1

Chapter I

The Problem and Its Background

Roll Mill mixing is the oldest method used specially in rubber mixing,

dating back to the very beginning of the rubber industry. Its general function is to

melt down the low melting point compound and mix it in the other compound in

the feed. In order to do this, some heating, cooling and mixing capability intended

to improve the machine efficiency for different raw material to be mix gives rise to

the development of automatic roll mills. (Compound Processing Characteristics

and Testing, 2004)

Early rolling mills were small and water driven, such as Matthew Boulton

suggested. He used steam for driving and heating a rolling mill. It was driven by

an engine that Watt invented with two cylinders and two beams, astonishing the

other ironmasters, and was the forerunner of numerous other mills in his own

works, and in those of envious rivals who followed this enterprising pioneer.

For many years after this it was the practice to have a Beam Engine,

either condensing or non- condensing, in the centre of the mill, driving a line of

shafting from which mills were driven, these being situated right and left of the

engine.

As mills became more powerful the central drive was found to be a

disadvantage: for one thing, if anything went wrong either with the engine or the
 2

line shafting, the whole works was stopped. Accordingly it became the practice to

drive the mills individually, and Horizontal Engines displaced the old Beam

Engines.

Now with the discovery of electricity, a modern age of roll mill was made.

Many types of roll mill made were commercialized and already available in the

market. Heating are done by electronically heating device and a set of motor are

used in driving the roll. Thus the progress of roll mixing in industries became

more easy and efficient.

In a production of tile board, roll mixing is a common method use for

breaking and masticating large and small aggregate. Such materials used in

making tile board that will be focused in this study are recyclable plastics.

With the help of specially modified automatic roll mill, temperature and

shear rate of raw material are properly controlled. Thus utilization of this material

for gaining homogeneous mixture will yield high efficiency and less time

consumed in making tile boards.

Objectives of the Study

The main objective is to design and construct a roll mill and test its

efficiency. The specific objectives are follows;

1. Design a machine that will make the raw material distributed equally

with one another as possible.

 3

2. Test the equipment relative to the rated speed of the motor against time

to achieve the homogeneous mixture.

3. Prepare an instruction manual of the prototype rolling mill machine.

Significance of the Study

The design and development of a prototype roll mill is intended to be used

as Unit Operation equipment in the laboratory particularly in mixing process for

making tiles.

The design of a roll mill is intended for moulding plastics and will be

utilized for the production of the tile boards. This will also be helpful in the

recycling of plastics to be utilized for other purposes.

Future researchers could make use of it as basis for modification.

Scope and Delimitation

The study focused mainly on the design of a prototype roll mill. The factors

that were considered in the design are the cost, capacity, economic viability and,

availability of the material. The properties of the materials were considered in the

selection of the material that will be utilized in creating the prototype.

The spacing between the two rolls was specifically fixed at 1.5 mm apart.

The binder that will be use for the testing of the prototype roll mill was limited only

on low density polyethylene plastics. In addition, the temperature setting of the

equipment is capable from ambient temperature up to 400°C. But for the tile
 4

board production the equipment was operated based on the melting point of the

plastic.

For checking the consistency or homogeneity of the material being

produced from the equipment, the resulting product was compared to the ones

produced by the equipment in Department of Science and Technology (DOST).

Particularly, to the 200 g paste produced by the DOST. The same amount was

also produced from the prototype and the homogeneity was checked and

compared by visual inspection. The homogeneity should be the same and the

time for this material to be produced for both the equipment in DOST and the

prototype was noted.

For the testing of the capability of the prototype, the drum rotational speed

was considered and evaluated based on low and high settings, relative to time

and the material loading.

The variation of the material loading was as follows: 50 and 100 grams.

The thermocouple attached in the equipment was not strategically

attached in such a way that there will be a direct reading of the drum temperature

due to financial limitations. A conversion table was materialized to give solution

to such problem.

Conceptual Layout

The design of a prototype roll mill is the central framework of the study.

This study originated from the analysis of the properties of the tile boards, which
 5

serves as a background information on the design of the prototype. From this,

the idea of developing a prototype able for the production of paste that will be

further processed by compression moulding to produce optimum product of tile

board.

The conceptual paradigm shown in Figure 1 gives a better insight of the

framework of the study.

 6

Figure 1. Conceptual Paradigm in the Development of Prototype Automatic Roll Mill

Definition of Terms

In order to facilitate understanding for study, the following terms are

defined:

Carbon Steel. Steel is considered to be carbon steel when no minimum

content is specified or required for chromium, cobalt, columbium [niobium],

molybdenum, nickel, titanium, tungsten, vanadium or zirconium, or any other

element to be added to obtain a desired alloying effect; when the specified

minimum for copper does not exceed 0.40 per cent; or when the maximum

content specified for any of the following elements does not exceed the

percentages noted: manganese 1.65, silicon 0.60, copper 0.60.(General Property

of Steel,2007)

Compounding. It refers to the process used to produce a compound.

Low-density polyethylene (LDPE) is a thermoplastic made from oil. It

was the first grade of polyethylene, produced in 1933 by Imperial Chemical

Industries (ICI) using a high pressure process via free radical polymerization

Paste. It is the mixture form after melting of the plastic cups.

