APPLICATION
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.
FEATURES
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.
STRUCTURE AND OPERATION
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.
PRODUCT LINE
| 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.
OPTIONS
Bucket loader
SELECTION
To select a suitable rubber mixer version, please, leave a request to our specialist. Describe the task you need to solve