The dispersion rubber mixer replaces roller mills in the production of compounds of natural and synthetic rubbers, plastics, and composites.

The closed mixer is more efficient than open mills, and is more convenient in the technological process.

The material after mixing is a lump of homogeneous elastic mass.

The rubber mixer is used for:

• Crushing
• Grinding (crumbs 2-5mm in 1,7-0.55mm)
• Mixing
• Adding additives (sulfur, etc.)
• Plasticization
• Heating

The processed rubber compound can be fed to the calender for the production of fabrics or sheet products.

The equipment has higher productivity compared to roller mills. The mixing cycle of the rubber mixer is 2 times shorter than that of open-type machines.

Thorough mixing is provided by a tangential or interpenetrating rotor. Using a dispersion rubber mixer expands the range of recipes that can be produced. For rubber compounds, interpenetrating rotors are usually used.

The hydraulic drive of the rubber mixer maintains a constant working pressure. O-rings are made of high-strength alloys. Rotating elements do not require lubrication due to a precise fit.

Chrome-plated moving elements (rotors, bearings) have a long service life.

The equipment is automated. PLC control. The following process parameters are controlled: rotation speed, cycle time, temperature.  Process settings can be saved to create custom modes. An emergency stop system is provided.

The mixing chamber is compact.  The compound heating/cooling efficiency is higher than that of the open roller mills.

The sealed mixing chamber protects the material from the environmental factors and dust during the production. The chamber and rotor are easy to clean after work.

The rubber mixer is manufactured with a lower or side discharge. Equipment with a lower discharge of the compound is placed on the 2nd level above the calender or hopper. For side unloading, a bucket loader is used to feed raw materials to the calender.

By the working principle, rubber mixers can be batch-operated and continuous.

The guaranteed maintenance period of the equipment is 1 year. Post-warranty service is available.

Operation

Rubber raw material is loaded into the rubber mixer chamber and plasticized.

The rotors create force for cutting, abrasion, and crushing deformation of the compound. Rolls heat the compound to soften it and enhance the mixing quality.

After plasticizing the rubber, additives (sulfur, carbon, plastics) are added. The compound is thoroughly rubbed with rotors. As a result, a homogeneous mass is produced.

Unlike roller mills, in a dispersion mixer the entire loading volume is mixed. For this reason, the rubber compound is more uniform.

At the end of mixing, the mass is cooled and discharged into the container or to the next machine in the production line.

 

General structure

The rubber mixer consists of a cutting chamber with two rotors, a hydraulic drive, and a heating/cooling system. The controller, sensors, and regulators control the rotor temperature and rotation parameters. The equipment components are mounted on a frame made of welded steel sheets.

 

 

 

Mixing chamber

The chamber is a closing metal hopper. Mechanical actuators are provided to open/close the chamber.

The chamber walls are made of alloy structural steel. The surface is chrome-plated (120-150um, HRC50) and polished for easy cleaning from the compound.

The chamber is heated and cooled by means of a jacket. Steam or oil is used as a heat carrier. Cooling is usually water-based. There is a thermocouple installed at the chamber bottom.

There are rotors inside the chamber.

 

Rotors

Rotors are cast metal rolls with hard alloy coating. The rotor blades are located at angle. There are 2-4 blades.  The rotor surface is chrome-plated and polished.

Two rotors are installed in the chamber. They rotate in opposite directions. The material is mixed throughout the entire volume of the chamber. The cutting load is created in the space between the rotors.

By design, there are two types of rotors: tangential (Banbury) and interpenetrating.

Rubber mixers with Banbury rotors are used in tire production.  This type of rotors is suitable for tasks where frequent changing the recipes is not required.

Equipment with interpenetrating rotors is used for the rubber products production. A higher temperature control accuracy is achieved on these rotors and the material cutting area is increased. This is due to the greater contact area of the rotors and the material, compared to tangential rotors. As a result, rubber mixers with interpenetrating rotors feature higher productivity and better mixing quality.

	Total volume of mixing chamber (I)	Efficient volume of mixing chamber (I)	Drive power (kW)	Power at an angle (kW)	Inclination angle (°)	Rotor speed in/out (rpm)	Overall dimensions (mm)
X(S)-3х32	8	3	5.5	0.55	140	32/24.5	2000 х 1000 х 2220
X(S)-5х32	15	5	11.0	1.10	140	32/23.5	1850 х 1200 х 2580
X(S)-10х32	15	5	11.0	1.10	140	32/23.5	1850 х 1200 х 2580
X(S)-20х32	45	20	37.0	1.50	140	32/27	2675 х 1650 х 2560
X(S)-25х32	55	25	37.0	1.50	140	32/27	2675 х 1650 х 2560
X(S)-35х30	75	35	55.0	2.20	140	32/24.5	3200 х 1900 х 2950
X(S)-55х30	125	55	75.0	2.20	140	30/24.5	3230 х 1927 х 2958
X(S)-75х30	170	75	110.0	4.00	140	32/24.5	3325 х 2615 х 3105
X(S)-110х30	250	110	185.0	5.50	140	32/24.5	4075 х 2712 х 3580
X(S)-150х30	325	150	220.0	11.00	135	30/24.5	4250 х 2750 х 4106
X(S)-200х30	440	200	280.0	11.00	135	30/24.5	4250 х 3400 х 4215

The set consists of a bed, frame, mixing, chamber and rotors. Pressing and temperature maintenance devices are supplied with the equipment. Emergency stop devices.