Plastics. It can cover many synthetic or semi synthetic polymerization

products.(Wikipedia, 2006))
 7

Prototype. It refers to something having the essential features of a

subsequent type, and on which later forms are modelled. (Microsoft Encarta

Premium Suite, 2004)

Roll Mills. It can provide exceedingly high localized shear while retaining

extended surface for temperature control.

Torque. It refers to a part of the basic specification of an engine: the

power output of an engine is expressed as its torque multiplied by its rotational

speed. (Wikipedia, 2006)

 8

Chapter II

Theoretical Background

This chapter presented some related information that will be used to

enhance and enrich the contents of the study. This presented the theories and

concept that was used to pursue the study.

Roll Mills

Rolling mills have been used in association with slitting mills since the

1590s for producing iron strips. Early rolling mills were small and water driven,

such as the one still in existence at Wortley Ironworks Lower Forge in Sheffield.

Wider iron sheets, for making tinplates, were produced by John Hanburry

in about 1720, and in 1784 Henry Court (of pudding furnace from fame) were

using grooved rolls to produce round and other sections.

In 1781, Matthew Boulton suggested, when on a visit to an ironworks in

Wales, using a steam engine for driving a rolling mill, and on his return home he
 9

had a coupled steam engine made and connected to a forge train. This was

adopted for the first steam driven rolling and slitting mill by John Wilkinson, in

collaboration with Boulton and Watt, at his Bradley Works. It was driven by an

engine that Watt invented with two cylinders and two beams, astonishing the

other ironmasters and was the forerunner of numerous other mills in his own

works, and in those in envious rivals who followed this enterprising pioneer.

For many years after this it was the practice to have a Beam Engine, either

condensing or non-condensing, in the centre of the mill, driving, line of shafting

from which mills were driven, these being situated right and left of the engine.

As mills became more powerful the central drive was found to be a

disadvantage: for one thing, if anything went wrong either with the engine or the

line shafting, the whole works was stopped. Accordingly it became the practice to

drive the mills individually, and Horizontal Engines displaced the old Beam

Engines.

With the advent of steel and the handling of heavier pieces, the individual

drive became an absolute necessity. For the earlier continuously rotating mills,

engines with fly wheels could be used. The advantage of the fly wheels is that it

stores energy at periods when little work is being done (as for example, when the

piece is being passed back over the top of the rolls) which it can give out again

when the maximum demand for power occurs – that is, when the piece is in the

rolls. In this way the engine cylinders only require to be designed for something

slightly over the average power required.

 10

With a view to avoiding the loss of time while the piece was being passed

back over the top of the rolls, Mr. James Naysmith (inventor of the Steam

Hammer in 1838), suggested the use of Reversing Engines.

This was tried at Crewe and found satisfactorily, with the result that the

standard drive for reversing Rolling Mills, became either a two or a three crank

Reversing Engine. It was of course impossible to use a flywheel with these

engines, as there was no reserve of stored energy to draw upon to take the peak

loads; with the result that the cylinders had to be made large enough to take the

maximum load. Thus the engine was running well under its power for most of its

time, which did not make for economy. Such engines were therefore referred to

as “steam eaters.”

For heavy plates the reversing mills has many advantages, and it was

obvious that if it could be driven by an engine provided with a fly wheel to store

energy, and give it out at the peak loads, considerable economy in steam, and

fuel, would result.

Attempts were made too do this by the use of trains of gearing and clutches. The

upkeep and breakage were, however, so serious as to more than absorb any

saving in fuel; and so the less efficient but more reliable reversing engine held

the field. (History of Steel, 2006)

Parts of a Roll Mill

 11

Roll Mill Drum – is the major part of the roll mill that mixed the feed into a

homogenous mixture and it is made from carbon steel that fabricated in a

machine shop.

Microcontroller – (or MCU) is a computer-on-a-chip used to control

electronic devices. It is a type of microprocessor emphasizing self-sufficiency and

cost effectiveness, in contrast to a general-purpose microprocessor (the kind use

PC).

DC Geared Motor – is one of the major part of the roll mill that drives the

shaft of the roll mill drum to rotate.

Thermocouple – are used as temperature sensor and can also be used as

a means to convert thermal potential difference into electric potential

difference. They are cheap, interchangeable, have standard connectors,

and can measure a wide range of temperatures.

Gears – toothed wheels or cogs are positive type drives which are used to

transmit motion between two shafts or a shaft and component having linear

motion, by meshing of two or more gears.

Power Supply – often referred to as “switching power supplies”, use

switcher technology to convert the AC input to lower DC voltages.

Front Panel Controls – the standard set of front panel controls on the units

are designed for ease of use and functionality. All mainframes have similar

firmware providing menu driven set-up of control features, remote interfaces and

front panel control parameters.

 12

Power Switch – a switch is a device for changing the course (or flow) of a

circuit. The prototypical model is a mechanical device which can be disconnected

from one course and connected to another.

Potentiometer – is used as an rpm controller for dc geared motor. A

potentiometer is constructed using a flat graphite annulus as the resistive

element, with a sliding contact (wiper) sliding around this annulus. (Wikipedia,

2006)

Two Roll Mills

This mill contains two parallel rolls mounted in a heavy frame with

provision of accurately regulating the pressure and distance between the rolls. As

one pass between the rolls does little blending and only a small amount of work,

the mills are practically always used as batch mixers. Only a small amount of

material is in the high-shear zone at any one time.

