Rubber Dispersion Kneader - Your Friend in Knead

 

Embed or link this publication

Description

Dispersion Kneader is energy efficient, maintenance-friendly, labor and time saving machinery that offers consistent quality of rubber mix compound at higher output as compared to an open mixing mill – thus making it truly Your Friend in 'Knead'

Popular Pages


p. 1

Rubber & Tyre Knowledge On-The-Go Special Supplement Machinery http://rubbermachineryworld.com World DISPERSION KNEADER Your Friend In ‘Knead’

[close]

p. 2



[close]

p. 3

| Editor’s Note | Your Friend In ‘Knead’ Is A True Friend Indeed For many years, open mill mixing has been the preferred form of mixing rubber. But then technology has been evolving. Thus came mixers and the major considerations had always been cost. Since last twenty five years, the Kneaders have become the most commonly used type of 'mixer' in the rubber industry. This popularity, prompted us to showcase Kneaders specifically in this Knowledge On-The-Go Special Supplement. Though developed initially for mixing thermoplastics, Dispersion Kneaders have a unique place in the elastomer mixing industry. Users love the ease of cleanliness on this machine especially when they have to change the colour of their compounds frequently. Dispersion Kneader is energy efficient, maintenance friendly, labour and time saving machinery that offers consistent quality of rubber mix compound at higher output as compared to an open mixing mill – thus making it truly Your Friend in 'Knead' for your rubber processing plant... I hope you agree and find this special supplement informative. As always, I welcome your feedback on rubbermachineryworld@gmail.com. BestRegards Prasanth Warrier Since last twenty five years, the Dispersion Kneaders have become the most commonly used type of 'mixer' in the rubber industry. 3 rubbermachineri rubbermachineryworld +Rubbermachineryworld1 grp/home?gid=8252803 rubbermachineri Special Supplement - Rubber Machinery World | NOV 2015

[close]

p. 4

| DISPERSION KNEADER | 4 Image: Hevea Engineering Works (HEW) Make Rubber Dispersion Kneader Special Supplement - Rubber Machinery World | NOV 2015

[close]

p. 5

| DISPERSION KNEADER | DISPERSION KNEADER Your Friend In ‘Knead’ Prasanth Warrier For many years, open mill mixing has been the preferred form of mixing rubber. But then technology has been evolving, your customers expectations growing - sustaining quality without compromising on cost, reducing wastage, extracting more out of available time has all been additional challenges that you come across in dayto-day operations. Thus came mixers and the major considerations had always been cost. In the world of rubber mixing, when 'purists' refer to 'mixer', they either mean a Tangential Rotor Type (Banbury®) Mixer or a Intermeshing Rotor Type (Intermix®) Mixer. While 'practitioners' have a third category viz. Rubber Dispersion Kneader. When discussing with the practitioners (mostly in Asia) you will hear the terms 'Kneader Banbury', 'Kneader Mixer', 'Kneader Intermix', 'Intensive Mixer Kneader', 'Internal Mixer Kneader', 'Dispersion Mixer', 'Tilt Mixer' etc. So, what is this dispersion kneader? Special Supplement - Rubber Machinery World | NOV 2015 5

[close]

p. 6

| DISPERSION KNEADER | To start with, a kneader means a machine that specializes in kneading substances, something to a dough form. I suspect it originates from Germany when Heinz List, a pioneer of modern industrial processing technology, first developed a kneader reactor to process high viscosity materials. Nilesh Parikh, Director of Microquick Engineers, says “In Kneader, the production of compound increases by 40 to 50 per cent than that of mixing mill. The batch preparation time could be between 10 to 15 minutes. The compounding takes place normally with a mastication time of 3 to 5 minutes and filler compounding time of 7 to 10 minutes.” Applications of Kneader Though developed initially for mixing thermoplastics, Dispersion Kneaders have a unique place in the elastomer mixing industry. 6 Image: Bharaj Make 110 Liters Kneader For Export to USA. Users love the ease of cleanliness on this machine especially when they have to change the colour of their compounds frequently. Informs Kulwant Singh Manpotra, Director of Modern Machines, manufacturers and exporters of Rubber Machinery “Kneaders are easy to operate, ensure uniform dispersion of compounds and can be employed in a wide assortment of material mixing ranging from low viscosity adhesives to high viscosity rubber.” Dispersion Kneaders have efficient cooling mechanism through jacketed construction. This, in turn, improves the mixing dispersion and prevents your rubber compound from scorching by facilitating low temperature mixing. Special Supplement - Rubber Machinery World | NOV 2015

