Rocktec partnered with Blue Pacific Minerals to deliver a purpose-built zeolite processing plant at their Tokoroa facility in New Zealand. This multi-stage plant handles various phases of mineral processing and enables high-efficiency production of zeolite for industrial, agricultural, and commercial use across Australasia.
Project Overview: Multi-Stage Zeolite Processing System
- Client: Blue Pacific Minerals
- Location: Tokoroa, New Zealand
- Industry: Industrial Minerals – Zeolite & Perlite
- Scope: Design, manufacture, and installation of a multi-stage zeolite processing plant
- Completion: Mid-2015 (Stages 1, 3 & 4)
The Challenge: Scalable Zeolite Production with Precise Screening
Blue Pacific Minerals needed a robust and scalable zeolite processing plant to support their expansion as New Zealand’s largest processor of zeolite and perlite ores. Additionally, they required screening and crushing systems capable of handling variable feed sizes while maintaining consistent product quality. To ensure long-term success, the plant also had to function as a fully integrated system—while still allowing independent operation in each stage.
Rocktec’s Solution: Stage-Based Mineral Processing Design
The plant started commercial production in mid July 2015 and is capable of producing 20 dry tonnes of zeolite per hour. Rocktec completed 3 stages of this plant (Stage 1, 3 & 4).
First Stage
- The system began with a 22m³ infeed hopper that ensured steady flow.
- Two belt feeders—measuring 900mm and 600mm wide—controlled the feed rate.
- Rocktec’s 6575 Rolls Crushers delivered uniform size reduction.
- The support structures were designed to accommodate later-stage connections.
Second Stage
- Four conveyors moved material efficiently between components.
- A Rocktec 8’ x 4’ Single Deck Medium Duty Screen handled first-pass sizing.
- Further screening occurred through a 6’ x 4’ Double Deck Medium Duty Screen.
- Rocktec added a third 6575 Rolls Crusher to increase throughput.
Fourth Stage
- Two conveyors completed the material flow into the final phase.
- A feed splitter chute and binset improved material control.
- Dust and fines were managed by two screw conveyors.
- A re-feed hopper redirected material back into the system as needed.
Implementation Process: Designed, Built and Delivered in Stages
- Planning: Rocktec worked alongside Blue Pacific Minerals to schedule delivery by production priority.
- Fabrication: Rocktec manufactured every component—including crushers and screens—at their Matamata facility using high-grade materials.
- Installation: The team installed each stage sequentially, maintaining uptime at the client’s site.
- Commissioning: Engineers completed testing after each phase, allowing for adjustments and immediate scale-up.
Results and Benefits
- High Output: The plant delivers 20 dry tonnes per hour, with stable, continuous operation.
- Scalable Design: Rocktec’s staged approach allowed expansion without disruption.
- Accurate Sizing: Screening and crushing systems provide tight particle control for quality output.
- Built for Longevity: The entire system performs reliably in industrial conditions with minimal downtime.
Conclusion: A Leading Zeolite Processing Facility in Australasia
This zeolite processing plant showcases Rocktec’s capability to deliver scalable, high-performance solutions for the minerals sector. As a result of this project, Blue Pacific Minerals now operates one of the most advanced processing facilities in the region—serving Australia, Asia, and the South Pacific.
Want to Learn More?
To explore zeolite applications in agriculture, filtration, and industry, visit the AZoMining guide to zeolite uses.
If you’re building a mineral processing plant or upgrading an existing system, get in touch with Rocktec to start your project.