Bucket loader

To select a suitable rubber mixer version, please, leave a request to our specialist. Describe the task you need to solve

Equipment for grinding and homogenizing rubber compounds. During processing, the raw material is heated, crushed, and thoroughly mixed when rolling between rolls.

The open type mixer performs plasticization of various polymer materials. Suitable for processing rubbers, plastics, and composites. The product is rolled into sheets.

The roller mill is used for:

• Crushing
• Grinding (crumbs 2-5mm in 1,7-0.55mm)
• Mixing
• Adding additives (sulfur, etc.)
• Plasticization
• Heating
• Rolling into sheet
• Cleaning

The processed rubber compound can be fed to the calender for the production of fabrics or sheet products.

The open roller mill can process rubber compounds and composites with various formulations. Raw material is fed manually.

The mixer has compact size. Junior models have a size of 1,5×1,0 m.

The equipment is automated. The gap, rotation speed and time, the roll temperature are set on the main panel of the mixer. Operation parameters can be saved in custom modes. An emergency stop system is provided.

The roller mixer is operated by 1 operator and 1-2 workers.

The drive is electric with frequency control.

The moving parts of the equipment (rolls and bearings) are covered with wear-resistant chrome-molybdenum structural steel.

The mixer rolls are heated. Steam or oil heating can be selected. The oil heating provides more uniform heating and is not subject to the permission of Rostechnadzor.

The surface texture of the rolls is selected depending on the processing task. Smooth rolls are used for heating, mixing, and grinding Grooved rolls are used for crushing.

The guaranteed maintenance period of roller mixers is 1 year. Post-warranty service is available.

Operation

The material to be processed on a roller mixer is loaded manually between the rolls. In the gap, the rubber compound is subjected to an abrasive and crushing load. As a result of deformation, the material is thoroughly crushed and mixed. In a contact with the heated rolls, the rubber mixture is heated and softened.

The mixing cycle usually takes 10 minutes. The roller mill capacity is determined by the volume of material loaded and the number of cycles per hour. The roll size and the processing mode determine the maximum load of the rubber compound. Depending on the version, the capacity can reach 250kg of compound per hour

 

Structure

Rolls are the main working element of an open mixer. They are made of hardened cast iron with NiCrMo coating. The surface layer with a hardness of HS76±2 has a thickness of up to 20mm.

The mill has 2 rolls. The roll axes are horizontal and parallel to each other. The rolls form a pair with the opposite direction of rotation. The rolls are heated with steam or oil. For the heating scheme, refer to the calender rolls.

A frequency-controlled electric motor rotates the rolls on rolling bearings. Four-row bearing saves 10-15% of energy. The bearing group is lubricated by hand pumps.

The gap between the rolls is regulated by a screw mechanism. The gap setting can be mechanical or motorized.

An emergency stop function is provided by pressing one of the 4 buttons on the frame or pulling the cable. Emergency braking will occur during 1/6 of the roll rotation. The main motor stops in 2 seconds.

The mixer is mounted on a frame made of steel plates.

Type	Diameter x Length (mm)	Linear speed (m/min)	Friction	Power (kW)	Dimensions (LxWxH) (mm)
XK-160	160 х 320	8.95	1:1.37	5.5	1500 х 750 х 1500
XK-230	230 х 600	10.21	1:1.19	15.0	2800 х 1200 х 1120
XK-250	250 х 620	14.10	1:1.17	18.5	3400 х 1500 х 1650
XK-300	300 х 750	15.10	1:1.25	22.0	3500 х 1600 х 1700
XK-360	360 х 900	16.25	1:1.25	30.0	3780 х 1850 х 1750
XK-400	400 х 1000	18.65	1:1.27	37.0	4350 х 1850 х 1785
XK-450	450 х 1200	24.26	1:1.27	55.0	5200 х 2380 х 1840
XK-560	560,510 х 1530	27.72	1:1.20	90.0	5845 х 2284 х 1978
XK-550B	550 х 1500	27.94	1:1.22	110.0	5870 х 2475 х 2045
XK-610	610 х 2000	28.42	1:1.17	160.0	7070 х 2290 х 1840
XK-660	660 х 2130	28.60	1:1.24	245.0	7465 х 3662 х 2080
XK-710	710 х 2200	30.00	1:1.09	280.0	7500 х 3500 х 1800

The set includes a bed, frame, and rollers. The equipment is supplied with devices for adjusting the gap and temperature of the rolls. Emergency stop devices.

• Bucket loader

To select equipment suitable for casting the required products, leave a request to our specialist. Indicate the required capacity and type of plastic. Product drawings can be attached to the application.