To increase the wiping action, the rolls are usually operated at different

speeds. The material passing between the rolls is returned to the feed point by

the rotation of the rolls. If the rolls are at different temperatures, the material

usually will stick to the hotter roll and return to the feed point as a thick layer.
 13

At the end of the period of batch mixing, heavy materials may be

discharged by dropping between the rolls, while thin mixes may be removed by a

scraper bar pressing against the descending surface of one of the rolls.

Two-roll mills are used mainly for preparing color pastes for the ink, paint,

and coating industries. There are a few applications in heavy duty blending of

rubber stocks, for which corrugated and masticating rolls are often used. (Perry’s

Chemical Engineers’ Handbook, 2001)

LCM150 Roll Mill

This type of roll mill can be found in the Department of Science and

Technology. Wherein the drum is chrome plated one. It is also a three phase

motor, the temperature can be controlled. The distance between the drum is

varied and each drums are heated with different temperature. The motor has a

constant speed of 100rpm.

Figure 2. LCM150 Roll Mill

 14

Features of LCM150 Roll Mill

■ Chrome-plated drum made.

■ 3 phase motor.

■ Controlled Temperature.

■ Varied Distance of Drums.

■ Each Drums are heated with different Temperatures.

■ Constant motor speed at 100rpm

The power requirement of LCM150 Roll Mill is 1680 KWh. The said roll mill has

no available manual according to the personnel from DOST. The said features

cannot be elaborated further.

Plastics

Plastics, materials made up of large, organic (carbon-containing)

molecules that can be formed into a variety of products. The molecules that

compose plastics are long carbon chains that give plastics many of their useful

properties. In general, materials that are made up of long, chainlike molecules

are called polymers. The word plastic is derived from the words plasticus (Latin

for “capable of molding”) and plastikos (Greek “to mold,” or “fit for molding”).

Plastics can be made hard as stone, strong as steel, transparent as glass, light

as wood, and elastic as rubber. Plastic are also lightweight, waterproof, chemical
 15

resistant, and produced in almost any color. More than 50 families of plastics

have been produced, and new types are currently under development.

Like metals, plastics come in a variety of grades. For instance, nylons are

plastics that are separated by different properties, costs and the manufacturing

processes used to produce them. Also like metals, some plastics can be alloyed

or blended, to combine the advantages possessed by several different plastics.

For example, some types of impact-resistant (shatterproof) plastics and

heat-resistant plastics are made by blending different plastic together.

Plastics are mouldable, synthetic (chemically-fabricated) materials derived

mostly from fossil fuels, such as oil, coil, or natural gas. The raw form of other

materials, such as glass, metal, and clay are also mouldable. The key difference

between these materials and plastics is that plastics consist of long molecules

that give plastics many of their unique properties, while glass, metals, and clay

consist of short molecules.

General Properties of Plastics

Plastics possess a wide variety of useful properties and are relatively

inexpensive to produce. They are lighter than many materials of comparable

strength and unlike metals and woods, plastics do not rust or rot. Most plastics

can be produce in any color. They can also be manufactured as clear as glass,

translucent (transmitting small amounts of light), or opaque (impenetrable to

light.)
 16

Plastics consist of very long molecules each composed of carbon atoms

linked into chains. One type of plastic, known as polyethylene, is composed of

extremely lone molecules that each contains over 200,000 carbon atoms. These

long, chainlike molecules give plastics unique properties and distinguish plastics

from materials, such as metals, that have short, crystalline molecular structures.

Table 1
Properties of Low Density Polyethylene (LDPE)

Properties Specifications

Maximum Temperature: 176 °F (80 °C)

Minimum Temperature: −58 °F (−50 °C)
Autoclavable: No
Melting Point: 248 °F (120 °C)
Tensile Strength: 1700 psi (11.7 MPa)
Hardness: SD55
UV Resistance: Poor
Density: 0.92 g/cm³

Wikipedia,2007

Type of Materials Used in Construction

The main types of materials will be utilized in the construction prototype

automated roll mills are:

Carbon steel was used as roll drum, it is chosen because of the following

properties: a metal alloy, a combination of two elements, iron and carbon, where
 17

other elements are present in quantities too small to affect the properties. The

only other alloying elements allowed in plain-carbon steel are manganese (1.65%

max), silicon (0.60% max), and copper (0.60% max). Steel with low carbon

content has the same properties as iron, soft but easily formed. As carbon

content rises the metal becomes harder and stronger but less ductile and more

difficult to weld. Higher carbon content lowers steel's melting point and its Carbon

content influences the yield strength of steel because they fit into the interstitial

crystal lattice sites of the body-centered cubic arrangement of the iron molecules.

