Superior surface area. Acid resistant. Stable up to 1000°C. Designed for continuous industrial use.
Our ceramic saddles are used by chemical plants, fertilizer units, refineries, and industrial towers across India and in 25+ countries. As a direct manufacturer and supplier based in Mandsaur, we produce ceramic saddle packing to consistent dimensional standards, test every batch before dispatch, and provide full technical support from product selection through to column loading.
Ceramic saddle packing is a type of random tower packing shaped like a curved saddle. The saddle geometry is specifically designed to prevent pieces from nesting on top of each other inside a column. This creates a more open, uniform packed bed with better liquid distribution, higher surface area utilisation, and lower pressure drop compared to simple ring-shaped packing.
The two most common types are Berl saddles and Intalox saddles. Intalox saddles are the more widely used modern design, offering improved performance over Berl saddles due to their smoother geometry and more uniform stacking behaviour.
Our ceramic saddles tower packing is manufactured from high-grade porcelain and stoneware ceramic, kiln-fired for mechanical strength, chemical resistance, and long service life.
Who is this for?
This product is designed for:
Key problems it solves:
Step 1: Tell Us Your Column and Process Requirements Share your column diameter, operating temperature, process fluids, flow rates, and current packing type if replacing existing media. A short email or inquiry form is all we need to get started.
Step 2: Technical Review and Product Recommendation Our process engineer reviews your requirements and recommends the right saddle type, size, and ceramic grade for your application. You receive a written technical proposal with specifications, quantity estimate, pricing, and lead time within 24 to 48 hours.
Step 3: Manufacturing Under Quality Control Your order is produced in our Mandsaur facility using controlled raw material batches and firing profiles. Dimensional inspection, crush strength testing, and bulk density verification are completed on every batch before approval for dispatch.
Step 4: Secure Packaging and Documentation Finished saddles are loaded into woven PP bags or jumbo bags with inner liners. Export shipments are created and labeled as per destination requirements. All quality documents, test certificates, and commercial paperwork are prepared and included with the shipment.
Step 5: Delivery and Post-Installation Support We deliver to your facility with complete documentation. Our technical team provides column loading procedures, installation guidance, and is available by phone and email for any questions during commissioning and operation.
Feature | Details |
Available types | Intalox saddles, Berl saddles |
Material grades | Porcelain, stoneware ceramic |
Size range | 13 mm to 75 mm (custom available) |
Temperature rating | Up to 1000°C continuous |
Bulk density | 500 to 700 kg/m3 depending on type and size |
Chemical resistance | All acids except HF, stable in alkalis and most solvents |
Void fraction | 60% to 75% depending on size |
Quality standard | ISO 9001 compliant manufacturing |
Packaging | PP woven bags, jumbo bags, export crating |
Every order includes:
We are a dedicated ceramic saddle packing manufacturer with our own production facility in Mandsaur. We control the full production process from raw material preparation through forming, kiln firing, inspection, and export packing. No outsourcing, no third-party supply, and no compromise on quality at any stage.
Expert on Our Team Our lead applications engineer, with years of hands-on experience in ceramic tower packing manufacturing, column performance troubleshooting, and process application engineering across the chemical, fertilizer, and petrochemical sectors. He personally leads technical reviews for all customer inquiries and oversees quality audits on production batches.
What sets us apart:
Real Customer Result from Madhya Pradesh: A phosphoric acid plant in Madhya Pradesh was experiencing channeling and poor acid absorption in a 0.9-meter diameter absorption tower packed with plain ceramic Raschig rings. After replacing the packing with our 38 mm ceramic Intalox saddles during a planned shutdown, their absorption efficiency improved by 14%, column pressure drop fell by 23%, and the plant reported stable, even liquid distribution across the full tower cross-section. The packing has operated continuously for 4 years with zero replacement or maintenance intervention.
Industry | Typical Application |
Sulphuric Acid Manufacturing | Drying towers, absorption towers, oleum columns |
Fertilizer and Agrochemical Plants | Ammonia scrubbers, acid absorption, nitric acid towers |
Petrochemical and Refining | Distillation, quench, and stripping columns |
Pharmaceutical Manufacturing | Solvent recovery, API distillation, fine chemical separation |
Chlor-Alkali Industry | Chlorine absorption, caustic concentration towers |
Air Pollution and Environmental Control | Industrial gas scrubbers, VOC destruction units |
Edible Oil Processing | Deodorization and fatty acid stripping towers |
Power Generation | Flue gas desulphurisation, wet scrubbing systems |
Water and Effluent Treatment | Degassing, aeration, and ammonia stripping towers |
Specialty and Fine Chemicals | High-purity separation and liquid-liquid extraction |
We provide application-specific recommendations for every industry. Our team understands the difference in operating conditions between a sulphuric acid absorption tower running at 100°C and a pharmaceutical solvent recovery column handling chlorinated solvents, and we advise accordingly.
Ceramic saddle packing consists of curved saddle-shaped ceramic pieces loaded randomly into industrial columns. The saddle shape prevents pieces from nesting, keeps the packed bed open, and creates a large surface area for gas-liquid contact. It is used in distillation, absorption, scrubbing, and stripping columns across chemical, fertilizer, and environmental industries.
Berl saddles were the original saddle design. Intalox saddles are an improved version with a smoother, more symmetrical geometry that gives more consistent packing behaviour, higher surface area, and lower pressure drop. For most modern applications, Intalox saddles are the preferred choice.
Ceramic saddles offer higher effective surface area, lower pressure drop, and better liquid distribution than Raschig rings of the same size. The saddle shape avoids nesting, which is a common limitation of ring packing. In most column applications, saddles give better performance per unit volume of packed bed.
Our ceramic saddle packing is rated for continuous service up to 1000°C. This makes it suitable for high temperature gas absorption, steam stripping, and thermal oxidation applications where plastic packing cannot be used.
Yes. Ceramic saddles resist attack from sulphuric acid, hydrochloric acid, nitric acid, phosphoric acid, and most organic acids at all working concentrations. The only exception is hydrofluoric acid, which attacks ceramic materials. This is why ceramic saddle packing is widely specified for acid towers and chemical scrubbers.
With correct installation and operation within rated chemical and temperature limits, ceramic saddle packing typically lasts 6 to 10 years in industrial columns. Service life depends on operating conditions, the aggressiveness of the process fluid, and the care taken during loading and unloading.
Wet loading is the recommended method. The column is partially filled with water before packing is poured in, allowing pieces to settle gently without breaking. Dry loading is also possible but requires more care to avoid damage to the saddles and column internals. We include a full loading procedure with every order.
Yes. Ceramic saddles are random packing and replace ring packing directly without changes to column internals. Many plants upgrade from Raschig rings to Intalox saddles during a scheduled shutdown to improve column efficiency without capital investment in new equipment.
Standard sizes and types are available within 7 to 15 working days. Large quantity orders or non-standard sizes may require 3 to 5 weeks. We maintain stock of popular sizes for urgent requirements and can dispatch samples within 5 to 7 working days.
Every shipment includes a product data sheet, dimensional inspection report, bulk density and crush strength test certificate, pre-shipment inspection report, and commercial invoice. Third-party inspection reports and material conformity certificates are available on request for export orders.
