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& MACHINERY
MODULE I -THE MIXING MACHINERY
1.1.0 To comprehend the mixing machinery
•Viscosity break down occurs during mixing and is essential for smooth
processing of the stock.
Mixing Mill
Working of a two roll mill
• Consists of two adjacent smooth , hardened steel rolls set horizontally
• They rotate in opposite directions, produces friction or grinding action
between them.
• Ratio between the operating speed of the front roll and back roll is
referred to as friction ratio
• Usually, the friction ratio is kept around 1: 1.25 to 1: 1.4 for the front to
back roll.
• Back roll moves faster than the front roll; a common friction ratio is 1:1.25
• The rolls of the mixing mill are connected to the drive motor through
appropriate gears to adjust speed.
• Mixing was achieved by the shearing action induced in the space between
the rolls which is adjustable
• During the mixing operation, cutting and blending is carried out in order to
obtain a thorough and uniform dispersion of the ingredients in the
polymer mix.
Parts of a two roll mill
Parts of a two roll mill
1. Rolls:
• These are chilled cast iron rolls, cylindrical, exactly identical in shape, horizontally drilled to
facilitate the circulation of hot/cool water and highly polished .These rolls are set in heavy
frames.
• Generally rolls are rotated in opposite direction with uneven speed back roll is faster than the
front roll.
2. Motor:
• Rolls are rotated by 3 phase induction motor of high torque.
3. Reduction gear unit:
• The driving force is transmitted from a motor to rolls through a reduction gear which reduces
the high speed of motor to maximize the torque and to reduce the surface speed of rolls.
4. Roll end gear:
• The mixing mill rolls are connected endwise with two small
speed to increase the friction and shearing force between the rolls . This friction and
shearing force causes the breakdown of large polymer chains and there by viscosity
tacky. The number of teeth of the roll end gears determines the surface speed of
Advantages Disadvantages
Banbury mixer
Internal Mixer
Intermix
The major difference between the two machines is due to the rotor and mixing chamber
design.
BANBURY MIXER
•Banbury mixer developed by Fernley H. Banbury
"side."
•The tangential mixer develops high shear mixing predominately between the
clearance between the rotor wings and chamber wall, where dispersive
consists of a hopper opening and door followed by a chute for loading the
materials into the mixing chamber ; opening provided at the operator side of the machine
can be lowered or raised allowing the raw materials to be added into also forces the
added materials into the mixing chamber. It is also named as ram (Banbury) or a Plunger
(Intermix). It is the air pressure (10 to 120 psi) applied by the bottom of the ram/plunger
that can affect the mixing time or shear on the compound, affecting distributive / dispersive
mixing.
Parts of an internal mixer
• Mixing Chamber
The mixing chamber houses the rotors inside it, receives the
top side, which is closed by the floating weight and at the bottom, has
Rotors rotating toward each other at the same speed (intermeshing design) or
The rotors are designed to interact with each other via the rotor blades, called
wings.
Short wings and long wings are used in combination on each rotor.
Rotors are arranged in the mixer such that the long wing of one rotor
Edge of the blade is called the wing tip, which forms the shearing gap
Rotors are temperature controlled with steam and/or water, which flows
Conventional Method
• Consists of adding the elastomer first followed by the dry ingredients and
finally the liquid ingredients, once the dry materials are well dispersed in
the elastomer.
• This method can achieve a homogeneous dispersion of all ingredients,
including fillers of very small particle size.
• However the mixing time required is usually long because of the difficulty
in incorporating liquid ingredients once the dry materials have been
dispersed in the rubber matrix.
• Significant amount of slippage and loss of efficiency occurs inside the
chamber till the time the oil is incorporated.
Internal Mixing Methods/ Procedures
• Under filling of the mixing chamber is essential for efficient mixing and fill
factors in the range 0.65-0.85 are generally used, depending on mix type.
• Within the range 0.65-0.85, it is possible to retain the batch in regions
where active mixing occurs.
• Very low fill factors are uneconomic and excessive high fill factor result in
material remaining on the throat of the mixer and not taking part in the
mixing
Advantages and Disadvantages of Internal Mixers
Advantages Disadvantages
Safer, cleaner, more healthy Rapid temperature rise
working conditions necessitates separate step for
curative addition
Shorter mixing time ( 5-6 min) High capital cost associated with
take away system and feed system
Minimum dependence on
operator
Farrel Continuous Mixer (FCM)
MVX has been shown to be capable of single – pass mixing of high reinforced compounds
without the generation of excessive rubber temperatures suggesting that it is more energy
efficient than FCM.
Transfermix
• Transfermix is a rubber extruder with specialized screw designs designed
for improving mixing capacity.
• The transfermix has helical channels machined in both the screw and the
barrel.
• The depth of the channel varies alternately along the length of the barrel.
• Thus the melt is transferred from the channel in the screw to the channel
in the barrel wall as it is transported down the barrel.
• Each transfer from one channel to another, the material passes over the
clearance between the two flights, where the shear stresses are
maximum.