The interstitial carbon reduces the mobility of dislocations, which in turn has a

hardening effect on the iron. To get dislocations to move, a high enough stress

level must be applied in order for the dislocations to "break away". This is

because the interstitial carbon atoms cause some of the iron BCC lattice cells to

distort. (Wikipedia, 2007)

Table 2
General Properties of Carbon Steel

Properties Carbon Steels

3
Density (1000 kg/m ) 7.85
Elastic Modulus (GPa) 190-210
Poisson's Ratio 0.27-0.3
 18

Thermal Expansion (10-6/K) 11-16.6

Melting Point (°C)  
Thermal Conductivity (W/m-K) 24.3-65.2
Specific Heat (J/kg-K) 450-2081
Electrical Resistivity (10-9-m) 130-1250
Tensile Strength (MPa) 276-1882
Yield Strength (MPa) 186-758
Percent Elongation (%) 10-32
Hardness (Brinell 3000kg) 86-388
(General Properties of Steel,2007)

Angular flat bars serve as the guide for the drum assembly, and support

for motors and other component. It was also use as frame for casing and stand of

the equipment.

Galvanized steel sheets were use as the protective casing of the

prototype. It also enhances the physical feature of the prototype. This material

was chosen due to its cheapness and hardness.

Chapter III

Design, Development and Testing of the Prototype

The two-roll mill is an external mixer whose main components are

two-counter rotating rolls that circulate and stretch the compound. Roll mill

general function is to melt down the low melting point compound and mix it in the

other compound in the feed of the roll mill.

 19

The LCM150 roll mill had its strong points and weak points. The electric

consumption of such is high due to high power requirement of the heater, the

motor and other auxiliary parts that consumes electricity. Also the rotations of the

drums were constant.

Major Parts Specification

The major part of the prototype roll mill are the roll mill drum, the

microcontroller that will control the temperature, the dc geared motor, the

cartridge type heater and the thermocouple.

Roll Mill Drum – is the major part of the roll mill that mixed the feed into a

homogenous mixture and it is made from carbon steel that fabricated in a

machine shop. Carbon steel was chosen because of its excellent thermal

properties and cheaper to use Roll mill drum has a diameter of 10.16 cm, a width

of 30 cm and a working with of 28 cm.

Microcontroller - (or MCU) is a computer-on-a-chip used to control

electronic devices. It is a type of microprocessor emphasizing self-sufficiency and

cost-effectiveness, in contrast to a general-purpose microprocessor (the kind

used in a PC). It controls the whole process operation, and serves as the central

processor of the prototype.

Table 3
Specifications of Microcontroller
 20

Absolute Maximum Ratings (PIC16F87X 28/40-Pin 8-Bit CMOS FLASH

Microcontrollers)

Parameters Specifications

Storage temperature -65°C to +150°C

Maximum current out of VSS pin 300 mA
Maximum current into VDD pin 250 mA
Input clamp current, IIK (VI < 0 or VI > VDD) 20 mA
Output clamp current, IOK (VO < 0 or VO > VDD) 20 mA
Maximum output current sunk by any I/O pin 25 mA
Maximum output current sourced by any I/O pin 25 mA
Maximum current sunk by PORTA, PORTB, and PORTE 200 mA
Maximum current sourced by PORTA, PORTB, and PORTE 200 mA
Maximum current sunk by PORTC and PORTD 200 mA
Maximum current sourced by PORTC and PORTD 200 mA

DC Geared Motor – is one of the major part of the roll mill that drives the

shaft of the roll mill drum to rotate.

The 1308 instrument dc geared motor is ideally suited to wide range

applications requiring a low speed operation and compact size unit. The integral

iron core dc motor provides smooth operation and a bi-directional variable speed

capability while gear head utilizes a multi-stage metal spur gear train and die cast

metal housing rated for a working torque up to 1.0 Nm.

The 1308 unit offers a range of gear ratio options for operating speeds

from 100- 1000 rpm and is ideally suited applications where combination of high

torque, compact size and economic unit price are important design criteria.

Table 4
Specifications of DC Geared Motor
 21

Parameters Specifications

Gear ratio 5.1

Nominal Voltage (DC) 90
Rated Speed (rpm) 360
Rated Torque (in, lbs.) 19
Rated Current (A) 1.33
Motor Power Consumption (hp) 0.125

Cartridge Heater – a device, apparatus or contrivance designed to

generate, impart, transmit or conserve heat. It was use as the heating element of

the prototype.

Table 5
Specifications of Cartridge Heater

Parameters Specifications

Max Temperature 400 °C

Power 800 watts
Voltage 220 V

Type K thermocouples - are made up of a positive Chromel wire and a

negative Alumel wire. They are the most popular thermocouple type and offer a

wide measurement range with good temperature precision. It serves as the

temperature sensing element, sends signal to temperature controller for the

regulation of the heater.

Table 6
Specifications of Type K Thermocouple

Parameters Specifications

Range 95 °C to 1260 °C

 22

Seedbeck Coefficient (µV/°C) @ 20°C) 7

DVM Sensitivity for FOR 0.1°C (µV) 0.7

Timing Chain – used to interchange rotary motion and linear motion,

where either high loads or a specific drive ratio.

Slip Ring - is a method of making an electrical connection through a

rotating assembly. Slip rings, also called rotary electrical interfaces, rotating

electrical connectors, collectors, swivels or electrical rotary joints, are commonly

found in electrical generators for AC systems and alternators and in packaging

machinery, cable reels, wind turbines.

