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Mineral filler optimization

Choosing and adjusting filler properties, mainly particle size, for a given application.

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Overview

The same mineral can behave very differently depending on how it is ground and classified. Particle size distribution, particle shape and surface properties affect how a filler works in a formulation.

We start from the application’s requirements and choose the mineral, fineness and particle size distribution to meet them. If no existing grade has the required properties, we look at adjusting the material.

Particle size distributionIllustrative frequency curve (bell-shaped) and cumulative curve (S-shaped) on a logarithmic particle size axis. D10, D50 and D90 are the sizes at which the cumulative curve reaches 10%, 50% and 90%.FrequencyCumulative volume0%10%50%90%100%D10D50D90Particle size (logarithmic scale)

What we look at

Particle size distribution
D10, D50 and D90 describe the fine end, the median and the coarse end of the powder. Each affects different properties.
Top cut
The coarsest particles often decide surface smoothness and film defects, so the coarse end is controlled closely.
Particle shape
Blocky, platy and irregular particles influence viscosity, packing and film properties in different ways.
Mineral selection
Density, hardness, chemistry and whiteness differ between minerals and limit which ones suit each application.

Relevant applications

  • Powder Coatings

    Filler selection and particle size for flow, surface appearance, gloss and cost.

  • Industrial Paints

    Mineral fillers for the application and film requirements of industrial paints.

  • Decorative Paints

    Fillers that support opacity, finish and application properties in architectural paints.

  • Protective Coatings

    Mineral selection for barrier and durability considerations in protective systems.

  • Plastics & Polymers

    Mineral fillers for plastics and polymer compounds, where particle size and surface compatibility affect processing and properties.

Related products

  • BaSO₄

    Micronized Barium Sulfate

    A dense, chemically inert white filler with low oil absorption, used mainly in coatings.

    Micronized grades

  • CaCO₃

    Micronized Calcium Carbonate

    A widely used filler for paints, coatings and polymers. Particle size and distribution affect gloss, rheology and cost.

    Micronized grades

  • Kaolin

    A platy aluminosilicate mineral used in some coating and polymer formulations for its effect on rheology, matting and film properties.

    Natural minerals

  • Special Mineral Fillers

    Minerals selected for a specific function in a coating or plastic formulation.

    Specialty and custom

All technical services

  1. Powder coating formulation development

    Help with developing and adjusting powder coating formulations, starting from the filler.

  2. Mineral filler optimization

    Choosing and adjusting filler properties, mainly particle size, for a given application.

  3. Formulation cost optimization

    Reviewing filler type and loading to lower formulation cost while keeping the required properties.

  4. Technical troubleshooting

    Diagnosing formulation and processing problems that may be linked to the filler.

  5. Product development

    Developing new mineral grades with customers when no existing grade meets the requirement.

  6. Application testing & technical support

    Testing fillers in formulations and supporting your team during qualification and production.

  7. Customized mineral solutions

    Mineral grades and compounds made to a customer’s own material specification.

Discuss Mineral filler optimization with our technical team

Tell us about your application, formulation and targets. We will come back to you with the next steps.

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