[close]

p. 7



[close]

p. 8

| DISPERSION KNEADER | Their varied applications include - Oil seal, Body seal, Belt, Gasket, Hose, Tube for Automobiles - Rubber for Electric wires - Conveyor Belts & Power transmission belts - Rubberized Rolls - Rubber based products like Plug, Cap, Glove, Dental for Medical line - Sporting goods like rubber ball, etc Construction of Kneader a closed environment. Introduction of ram pressure forces the material into the chamber and hence the rotors. The Kneader with its uniquely designed rotors, rotor blades, mixing chamber and pressure lid allows for thorough material flow and controlled shear mixing within the mixing chamber. Nilesh Parikh says, “The differential rotation of rotors; Helical, Wide width of rotor wings and clearance of rotors gives excellent pressing/shear/tear/folding/ stretching/smear of ingredients of compound. This leads to the best kneading effect and promotes the uniform dispersion of fillers”. 8 The construction comprises of a hopper with ram, mixing chamber with dust seals, pressure lid, rotors (blades), tilting mechanism to facilitate discharge, gearbox, motor-controls. Operating Principle of a Dispersion Kneader The concept of mixing inside Kneader is essentially a carry forward of what happens in TwoRoll mills. This means that there is friction between two rotors (similar to rolls in mills) to aid mixing. However, here it happens in Special Supplement - Rubber Machinery World | NOV 2015 Image From Web The production of compound increases by 40 to 50 per cent than that of mixing mill. Nilesh Parikh Director, Microquick Engineers

[close]

p. 9



[close]

p. 10

| DISPERSION KNEADER | Evolution and Technology Developments in Kneader Since last twenty five years, the Kneaders have become the most commonly used type of 'mixer' in the rubber industry. “Highest quality mixing with minimum time has been a major push force for regular technology developments. Kneaders have come a long way. They have evolved from shabby mixing rooms and are respectfully placed in air-conditioned areas” says Amardeep Singh Bharaj, Director (Sales) of leading rubber machinery manufacturer, Bharaj Machineries Pvt Ltd. Image: Bharaj Make 75 Liters Kneader For Japanese Co. 10 He further adds, “Efficient dust proof systems and technology has made the compounding room a matter of pride. Hydraulic rams and lid designs for controlled dispersion effect, automatic stage mixing features for consistent compound, PLC controlling systems with energyefficient variable frequency drives.”. Highest quality mixing with minimum time has been a major push force for regular technology developments. Kneaders have come a long way. They have evolved from shabby mixing rooms. Amardeep Singh Bharaj Director (Sales) Bharaj Machineries Pvt. Ltd. Special Supplement - Rubber Machinery World | NOV 2015

[close]

p. 11



[close]

p. 12

| DISPERSION KNEADER | Rotors Traditional Kneaders have two counter rotating rotors with each rotor having two wings affixed on it. For example, Bharaj Machineries has specially developed tri-blade rotors where mixing with highest quality dispersion effect is achieved with a 15% reduction in the mixing time. Amardeep Singh Bharaj Director (Sales) Bharaj Machineries Pvt. Ltd. 12 Image of Rotors The two wing rotors rotate at different speeds facilitated through connecting gears. The wings move your rubber material from one portion of the chamber to the other while also providing material movement along the rotor axis. Conventional Kneaders have a one piece rotor design which includes a rotor shaft with two long, high and narrow wings welded on the shaft. Water cooling is provided through a passage in the rotor shaft and small jackets in each wing in traditional kneaders. This cooling method is not sufficient for single pass mixing. Explains Amardeep Singh, “In terms of mixing technology and usage, there Hevea Engineering Works is major development has recently launched their happening in the Kneader rotor. Rotor designs have changed with cooling Image: Microquick Engineers. channels for better and quick mastication. For example, Bharaj has specially developed tri-blade rotors where mixing with highest quality dispersion effect is achieved with a 15% reduction in the mixing time.” Special Supplement - Rubber Machinery World | NOV 2015 Opines Tom C. Abraham, Director of the leading TSR processing machinery manufacturer Hevea Engineering Works Pvt. Ltd. “Introducing peripheral cooling to the rotor improves the mix quality”.