Solid State Relay (SSR) - is an electronic switch, which, unlike an

electromechanical relay, contains no moving parts. The types of SSR are

photo-coupled SSR, transformer-coupled SSR, and hybrid SSR. A photo-coupled

SSR is controlled by a low voltage signal which is isolated optically from the load.

The control signal in a photo-coupled SSR typically energizes an LED which

activates a photo-sensitive diode. The diode turns on a back-to-back thyristor,

silicon controlled rectifier, or MOSFET transistor to switch the load.

Power Supply - often referred to as "switching power supplies", use

switcher technology to convert the AC input to lower DC voltages. The typical

voltages supplied are: 3.3 volts, 5 volts and 12 volts

 23

Front Panel Controls - The standard set of front panel controls on the units

are designed for ease of use and functionality. All mainframes have similar

firmware providing menu driven set-up of control features, remote interfaces and

front panel control parameters. The panel is easy to use for either left or right

handed personnel.

Liquid Crystal Display LCD – display signal which can be interpreted by

human operator.

Table 7
Specifications of LCD

HITACHI (LM044L)

Parameters Specifications

Input high voltage 2.2v min

Input low voltage 0.6v max
Output high voltage 2.4v min
Output low voltage 0.4v max
Power supply current 2.0mA typ, 3.0mA max

Assembly
 24

The prototype roll mill was fabricated in Project 8, Quezon City. The

methods included the fabrication of the pinion gears (Fig. 3) and roll mill drum

(Fig. 4),. The researchers were the ones who conceptualize the design of the

prototype. Finishing like paint application is included in the fabrication of the

prototype. Putting of corresponding label to the parts presented to understand

how the prototype roll mill is being fabricated. Labelling was done from the

auxiliary parts up to the main parts so that the researchers can easily identify the

damage that may accidentally occur when the developed prototype roll mill is in

operation.

Figure 3. Pinion gears

 25

Figure 4. Roll Mill Drum

 26

Figure 5. Prototype Automatic Roll Mill

Table 8
Limitations and Specifications based on Max Operating Conditions

Parameters Specifications

Max Capacity of Roll Mill Drum 160 grams

Max Working Width 36 cm
Max Motor RPM 360 rpm
Max Motor Power Consumption 0.125 hp
Microcontroller power consumption 4.5 watts
Motor max rpm w/ load 120 rpm
Motor max rpm w/o load 200 rpm
Max Temperature 400 °C
 27

Procedure for Testing the Performance of the Roll Mill

Plastic cups were gathered from McDonalds Batangas and washed by

detergent soap. This was used as the main material for producing the paste.

Different weights of plastic cups were measured by analytical balance.

The researcher conducted a series of tests and experiments in

determining the effect of the varying conditions in the process. These were the

analysis of paste homogeneity based on 200 g samples produced and varying

weight of samples against varying speed of drum noting the time to achieve the

best result. Also, a conversion table was materialized due to problems

encountered in temperature readings. The thermocouple was not strategically

attached and due to financial constraints, this was not remedied. This will need

additional fabrication which will entail additional cost to the researchers.

For checking the consistency or homogeneity of the material being

produced from the equipment, the resulting product was compared to the ones

produced by the equipment in DOST. Particularly, to the 200 g paste produced by

the DOST. The same amount was also produced from the prototype and the

homogeneity was checked and compared by visual inspection. The homogeneity

should be the same and the time for this material to be produced for both the

equipment in DOST and the prototype was noted.

 28

For the next parameter check, the researcher fed 50g both in high and low

rpm settings in the roll mill and then evaluates the paste homogeneity if achieved

and record the time. Second, the researcher fed 100g both in high and low speed

and then evaluated again the paste until it the best homogeneity was reached

and recorded the time again. Lastly in its maximum capacity which is 200 g both

in high and low rpm setting was fed into the roll mill and again evaluated the

paste and recorded the time. This was done to evaluate the effect of varying the

material loading and rotational drum speed on the time of production of paste.

The performance of the roll mill was determined by comparing the paste

produced by the prototype to the paste that is produced by DOST available mill

and the time it took for the compound to be mixed was noted. Through this, the

researcher evaluated the capability of the prototype to achieve the same efficient

equipment as the DOST mill.

Operation Manual

The researcher developed a manual that will guide users and will have a

better understanding of the equipment’s capability and for better result in its

operation.

Table 9
Specifications of Roll Mill

Parameters Specifications
Roll diameter 10.16 cm
Roll width 36 cm
 29

Working width 33 cm
Max Motor RPM 360 rpm
Motor power consumption 187 watts
Microcontroller power consumption 4.5 watts
Parameters Specifications
Motor max rpm w/ load 120 rpm
Dimensions Length x Width x Height 100 cm x 56.4 cm x 60 cm
Cartridge Heater power consumption 1600 watts
Total Power Requirement 1791 watts

Step Wise Guide

The researchers will consider the following procedures to operate the

prototype roll mill.

- Proper positioning of the equipment

- Plugging the main plug.

- Switching on the power.

- Setting the melting temperature of the plastic materials

- Setting the desired RPM of the Roll Mill Drum

- Loading of the raw materials.

- Operation while processing the materials for production.

- Collecting the paste for in the compression moulding machine.

