Home / News & Blog / Abrasive Blog / How DOMILL Ensures Product Quality and Consistency in Production and Delivery
In today`s manufacturing landscape, product quality and consistency are the cornerstones of a company`s competitiveness. As a leading manufacturer of brown fused alumina abrasives, DOMILL has implemented a series of rigorous measures and advanced management practices to ensure the highest standards of quality and consistency throughout the production and delivery process. Here`s how we do it:
We have introduced international advanced production equipment and technologies to ensure the precision and stability of the production process. For example, during the abrasive production process, automation production lines and intelligent control systems are used.
Automation Production Lines: We have invested in multiple automated production lines, including roller production lines, Barmac production lines, natural gas calcining tunnel kilns, shaping machine production lines, and air washing production lines. This enables the entire process from raw material input to finished product packaging to be automated, reducing errors caused by manual operations and significantly improving production efficiency and product consistency.
At the same time, we have a dedicated process research and development team that continuously optimizes the production process to improve product performance. For example, by improving the sintering process, the hardness and wear resistance of abrasive particles are enhanced. We can also set different parameters according to the quality requirements of customer orders.
We implement full-process quality monitoring during production. Each production stage has dedicated inspection points to monitor key parameters of the product in real-time. For example, during the production of abrasive particles, strict testing is done on particle size, shape, hardness, and other metrics to ensure that every batch meets design requirements. We also have an advanced laboratory equipped with laser particle size analyzers, scanning electron microscopes (SEM), and other equipment for high-precision analysis and evaluation of products.
Raw Material Inspection: Bauxite is the primary raw material used to produce brown fused alumina abrasives. The higher the aluminum oxide content, the better the quality of the final product. Before raw materials enter the production process, quality inspectors conduct tests to ensure that all materials meet strict standards. In the raw material storage area, the ground is covered with steel plates to prevent contamination during loading and unloading.
Smelting Process: We use a specific raw material ratio to smelt and refine materials using the dump method. Compared to the block method, the dump method has advantages like semi-continuous production, better heat energy utilization, high production efficiency, and low power and material consumption. The process involves: crushing raw materials, mixing furnace materials, smelting, bagging, cooling, crushing, and storing semi-finished products.
Granulation Process: We choose suitable raw materials based on the finished product standards, using Barmac or roller production lines for crushing, dust removal, magnetic separation, mixing and sieving, calcining, deep processing, air washing, and packaging. During this process, strict control is exercised over the abrasive grain’s particle size composition, bulk density, metal impurity content, color, etc. For calcined products, raw materials are tested and pre-fired before batch production, with process parameters adjusted, and then processed to ensure consistency in product parameters.
Process Monitoring: Every product in production has quality labels for batch management, making it easy to trace later. During production, the size, purity, and chemical composition of the particles are continually monitored to ensure that each batch meets the specified standards.
Final Product Testing: Every batch of products undergoes comprehensive testing, including tests for particle size composition, magnetic content, bulk density, ball mill toughness, iron, impurities, and particle shape to ensure it meets customer requirements. Samples are tested in the lab, and delivery samples are stored for one year. Test data is uploaded to an electronic system, ensuring consistent quality for bulk orders.
We have established a comprehensive quality management system that spans every stage, from raw material procurement to product delivery. We have been ISO 9001 certified to ensure that all production processes meet international standards. Regular internal audits and external evaluations help optimize processes and ensure the effectiveness and continuity of the quality management system.
Internal Audits: We conduct a thorough internal audit every quarter to review the quality management practices in each department and promptly correct any issues.
External Evaluation: Each year, we invite a third-party certification body for an external evaluation to ensure that the quality management system complies with the latest standards.
Raw materials form the foundation of product quality. We have long-term partnerships with well-known suppliers both domestically and internationally to ensure a stable supply of high-quality raw materials. Every batch of raw materials undergoes strict testing, including chemical composition analysis and physical performance testing, and only materials that meet standards are allowed into production.
Supplier Evaluation: We have a supplier evaluation system that assesses vendors based on quality, delivery times, service, and other criteria to select the best suppliers.
Raw Material Testing: When raw materials arrive, the quality control department conducts sampling tests, including checks on chemical composition, particle size distribution, and hardness, to ensure the materials meet production requirements.
One of the key factors for abrasive particle quality is the purity of the raw materials used. We place a strong emphasis on using high-purity raw materials to reduce impurities that could affect the performance of the final product. This helps ensure the consistency of abrasive tools, such as cutting speed, surface finish, and tool lifespan.
We are always customer-oriented and have established a complete customer feedback system. After product delivery, we actively collect feedback from customers and use it as a basis for improvement. Through continuous improvement, we not only meet current customer needs but also anticipate future market demands and proactively optimize products.
Customer Satisfaction Surveys: We regularly conduct customer satisfaction surveys to understand customers’ assessments of product quality and service, identify areas for improvement, and make timely adjustments.·
Continuous Improvement Projects: Multiple continuous improvement projects are set up to address issues found through customer feedback and internal audits, with improvement measures developed and tracked for implementation.
At the final stage of product delivery, we also focus on details. We use standardized packaging and shipping processes to ensure that products are not damaged during transit. For precision abrasives, moisture-proof and shockproof packaging materials are used, and reliable logistics partners are selected to ensure safe delivery to customers.
Packaging Design: We design specialized packaging based on product characteristics, such as moisture-proof, shockproof, and anti-static features, to protect the products from environmental influences during transport.
Logistics Cooperation: We partner with several well-known logistics companies to ensure that products are safely and timely delivered to customers.
We place a high priority on environmental protection and safety during production. We use low-temperature control production processes that meet environmental standards and are minimally affected by environmental regulations. Additionally, we have equipped various environmental protection devices, such as online wind dust collection systems and sedimentation collection equipment, to ensure effective treatment of dust and impurities during production.
Environmental Protection Measures: We use various environmental technologies, such as wind dust collection, sedimentation collection, centrifugal separation, and natural gas calcining tunnel kilns, to ensure that waste gas and wastewater are properly treated.·
Safety Measures: We are also equipped with safety devices, such as temperature control systems and electrolyte treatment systems, to ensure safety and environmental protection during production.
Through a combination of advanced technology, rigorous quality control, robust management systems, and a commitment to continuous improvement, DOMILL ensures the highest levels of product quality and consistency. These efforts not only strengthen our competitive edge but also deliver reliable solutions to our customers.
Looking ahead, DOMILL remains dedicated to our Quality First philosophy, driving innovation and excellence in the abrasives industry while creating lasting value for our customers.