[close]

p. 13

Attention: Equipment Buyers & Users Rubber And Tyre Machinery Now Has An Online Address - Power Your Business Forward With Authentic Information On - Equipment & Allied Machinery - Technology - Equipment Suppliers - Read, Absorb & Implement Ideas From - Insightful Interviews Of Leaders - Informative Articles - Special e-Editions & e-Books - Short Updates Curated from the World Of Machinery Every Thursday In Your Inbox - Resourceful Downloads For Day-to-Day Use - Plan For Your Conferences & Expo from event dates - Book Store with Best Rubber Books For Your Quick Buy - Key Documents/Directories to take Powerful Business Decisions Available For Purchase. - Left-Oriented Clean Layout for your easy reading. - Follow Us on Twitter, Google+, LinkedIn & Pinterest. http://rubbermachineryworld.com FREE Access On All Your Devices http://rubbermachineryworld.com AUTHENTIC INFORMATION TO SOURCE MACHINERY WISELY JOIN OUR READERS FROM 68+ COUNTRIES SUBSCRIBE TODAY FOR FREE & BENEFIT

[close]

p. 14

| DISPERSION KNEADER | Introducing peripheral cooling to the rotor improves the mix quality. We have our own rubber processing unit where we test our machinery. We continuously innovate and improve our machinery based on our experience and customer feedback. Tom C. Abraham Director Hevea Engineering Works Pvt. Ltd. range of Kneaders, expanding their engineering competence from TSR processing machinery. The materials are subjected to a larger smearing action of the batch against the rotor tip to chamber wall as well as the rotor tip to rotor shaft. Informs Nilesh Parikh, “The new kneader has much wider land width and stubby in shape. The wide rotor tips enhance the dispersion effect.” Intermeshing rotors have a much larger outside diameter than conventional kneader rotors. This allows for more cooling surface as well as larger mixing surfaces. The cooling circuit is designed inside wing of rotors and all around mixing chamber. The result is quality compounding at less temperature even at high rate of production. Hopper and Feed Area Conventional Kneaders use pneumatic pressure to push the batch down into the rotors and mixing chamber with a floating weight (ram). This pneumatic system is unreliable and inconsistent. The pneumatic ram moves completely uncontrolled and the ram position is controlled by the rotor dragging force as well as the size of rubber pieces it is trying to force into the rotors. The hydraulic ram exerts positive pressure on the batch and can be accurately controlled in the desirable position which leads to better batch to batch consistency. 14 Validates Tom C. Abraham on their unique advantage to benefit customers “We have our own rubber processing unit where we test our machinery. We continuously innovate and improve our machinery based on our experience and customer feedback.” Intermeshing type of rotors in Kneader imparts superior dispersion during the kneading process. This advancement is similar to those observed in Intermix® Rotors that have a rotor shaft with two nogs (small blades) for mixing. Special Supplement - Rubber Machinery World | NOV 2015

[close]

p. 15

ODER M A C H I N E S designed for tomorrow’s technology... Since 1981, we helped SME’s in different developing countries including India, Dubai and Africa grow. Manufacturing, Supply, Erection and Commissioning of New - Dispersion Kneaders - Mixing Mills - Calenders - Bale Cutters - Extruders - Hydraulic Presses Repair Services of Old Machinery. EXPERIENCE WITH RELIABILITY A Modern Make Dispersion Kneader of 90's that is in use at a rubber plant in India. Over 1000 units of Rubber Processing Machinery Installed in Tread Rubber, Precured Tread Rubber, Micro-cellular Sheets, Cycle Tyres & Tubes, Automotive Tubes, Conveyor Belts & Vee Belts, Hawai Chappals, Footwears, Injection Bottle Caps and Allied Rubber Plants. For more info, please contact MODERN MACHINES Manufacturers & Exporters Corporate Office: 8, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai - 400 063. India. Tel: +91-22-690 4519, +91-22-871 7308. Fax: +91-22-8740465. Works: C-1, 255/1, GIDC Estate, Umargam Dist. Valsad. Gujarat - 396 171. India. Tel: +91-260-562398, +91-260-564730. Or email us at modernmachines1@hotmail.com

[close]

Comments

no comments yet