(Unloading the product.)

- Cleaning the machine.

 30

Maintenance

Maintenance of the roll mill will only cover the application of coating such

as paint to prevent the body of the roll mill from rusting. Furthermore, application

of oil to the gears and motor is necessary to minimize the noise in the operation.

Thermocouple should be calibrated periodically to assure proper temperature

reading. Lastly, the roll mill is to be brought to the fabricator of the roll mill for

check-ups and overhauled.

 31

CHAPTER IV

Experimental Results and Discussion

This chapter presents the material and methods used by the researchers

in their experimental study together with the results.

Inventory

The following materials were the ones used in the study together with the

individual cost:

Table 10
Bill of Materials of the Prototype

QTY MATERIALS PRICE

1 Steel frame / Casing 8,000
2 DC Geared Motors 7,000
2 Rollers (Machined) 18,000
2 Buffing of roller 2,000
4 Heavy Duty Roller Bearings 2,000
4 Roller Bearing block 3,800
4 Gear Sprockets 2,800
2 Timing Chain 1,000
1 Roller scraper 2,500
2 Thermocouples 2,000
2 Temperature controller 5,000
2 Cartridge heaters 2,000
 32

4 Slip Rings 8,200

2 Slip ring holder (FIBRA) 2,500
QTY MATERIALS PRICE
1 13mm extra long drill bit 2,600
6 Door Hinges 300
2 Door Locks 200
1 Paint 500
2 Paint roller / brush 220
1 LCD 4X20 1,600
1 PIC16F877 MCU 400
1 DC Power Supply 450
2 Motor Power Supply 1,500
1 Keypad 160
3 8-pin M/F connector 108
7 2-pin M/F connector 56
6 3-pin terminal block 90
6 2-pin terminal block 60
10 1N4001 Diode 25
1 AC heavy duty power cord 200
1 Power switch 250
1 Safety breaker 300
- Wires and cables 500
4 Relay SPDT 12V 240
2 Solid State Relay 400
1 Presensitized PCB 400
- Miscellaneous 2,000
- Labor and travel expenses 45,400
TOTAL 124,750
 33

Performance Evaluation

Evaluation of the performance of the two roll varied with the specifications

attached to every part of the machine. Every part has its own advantages and

disadvantages depending necessarily on the availability of the materials.

The table below shows the comparison between the LCM150 roll mill and

the developed one.

Table 11
Comparison between LCM150 Roll Mill and the Prototype
Parameters LMC150 Roll Mill Developed Roll Mill

Drums Chrome plated carbon steel non-plated

Temperature Controller Digital Analogue

Drum Rotation Fixed Variable

Drum Distance Variable Fixed

Control Panel Without Security Lock With Security Lock

Drum Selection Dual With Selection

Motor AC 3phase DC Geared Motor

Size Industrial Laboratory Scale

Nip Guarding With Nip Guard Without Nip Guard

Temperature Setting of Drums Different Temp. Controller Single Controller

There was a problem encountered regarding the temperature reading

obtained in the digital reading device of the thermocouple. This will require for
 34

additional fabrication that will entail additional cost. Due to financial constraints

the additional fabrication was not done. Instead, a conversion table was made to

remedy the temperature reading problem. The machine achieved the required

homogeneity of the paste that this should produce.

The table below shows the temperature reading obtained in the digital

reading device and the actual drum temperature.

Table 12
Temperature Conversion

Actual Drum Temperature Temperature Reading

28 27
30 30
34 31
39 37
43 39
47 42
55 44
57 49
59 52
65 55
69 58
73 61
78 64
82 67
86 71
90 74
95 77
99 80
103 83
107 86
112 89
116 93
120 96
125 99
129 102
133 105
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Actual Drum Temperature Temperature Reading

137 108
142 112
146 115
150 118
154 121
159 124
163 127
167 130
171 134
176 137
180 140
184 143
188 146
193 149
197 152
201 156
.

The following data was obtained by measuring the actual drum temperature

and shaft temperature using a thermocouple with the same time interval. It shows

that the drum temperature is behaving greater temperature interval as the shaft

temperature increases.

Production of Paste: Homogeneity Check

The authors produced 200 g paste of pure plastic and conducted this at

the Department of Science and Technology using LCM150 Roll Mill. The paste

produced by the said roll mill was done in 121 seconds. The said roll mill

operates at 100 rpm of drum rotational speed. Whereas, the prototype produced

the paste of the same homogeneity in 103 seconds for low drum rotational

speed; and 80seconds for high drum rotational speed setting.

 36

The homogeneity of the paste produced from the type was comparable to

the paste produced by LCM150 roll mill. Based from the conducted analysis, the

advantage of the prototype is the low production time which entails lesser

electricity consumption. Thereby, making the prototype more economical based

on operation cost. With regards to machine cost, the LCM150 roll mill cost

approximately 1 million while the developed one cost Php122,250.

Performance Testing of the Prototype Roll Mill Based on Drum Rotational

Speed against Time of Production

The performance of the developed prototype was evaluated using 100%

plastic. Paste was produced for the prototype alone and the homogeneity was

checked using the 200g paste produced from LCM150 roll mill of DOST. The

weight was varied to determine the effect of material loading against the time in

producing the paste.

