Production Process

In contrast to conventional manufacturing methods used by other producers of lightweight fill materials (e.g. expanded glass or expanded clay manufacturers), we are able to satisfy a wide range of requirements on the granulates. Our facility concept allows a temperature range of up to 1,200 °C, which we can control precisely during the expansion process. Conventional facilities only run standard temperatures and can, as with e.g. expanded glass manufacturers, only reach around 800 °C, which limits production opportunities.


Out of glass powder, stone dust, flux agents, expanding agents, separating agents and water, in various work steps and in various mixtures, the facilities manufacture the special mineral foam granules in the qualities of keraplus®, keraglas®, kerafil® and kerabims® as well as the special granules. Here each of the individual components is mixed together into a micro-granulate in a mixing machine, and subsequently formed into pellets. These are then ‘crumbed’ with a separating agent.

The separating agent prevents the agglomeration of the pellets through unwanted adhering during the expansion process.


After being formed this way, the moisture is drawn out of the “green pellets” in a dryer. Then they are expanded in an expansion oven at high temperatures, and subsequently stabilized at the oven exit by targeted cooling. After that the material is run through a cooler and a mechanism to separate the separating agent, which is returned back into the process. Before packaging, the product is separated into the individual grain sizes by a sieve.


This production method is protected by a patent. In addition to this, other property rights apply to the products and the configuration of the facilities.