With both the fine and coarse kaolin particle fractions, brightness is enhanced through one or move processes including bleaching, magnetic separation, flocculation, ozonation, flotation, and oxidation, which will remove iron, titanium, organic, and other undesirable materials.

The process involving the following:

•         Delamination

•         Filtering & drying

•         Additional processing

•         Packaging & shipping

Delamination

For customers who want a delaminated clay product suited for lightweight coating applications, coarse particles are used. Delamination occurs as the coarse particles of kaolin ­ which when magnified appear as "booklets" ­ are broken into thin platelets.

After delamination, the brightness of the coarse particles may be enhanced through one or more of the same processes used in the fine particle fraction.

Filtering & drying

Large rotary vacuum filters remove water from the slurried kaolin. Large gas-fired spray dryers remove and evaporate the remaining moisture.

Additional processing

Additional processing (for example, calcining), further increases its brightness, whiteness, and opacity, electrical insulating properties, hardness and durability, which enhance the value of higher-grade kaolin.

Packaging & shipping

Following the final treatment processes, kaolin-based products may be stored in tanks in slurry form or in silos and warehouses in dry form.

Most kaolin-based products shipped to paper customers are transported in slurried form. Others may use dry bulk. Kaolin is also packaged in one ton bags and 50 lb. and 25 kg. bags.