On the basis of the trial run of the machine considering the loading and

speed variation the prototype exhibited various results. The table below shows

the time it takes to produce the homogenous paste considering the two varied

factors. The ease in achieving the homogenous mixture at the shortest possible

time can be achieve best using low drum rotational speed setting. For high drum

rotational speed setting, short loading time was experienced and the color of the

paste was lighter in hue. But the time in achieving a good homogeneity of the

mixture was longer.

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Table 13
Production Time of the Prototype
(Variable Rotational Speed and Material Loading)

Drum Mass
Rotational
Speed (rpm) 50 grams 100 grams
80 seconds 154 seconds
119 seconds 194 seconds
Low
80 seconds 193 seconds
100 seconds 196 seconds
114 seconds 166 seconds
118 seconds 182 seconds
High
93 seconds 169 seconds
112 seconds
Note: All production time is in seconds.

The design of such experimental analysis is based on factorial

experimental design. F-test will be calculated to determine the level of

significance of variable drum rotational speed and material loading on the time of

production of paste from the prototype using three replicates only.

 38

Based on analysis of variance results, the drum rotational speed gave the

most significant effect on the time of production of homogenous paste. Though

other factors maybe considered specifically human factors that have to do with

manipulating of machine; this can be controlled by the person operating the

machine. The effect on the production time can be minimized. Presented are the

analysis of variance results in the following table:

Table 14
Analysis of Variance (ANOVA) Table

Degrees
Source of Sum of Mean
of Fo F0.05, 1, 8
variation square square
freedom
Weight (A) 20501.3333 1 20501.3333 377.3248 4.41
Drum
Rotational 27 1 27 0.4969
Speed (B)
Interaction AB 1875.0000 1 1875.0000 34.5092
Error 434.66667 8 54.333338
Total 22838 11 2076.1818
Note: B Factor gives a significant effect since its F0 is less than the F value.

INSTRUCTION MANUAL

The two-roll mill is an external mixer whose main components are

two-counter rotating rolls that circulate and stretch the compound. Roll mill
 39

general function is to melt down the low melting point compound and mix it in the

other compound in the feed of the roll mill.

Parts of the Prototype

Roll Mill Drum – is the major part of the roll mill that mixed the feed into a

homogenous mixture and it is made from carbon steel that fabricated in a

machine shop. Carbon steel was chosen because of its excellent thermal

properties and cheaper to use Roll mill drum has a diameter of 10.16 cm, a width

of 30 cm and a working with of 28 cm.

Microcontroller - (or MCU) is a computer-on-a-chip used to control

electronic devices. It is a type of microprocessor emphasizing self-sufficiency and

cost-effectiveness, in contrast to a general-purpose microprocessor (the kind

used in a PC). It controls the whole process operation, and serves as the central

processor of the prototype.

DC Geared Motor – is one of the major part of the roll mill that drives the

shaft of the roll mill drum to rotate.

The 1308 instrument dc geared motor is ideally suited to wide range

applications requiring a low speed operation and compact size unit. The integral

iron core dc motor provides smooth operation and a bi-directional variable speed

capability while gear head utilizes a multi-stage metal spur gear train and die cast

metal housing rated for a working torque up to 1.0 Nm.

 40

Cartridge Heater – a device, apparatus or contrivance designed to

generate, impart, transmit or conserve heat. It was use as the heating element of

the prototype.

Type K thermocouples - are made up of a positive Chromel wire and a

negative Alumel wire. They are the most popular thermocouple type and offer a

wide measurement range with good temperature precision. It serves as the

temperature sensing element, sends signal to temperature controller for the

regulation of the heater.

Timing Chain – used to interchange rotary motion and linear motion,

where either high loads or maintaining a specific drive ratio.

Slip Ring - is a method of making an electrical connection through a

rotating assembly. Slip rings, also called rotary electrical interfaces, rotating

electrical connectors, collectors, swivels or electrical rotary joints, are commonly

found in electrical generators for AC systems and alternators and in packaging

machinery, cable reels, wind turbines.

Solid State Relay (SSR) - is an electronic switch, which, unlike an

electromechanical relay, contains no moving parts. The types of SSR are

photo-coupled SSR, transformer-coupled SSR, and hybrid SSR. A photo-coupled

SSR is controlled by a low voltage signal which is isolated optically from the load.

The control signal in a photo-coupled SSR typically energizes an LED which

 41

activates a photo-sensitive diode. The diode turns on a back-to-back thyristor,

silicon controlled rectifier, or MOSFET transistor to switch the load.

Power Supply - often referred to as "switching power supplies", use

switcher technology to convert the AC input to lower DC voltages. The typical

voltages supplied are: 3.3 volts, 5 volts and 12 volts

Front Panel Controls - The standard set of front panel controls on the units

are designed for ease of use and functionality. All mainframes have similar

firmware providing menu driven set-up of control features, remote interfaces and

front panel control parameters. The panel is easy to use for either left or right

handed personnel.

Liquid Crystal Display LCD – display signal which can be interpreted by

human operator.

