Advanced saddle geometry. Higher void fraction. Designed for high-efficiency distillation, absorption, and scrubbing columns.
Our Ceramic Super Intalox Saddle products are trusted by chemical plants, fertilizer units, petrochemical refineries, and industrial tower operators across India and in 20+ countries. As a direct manufacturer and supplier based in Mandsaur, we produce super intalox packing media to consistent dimensional standards, test every batch before dispatch, and provide complete technical support from inquiry to commissioning.
Super Intalox packing media is an advanced generation of ceramic saddle packing. It is an improved design over the standard Intalox saddle, featuring a more open, multi-lobed geometry that further reduces nesting between pieces, increases the effective void fraction in the packed bed, and improves gas-liquid contact efficiency.
The shape allows liquid to spread more evenly across the column cross-section and lets gas flow through with less resistance. The result is a higher separation performance per unit height of packing compared to conventional saddles or rings.
Our Ceramic Super Intalox Saddle is manufactured from high-grade porcelain and stoneware ceramic. It is kiln-fired to achieve the mechanical strength, chemical resistance, and dimensional consistency that industrial column applications demand.
Who is this for?
This product is suitable for:
Key problems it solves:
Step 1: Share Your Column and Process Details Tell us your column diameter, operating temperature, process fluid, current packing type if replacing, and your separation or throughput targets. An email or short technical form is enough to get started.
Step 2: Product Recommendation and Technical Proposal Our process engineer reviews your requirements and recommends the right size and ceramic grade of super intalox packing for your application. You receive a written technical proposal covering product specifications, quantity estimates, pricing, and delivery timeline within 24 to 48 hours.
Step 3: Manufacturing and Quality Control Your order is produced at our Mandsaur facility using controlled raw material batches and kiln firing profiles. Dimensional checks, bulk density verification, and crush strength testing are completed on every batch before it is approved for packing and dispatch.
Step 4: Secure Packaging and Shipment Finished packing is loaded into woven PP bags or jumbo bags with inner liners. Export shipments are created and documented as per destination country requirements. All quality certificates, test reports, and commercial documents are prepared and included.
Step 5: Delivery and Ongoing Technical Support We deliver with full documentation. Our team provides column loading procedures, installation guidance notes, and post-commissioning technical support by phone and email at no additional charge.
Feature | Details |
Product type | Ceramic Super Intalox Saddle packing |
Material grades | Porcelain, stoneware ceramic |
Size range | 25 mm to 75 mm (custom sizes available) |
Temperature rating | Up to 1000°C continuous service |
Void fraction | 65% to 75% depending on size |
Bulk density | 480 to 650 kg/m3 depending on size |
Chemical resistance | All acids except HF, stable in alkalis and most solvents |
Quality standard | ISO 9001 compliant manufacturing |
Packaging | PP woven bags, jumbo bags, export crating |
Every order includes:
We are a dedicated manufacturer of super intalox packing media in Mandsaur with full in-house production capability. Raw material preparation, forming, kiln firing, quality inspection, and export packing all happen under our direct supervision. We do not source from subcontractors or third-party producers at any stage of the process.
Expert on Our Team Our lead column packing engineer, Mr. Ramesh Agarwal, has 22 years of experience in ceramic tower packing design, mass transfer application engineering, and column performance analysis across the chemical, fertilizer, and petrochemical industries. He personally reviews all technical inquiries and signs off on quality inspection reports for every production batch before dispatch.
What sets us apart:
Real Customer Result from Andhra Pradesh: A nitric acid plant in Andhra Pradesh was operating an absorption column with standard ceramic Intalox saddles and experiencing capacity constraints and higher than designed pressure drop. After upgrading to our 50 mm Ceramic Super Intalox Saddle packing during a planned turnaround, column throughput increased by 17%, pressure drop across the packed bed reduced by 26%, and absorption efficiency improved by 12%. The packing has now been in continuous service for 3.5 years with no damage, bridging, or replacement required.
Industry | Typical Application |
Nitric and Sulphuric Acid Manufacturing | Absorption towers, drying columns, tail gas scrubbers |
Fertilizer and Agrochemical Plants | Ammonia absorption, urea process columns |
Petrochemical and Refining | Distillation, quench, and stripping towers |
Pharmaceutical Manufacturing | Solvent recovery, API purification columns |
Chlor-Alkali Industry | Chlorine absorption, caustic concentration towers |
Air Pollution and Environmental Control | VOC scrubbers, acid gas absorption units |
Edible Oil Processing | Deodorization and fatty acid stripping towers |
Power Generation | Wet scrubbing and flue gas desulphurisation |
Water and Effluent Treatment | Ammonia stripping, aeration, and degassing towers |
Specialty and Fine Chemicals | High-purity separation, extraction, and reaction columns |
We supply application-specific recommendations for every sector. Our team understands that column operating conditions, chemical environments, and performance requirements differ significantly between industries and we tailor our technical advice to match each customer situation.
Super intalox packing media is a next-generation saddle design with a more open, multi-lobed geometry than standard intalox saddles. The improved shape gives higher void fraction, better liquid distribution, and lower pressure drop in the same column volume. It offers better efficiency than conventional intalox saddles of equivalent size.
Our Ceramic Super Intalox Saddle products are made from high-grade porcelain and stoneware ceramic. These materials provide good chemical resistance to most industrial acids and alkalis, thermal stability up to 1000°C, and sufficient mechanical strength for standard industrial column loading and operation.
Standard sizes range from 25 mm to 75 mm. The most commonly used sizes for industrial distillation and absorption columns are 38 mm and 50 mm. The right size depends on your column diameter. As a general rule, the column diameter should be at least 8 times the packing size for good flow distribution.
Our ceramic super intalox packing handles continuous operating temperatures up to 1000°C. This covers the full range of distillation, absorption, and gas scrubbing applications in chemical and industrial processing where thermal stability is a requirement.
Yes. The ceramic material resists sulphuric acid, hydrochloric acid, nitric acid, phosphoric acid, and most organic solvents at all working concentrations. The only exception is hydrofluoric acid. This makes it a reliable choice for acid towers, scrubbers, and chemical absorption columns.
Yes. Super intalox packing loads randomly into existing columns the same way as other random packing types. No changes to column internals, distributors, or supports are typically needed. Many plants upgrade to super interlocks packing during scheduled shutdowns to improve column efficiency without capital investment.
Void fraction ranges from 65% to 75% depending on the size selected. Higher void fraction compared to standard saddles and rings means greater column capacity, lower flooding risk, and lower pressure drop at equivalent gas and liquid flow rates.
With correct installation and operation within rated chemical and temperature limits, ceramic super intalox packing typically lasts 6 to 10 years in standard industrial environments. Actual service life depends on peak operating temperature, chemical aggressiveness, and mechanical care during loading and unloading.
Wet loading is the standard and recommended method. The column is partially filled with water before packing is added, allowing pieces to settle gently without breakage. Dry loading is also used for smaller columns with appropriate care. We provide a full loading procedure document with every order.
Every shipment includes a product data sheet, dimensional inspection report, bulk density and crush strength test certificate, pre-shipment quality inspection report, packing list, and commercial invoice. Third-party inspection reports and material conformity certificates are available on request for export and project orders.
