In today’s manufacturing environment, reduced production time and increased quality and products flexibility are important to remaining competitive. The most important steps in the ceramic manufacturing process arguably lie in the drying and sintering. The process for manufacturing these insulators enables the green components to contain 15-18% moisture after the fabrication stage. The components need to be dried to < 1% moisture prior to glazing and sintering. Conventional dryer takes a few hours to dry the ceramic which is poor heat conductive feature. In the conventional process, the drying of the insulators is carried out using a humidity-assisted dryer in order to avoid the formation of defects during drying. Due to the insulators’ complex shapes and sizes, the drying times varied from 50-60 hours for disc insulators, and 250-300 hours for solid core insulators. It was therefore essential to develop a technology for the fast drying of these components without introducing defects.

All of the above problems can be overcome through the use of environmentally friendly microwave technology for ceramic processing. The heating rate can be substantially higher during microwave processing, which results in shorter cycle times and lower energy costs. The use of 2.45 GHz microwave energy has been used by many researchers worldwide, mainly for sintering various ceramic materials at high temperature. However, though microwave drying has been extensively studied by many worldwide materials researchers, few reports are available on the use of the technology for processing ceramic materials.

In all cases, the temperature can cause these interactions to change. The ideal microwave dryer enables the temperature profile to be adjusted to optimize drying for each material.

“Are microwave drying systems a good investment?” This question is often asked in the ceramic industry. The answer is a resounding “yes” for many applications. Microwave drying systems tested in various areas of the ceramic industry have produced shortened drying times; reduced drying defects; the potential for product innovation; and easy integration into flexible, automated manufacturing systems. A new drying technology can shorten drying times, reduce drying defects, increase the potential for product innovation and provide a seamless integration into automated manufacturing systems

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