Equipment and Materials Needed for Paste Production

Developed roll mill

Flat form balance

Plastic cups

Safety
 42

The prototype and its process itself can cause harm if improperly used or

if procedures are not properly followed. For safety purposes the following were

materialized:

Wear personal protective equipment like protective gloves, safety jacket,

eye protection, and protective mask. The working area should have proper

ventilation. The roll mill should be position near the hood. Plastic vapours emitted

while working is highly toxic and if inhaled can cause a wide range of harmful

effects to the body.

Roll mill is mechanically operated equipment. Using it in a proper way,

accidents risk will be minimized. Carefully load the raw materials in the drum.

Always keep distance in the gap between two drums to avoid unnecessary hand

accidents. Do not touch the hot surface especially the two drums. When other

materials are accidentally drop in the drum while rolling, immediately press the

emergency stop button.

Equipment Start up

1. Carefully attach the plug into the socket.

2. Turn on the equipment by pressing the on button on the right side of

the equipment.

3. Enter the right password in the keypad of the control panel to

manipulate the equipment.

 43

4. Set the operating temperature in the temperature controller. Operating

temperature should be based on the melting point of the plastic that

will be used.

5. Wait until the set operating temperature is attain.

6. Pull in the emergency stop button and rotate the motor rpm controller

to start drum rotation. Clockwise rotation of the motor rpm controller for

high speed drums rotation and vise versa.

Production of Primary Paste

1. When the drums are heated to the set temperature, gradually load the

plastics in the roll drum. Always keep distance in the gap between two

drums to avoid unnecessary hand accidents.

2. Scraped and load again the plastic to avoid plastic decoloration and for

further blending of plastic paste.

3. Carefully add the material little by little.

4. Repeat scraping and loading until it reached the desired mixture.

5. Scraped and unload the primary paste when desired homogeneity is

achieved.

Maintenance and Cleaning

Scraping while heating the drum should be done to cleanup sticky material

stuck on the drum. Use oil on the drum when deemed necessary. Maintenance of

the roll mill will only cover the application of coating such as paint to prevent the
 44

body of the roll mill from rusting. Furthermore, application of oil to the gears and

motor is necessary to minimize the noise in the operation. Thermocouple should

be calibrated periodically to assure proper temperature reading. The roll mill is to

be brought to the fabricator of the roll mill for check-ups and overhauled.

Chapter V

Summary, Conclusion and Recommendations

This chapter presents the summary, findings, conclusions and

recommendations of the study.

 45

Summary

This study was mainly focused on the development of the prototype two

roll mill. This included the different factors such as design, the cost, capacity and

availability of the materials.

Specifically, the study aimed to:

1. Design a machine that will make the raw material distributed equally

with one another as possible.

2. Test the equipment relative to the rated speed of the motor against time

to achieve the homogeneous blended mixture.

3. Prepare an instruction manual of the prototype rolling mill machine.

Findings

The following were the findings based on the development of the prototype

automatic two roll mil.

1. The roll mill was composed mainly of a two roll drum, made of carbon

steel rod that is capable of handling a maximum capacity of 217

grams, microcontroller, cartridge heater, type K thermocouple and DC

geared motor. The total cost of the prototype assembly including the

materials used for its construction was Php122,500.

2. The performance of the prototype produced good results in terms of

homogeneity of the paste. There are some production time results

 46

which are out of the trend behaviour. Discarding of points were done to

statistically evaluate the drum rotational speed and material loading

effects on production time of the homogenous paste. The ease in

achieving the homogenous mixture at the shortest possible time can

be achieve best using low drum rotational speed setting. For high drum

rotational speed setting, short loading time was experienced and the

color of the paste was lighter in hue. But the time in achieving a good

homogeneity of the mixture was longer. The low speed setting was

more effective against high speed in achieving the homogeneity.

3. The instruction was made and prepared in accordance with the

specification and operation of the machine.

Conclusions

Based on the experimental results and data acquired from the

performance test of the developed prototype two roll mill, the authors concluded

the following:

1. The prototype automatic two roll mill was designed taking into

consideration its manufacture design, system components, economic

viability, availability of materials and the material requirements and

specifications. The prototype was fabricated in accordance with the set

dimensions; however availability of parts and components limited its

capacities. Temperature conversion table was made to remedy the

 47

problem in temperature reading of the thermocouple. The developed

prototype can be used in order to produce a paste for the tile board

production that can be sold in the market. Thus the developed prototype

can be a potential source of income.

2. The color of the paste produced is lighter in high speed setting as

compared with the low speed setting. Due to the higher retention time of

heat exchange, the lower speed setting is faster in achieving a

homogenous paste as compared with the high speed setting.

3. The instructional manual is comprehensive.

Recommendations

Based on the findings and results of experiment conducted, fabrication of

the prototype and the performance test of the prototype automatic roll mill, the

following suggestions were recommended:

1. For the improvement of prototype, temperature sensor is suggested to

place strategically to the be able to achieve more accuracy in heating and

melting of plastics.

2. Adjustable drum spacing is suggested to maximize its working capacity

and for further effectiveness of the machine relative to the time of mixing.

3. For further testing of equipment capability on different component of

plastics and other mixtures.

 48

4. Fabrication of nip guard in order to protect the equipment against

overloading of the feed to the shaft.

5. Finally, chromium plating the drum to ensure its corrosion resistance and

for better heat conductivity.