Ro-Star™
Ro-Star™ Ultra-Fine Grinding Technology
The Ro-Star™ is a vertical stirred media mill developed by Maelgwyn Mineral Services (MMS) and manufactured in collaboration with Ersel Heavy Machinery for ultra-fine grinding applications.
The technology has been developed in response to the industry’s increasing move away from conventional ball milling in ultra-fine duties, where energy efficiency and effective stress application reach practical limits, and toward stirred milling solutions better suited to these requirements.
Ro-Star™ Technical Specifications
Industrial Operating Envelope
- Installed Power: 300–500 kW
- Feed Size (F80): <300 µm
- Product Size (P80): 10–25 µm
- Throughput: 10–20 tph (ore dependent)
- Operating Mode: Continuous
Mechanical Configuration
- • Vertical orientation
- • Heavy-duty fabricated steel shell
- • Replaceable rotor and stator wear components
- • Ceramic grinding media
- • Top-entry drive configuration
- • Sealed bearing assembly
- • Variable Frequency Drive (VFD) control
Scale-Up Philosophy
Scale-up is based on signature plot methodology and specific grinding energy determination.Pilot validation is recommended for new ore types or higher-risk applications.
Ro-Star™
At the core of the Ro-Star™ design is a suspended, bottom-fed vertical configuration incorporating a rotor–stator grinding chamber. This geometry relocates the active grinding zone away from the shaft and toward the mill shell, promoting more uniform stress distribution, reducing inactive grinding zones, and improving the transfer of energy to the grinding media.
The wider, lower grinding chamber also supports improved wear behaviour and accessibility for inspection and maintenance.
The Ro-Star™ has progressed through a structured programme of
- laboratory testwork,
- pilot development, and
- industrial-scale design.
A dedicated laboratory mill and repeatable test procedure enable transparent benchmarking against established ultra-fine grinding technologies, while industrial-scale units of up to 500 kW have been mechanically completed in collaboration with Ersel Heavy Machinery.
The technology is intended for integration into modern comminution circuits where ultra-fine product sizes, energy efficiency, and wear performance are critical. Ongoing industrial placement and operation will continue to define operating envelopes and support broader commercial deployment of the Ro-Star™ mill family.
Ro-Star™
Grinding Is Not a Catalogue Selection
Ultra-fine grinding performance is ore-specific. Energy demand, breakage response and slurry behaviour vary significantly between deposits.Ro-Star™ integrates structured laboratory validation directly into equipment specification.
Why Ro-Star™
- • Method-led equipment selection
- • Data-driven motor sizing
- • Controlled VFD tip speed (2–6 m/s)
- • Compact vertical configuration
- • Ceramic media technology
- • Industrial 300–500 kW platform
Typical Industrial Range
- • Installed Power: 300–500 kW
- • Feed Size: <300 µm
- • Product Size: 10–25 µm
- • Continuous operation
Validated Scale-Up. Reduced Risk.
Ro-Star™ projects are supported by structured signature plot testing.- 1. Laboratory multi-energy testing
- 2. Specific grinding energy (kWh/t) defined
- 3. Energy–size relationship established
- 4. Industrial motor size calculated directly from data
Applications
- • Copper flotation regrind
- • Zinc regrind
- • Ultrafine sulphide liberation
- • Magnetite concentrate grinding
- • Silica & industrial minerals
Catalog
Discover the Ro-Star™ ultra-fine grinding technology in detail.
Download our catalog for technical specifications, design features, and performance data.
Ro-Star™
Ro-Star™
Ro-Star Ultra-Fine Grinding Featured in International Mining – March 2026
The Ro-Star™ ultra-fine grinding technology has been featured in the March 2026 issue of International Mining magazine.
The full article is available in International Mining – March 2026 Edition.
Read More
Ro-Star™
Technical Enquiries – Testwork & Application Engineering
Maelgwyn Mineral Services
Address
Ty Maelgwyn, 1A Gower Street Cardiff
CF24 4PA, United Kingdom
www.maelgwyn.comContact Number
(+44) 2920 340800
Commercial & Manufacturing Enquiries – Equipment Supply
Ersel Heavy Machinery
Address
TOSB Otomotiv Yan Sanayi O.S.B. 1.Cadde No:24/2
41420 Çayırova / Kocaeli / Türkiye
www.ersel.comContact Number
(+90) 262 658 13 40