LABORATORY REPORT OF

POLYMER PROCESSING DESIGN LAB

6th Semester

Submitted to: Dr. Farhan Saeed

Submitted by: Faisal Iqbal 2018-PE-02

DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY
LAHORE
 Table of Contents:

1. Contents.

Table of Contents:............................................................................................................................2
1. Contents....................................................................................................................................2
2. Objective:.................................................................................................................................3
3. Equipment:...............................................................................................................................3
4. Process Condition.....................................................................................................................3
Material........................................................................................................................................3
Temp set of different zone...........................................................................................................3
5. Results and Discussion:............................................................................................................4
6. Conclusion:...............................................................................................................................4
2. Objective:
 To study the preparation routes involved in the manufacturing of master batches for
commodity thermoplastics on a laboratory scale internal mixer.
 To examine the effects of process variables (mixing time, mixing temperature, and
mixing speed) on polymer blend formation in a laboratory scale internal mixer.

3. Equipment:
Internal Mixer

Figure 5.1: Horizontal Injection Molding Machine

 4. Compounding Process:

Polymers are first broken down in an internal mixer where, in addition to the polymer, a
appetizer may also be added. This stage is essentially a polymer molecular weight reduction
phase. After initial breakdown of the polymer, carbon black, rubber chemicals, and oils can be
added to the polymer at intervals to complete the compound formulation. Polymer breakdown
and mixing generally occur at a high temperature, up to 180°C. Compounds may also be mixed
on open mills, but this takes considerably more time, batch weights are lower, and it is thus less
efficient than use of internal mixers.
Degree of breakdown with both types of equipment is dependent on the “friction ratio” or the
difference between the operating speeds of the front and back rolls (or rotors, for internal
mixers). In addition, clearance, conditions of the rotor surfaces, pressure, and speed influence
breakdown.
The mixing operation is designed to obtain uniform dispersion of all the compounding materials
in a formulation. For every batch there is a defined mix period, temperature, mill or mixing
speed, and sequence of material addition. Though the general guidelines on compound
preparation for both mill mixing and internal mixers are similar, mill mixing has been replaced
by internal mixers because of efficiency, automation, quality, and uniformity. For example,
internal mixers can be computer controlled, allowing monitoring of power consumption, mix
times, and batch drop temperatures and control of temperature gradients through a mixing
compound at any point in the mix cycle[2].

5. Results and Discussion:

No of Blend Mixing time Temperature Rpm of Weight

Observations (min) (oC) Screw loss(g)
01. HDPE(44g)
Dye(1 g) 6 180 45 1
02. HDPE(44 g)
Dye(1 g) 8 180 45 1
03. HDPE(44g)
Dye(1 g) 10 180 60 2
04. HDPE(44g)
Dye(1 g) 10 180 75 2
 6. Conclusion:
The ultimate aim is to achieve good dispersion and distribution of constituents to attain uniform

properties and satisfactory mixing. As the mixing time increases time for heat transfer and mass

transfer also increases. Proper temperature distribution will melt/soften the whole material and

the mass transfer is also better with increase in time to achieve magnificent mixing. By

increasing mixing speed shear rate increases which act more force on solid particles for

distribution and dispersion. By seeing with naked eye the sample with maximum mixing speed

and time shows well distribution of dye(color) no agglomerates have been seen their.

Figure 2 (sample 1at minimum time and speed)

7. References:
1. J. W. Gooch, “Internal Mixer,” pp. 394–394, 2011, doi: 10.1007/978-1-4419-6247-
8_6413.