameras and specialized algorithms allow for precise analysis of each particle. Dark impurities are specifically removed from the material stream using air blasts, ensuring only the highest quality limestone is used for PCC production.

Results and Benefits for Cales de Llierca

Improved product quality: Thanks to the precise sorting, the quality of the raw material has been significantly enhanced.
Optimized production processes: Automated sorting improves efficiency in downstream processing.
Increased cost-effectiveness: The reduction of material losses and fewer off-spec batches leads to cost savings.

CUSTOMER FEEDBACK

"Thanks to the double-camera system, the purity of the limestone is exceptionally high – an investment that has paid off in every way. Choosing REDWAVE was a clear step towards future-proofing and quality assurance. The machines deliver excellent sorting performance, reduce manual labor, and help us increase the efficiency of our production. We are extremely satisfied with the collaboration and the results achieved with the REDWAVE ROX sorting machines," says Albert Alias, Quarry Manager at Cales de Llierca.

CONCLUSION

The implementation of the REDWAVE 2000 ROX CC sorting systems has proven to be a groundbreaking investment for Cales de Llierca. The combination of high processing capacity, intelligent sensor technology, and precise color selection enables a sustainable optimization of production processes. This solidifies Cales de Llierca's position as a leading provider of high-quality lime products and highlights its commitment to utilizing cutting-edge technologies for an efficient and resource-saving future.

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