LECA Production Line Solutions
We don’t just supply kilns — we deliver guaranteed LECA productivity.
AGICO introduces a new LECA production line solution(Lightweight Expanded Clay Aggregate). Our LECA production line solutions go beyond simply producing lightweight bentonite aggregates; they encompass the entire process, from raw materials and production technology to capacity and quality standards. We are not merely a supplier of equipment for producing lightweight expanded clay aggregates, but a turnkey solution provider for LECA plants.
Core Selling Point 1:
Raw Material Testing and Trial Run Services
“Can my raw material be used to produce LECA?”
“Will it produce lightweight or dense expanded clay aggregate?”
“What will be the expansion ratio of my material?”
Whether LECA can expand or not depends 50% on the raw material. Many clients have similar questions during their early-stage raw material preparation. After all, if the raw material is unsuitable, it will directly affect the expansion performance, expansion ratio, strength, and bulk density of the final product. In severe cases, the pellets may fail to expand (“no blooming”), show low expansion, become powdery, or have irregular shapes — all of which can seriously impact production results.
AGICO’s LECA production line solution provides you with raw material testing and trial operation services, helping you solve the biggest uncertainties in raw materials and ensuring worry-free production.
Core Selling Point 2:
Proven Rotary Kiln Expansion Process and Precise Pelletizing
Producing lightweight expanded clay aggregate is not simply about having a rotary kiln. The entire process mainly involves pelletizing followed by expansion firing. As a professional LECA rotary kiln supplier, AGICO provides rotary kiln equipment with stringent control over the expansion reaction, precise requirements for heat transfer, material layer thickness, and rotation speed. Professional granulation is necessary before firing. All of these aspects require precise control from a professional equipment supplier.
Core Selling Point 3:
Guaranteed Production Capacity and Optimized Energy Consumption
AGICO offers you more than just lightweight expanded clay aggregate production equipment; we provide high-quality production lines that achieve target output, lower energy consumption, and higher profits. Our goal in serving our clients is not merely “good equipment quality.”
Achieve target production capacity
Achieve target density and strength
Low operating costs
No quality control incidents
Why Invest in LECA Projects?
Lightweight Building and Green Building Materials Trends
LECA (Lightweight Expanded Clay Aggregate) possesses excellent thermal insulation, fire resistance, and structural strength, making it an important material for green building systems, lightweight concrete, and precast wall panels.
Rapid Growth in the Horticulture and Hydroponics Market
The rise of urban agriculture, rooftop gardens, and hydroponics has led to a continuous increase in demand for LECA. LECA granules are porous, offering both air permeability and water retention, and can be recycled multiple times, making them an ideal alternative to traditional substrates such as perlite and peat.
Resource Substitution and Circular Economy Advantages
LECA uses natural clay or shale as raw materials, does not consume scarce resources, and can partially replace sand and gravel aggregates in concrete. The production process significantly reduces ore mining and carbon emissions.
Strong Market Prospects
The global LECA market is projected to reach $2.5-3 billion by 2030, with the main growth coming from energy-efficient building materials and the horticulture industry.
Complete LECA Production Line Engineering & EPC Services
Raw Material Testing and Analysis
We offer laboratory testing for your raw materials to assess plasticity, loss on ignition, and expansion potential. We provide detailed data and recommendations before design.
Process Formulation and Granulation Solution
We control various granulation parameters such as moisture, binder, and disc speed to achieve stable granulation and uniform expansion.
Rotary Kiln Expansion Firing Scheme Design
We design precise temperature zones and rotation control for rotary kilns to achieve optimal expansion rate and strength with minimal fuel consumption.
Equipment Layout, Piping, and Dust Collection Design
AGICO provides plant layout, process piping, dust collection, and auxiliary equipment system design to ensure smooth workflows and environmental compliance.
Equipment Manufacturing and Installation Guidance
We provide high-quality equipment and conduct pre-assembly checks, on-site supervision, and commissioning support to ensure a smooth factory start-up.
LECA Production Line Manufacturing Process
1. Raw material crushing and screening
2. Ingredients and Mixing
3. Granulator system
4. Drying preheating section
5. Rotary kiln expansion calcination
cooling
6. Screening, packaging, and warehousing
Frequently Asked Questions (FAQ)
Which raw materials are suitable for producing expanded ceramsite?
LECA typically uses clay, shale, mudstone, or fly ash as its main raw materials, but not all raw materials can produce ideal expansion results. Before determining the process, the chemical composition and expansion properties of the raw materials need to be tested.
AGICO provides raw material analysis and expansion property testing services to help customers determine the formulation and optimal firing temperature range.
What is the typical energy consumption of a LECA rotary kiln?
Taking a production line with an annual capacity of 100,000 cubic meters as an example, the energy consumption is typically between 850-110 kcal/kg of finished product, depending on the moisture content of the raw materials, the kiln type, and the insulation design.
Through combustion system optimization and kiln insulation modification, AGICO can help customers reduce energy consumption by 8-12%.
How can the stable expansion of ceramsite be guaranteed?
The stable expansion of ceramsite depends on the following key factors: uniform granulation, with a particle size controlled between 5-20mm; a reasonable raw material ratio and moderate moisture content; and precise control of the kiln temperature profile within the range of 1100–1250℃.
AGICO can provide customized granulation processes and firing temperature profile design to ensure a stable expansion rate and strength.
What is the difference between EPC (Engineering, Procurement, and Construction) turnkey projects and simple equipment supply for a LECA production line?
Equipment supply: Only provides the manufacturing and delivery of mechanical equipment.
EPC (Engineering, Procurement, and Construction): Covers a complete service package from raw material testing, process design, equipment manufacturing, installation guidance, commissioning, and final production capacity.
The EPC model is particularly suitable for clients investing in a LECA project for the first time, as it better guarantees production capacity and energy consumption targets.
How long does it take to build a LECA production line?
For example, a medium-sized production line (100,000 cubic meters per year) typically takes 8–12 months from design to commissioning.
AGICO utilizes modular equipment design and parallel construction methods, which can reduce the cycle time to 6–8 months.