Laboratory Small Kneader High Viscosity Material Development Mixing Equipment

Equipment introduction

     1) The kneader is an ideal equipment for mixing, kneading, crushing, dispersing and re-polymerizing high-viscosity elastic-plastic materials. It has the advantages of uniform mixing and high kneading efficiency;

     2) Stirring method: Use two sets of stirring paddles with different speeds (Z-type or Σ-type) to squeeze and shear the materials evenly;

     3) Kneaders can be divided into three types: vacuum type, pressure type and normal pressure type;

     4) Heating and cooling methods: thermal oil heating, jacket electric heating, steam heating, water cooling, etc.;

     5) Cover opening method: hydraulic opening.

     6) Discharging method: hydraulic cylinder dumping, bottom discharging, screw extrusion, etc.

     7) Various safety, measurement, control instruments, etc. can be installed on the equipment.

     8) The parts in contact with materials are made of stainless steel, and can also be made according to the requirements of the purchaser;

     9) The mixing shaft seal adopts vacuum structure. Preventing sealing filler particles from entering the cylinder can ensure the quality and purity of materials.

Kneader product picture

Product structure

1. Transmission part

     1) Motor: 1.1-160KW (according to equipment size and product viscosity requirements); kneaders above 2000L can be configured with dual motors;

     2) Reducer: 1.1-55KW can be equipped with a helical gear reducer, and the motor reducer is directly connected; 22-160KW can be equipped with a hardened cylindrical gear reducer;

     3) Motor and reducer transmission mode: 1.1KW-22KW generally adopt direct connection, and above 22KW generally adopt belt transmission (with buffer function)

     4) Reducer and mixing shaft transmission: cross slide coupling or spline coupling;

     5) Transmission between mixing shafts: gear transmission, the number of gear teeth is different, the speed ratio is generally about 1:1.5;

Kneader structure diagram

2. Stirring paddle

     1) Mainly use Σ type and Z type. Normally, Σ type is used. In special cases: such as making DMC and other products, it is required to minimize the shearing of the product.

     2) Material: 5-50L kneader blades are all stainless steel, V≥100L kneader blades are generally made of cast steel body covered with stainless steel plates;

     3) Shaft seal: Packing seal structure: hard PTFE tube + PTFE V-ring + PTFE packing; to prevent packing wear and impurities from entering the cylinder, a vacuum box structure can be added (principle: the vacuum box and the kneader are pumped at the same time When vacuuming, the volume of the vacuum box is smaller than that of the cylinder, and the vacuuming is faster, and the wear material is pumped to the vacuum box)

Kneader sealing structure diagram

Sealed structure

     4) Stirring speed: fast propeller: slow propeller ≈ 48:32 (V ≤ 300L), ≈ 42: 28 (V ≥ 500L), speed ratio ≈ 1.5:1. Frequency converter can be used to adjust the speed;

     5) The stirring paddle can rotate forward and reverse.

kneader blades

3. Cylinder

     1) The inner cylinder is W-shaped, and the material is generally stainless steel. The outer jacket is heated and cooled. The two ends are detachable wall panels. The material is thick carbon steel plate lined with stainless steel plate; asbestos rubber plate+ is used between the cylinder body and the wall panel. Sealant sealing (for products with high requirements such as food, polytetrafluoroethylene sheets (PTFE) are used for sealing).

     2) Cylinder head: arched, equipped with a feeding port, feed port, vacuum port, sight glass, etc., made of SS304 stainless steel; the cover opening method is generally hydraulic, and the opening angle is ≥75°.

     3) The gap between the mixing paddle and the cylinder wall is 3-5mm, and the gap between the mixing paddle and the wall panel is 3mm; 4) The exterior of the cylinder is covered with thermal insulation cotton and covered with stainless steel plates.

4. Discharging method

     1) Hydraulic cylinder turning and discharging: it can be used for materials with low viscosity; the cylinder turning angle is ≥95°; the material discharging is relatively clean;

     2) Bottom discharging: For low-viscosity materials, this discharging method is convenient and safe, and can be directly transported by pipelines with a high-viscosity pump. There is residue in the pipe.

     3) Screw discharging: It is suitable for materials with high viscosity and consistency. It can be directly formed when adding a die. There is residue on the screw part.

Kneader discharge

**Note: The small laboratory vacuum kneader uses a turning cylinder to discharge materials.

5. Heating and cooling methods

     1) Jacket electric heating: 5L→2KW, 50L→6-9KW, 100L→12-15KW, 200L→15-18KW, 300L→20-24KW, 500L→24-36KW, 1000L→36-42KW, 2000L and above It is recommended to use heating furnace circulation heating.

     2) External circulation heating: Electric heating furnace specifications: 12KW, 24KW, 30KW, 45KW, 60KW, 75KW, 90KW, 120KW, 150KW, etc. Generally, 2 sets of hot oil pumps are required;

     3) Steam heating: When steam heating is required, the user's request must be made first. Different steam temperatures require completely different cylinder thicknesses, and the jacket's pressure resistance requirements are also different. The cylinder body and jacket must be thickened, and the equipment price must also increase.

     4) Cold water can be passed through the jacket for cooling. When heating the heat transfer oil, an external oil cooler can be connected for circulating cooling.

Parameter configuration

     1) Motor reducer: Jiangsu Guomao Cathay (a well-known domestic brand, with a warranty of more than 10 years).

     2) Material: All parts in contact with the material are made of SUS304 stainless steel or SUS316L stainless steel.

     3) Cylinder plate thickness: >8mm to ensure cylinder strength.

     4) Polishing accuracy: >200 mesh.

     5) Shaft seal: Three-layer special sealing structure ensures vacuum and no filler wear and black particles enter the cylinder.

     6) Introduce Japanese vacuum box balance structure technology to ensure the same vacuum degree inside and outside the cylinder.

     7) The overall cylinder body has an armored shaft hole to ensure the concentricity of the mixing paddle.

     8) Vacuum degree: ≤-0.096MPa.

     9) Cylinder pressure test: ≥0.04MPa.

     10) Jacket pressure test: >0.06MPa.

     11) Bearing: Harbin Bearing (one of the three major production bases in China's bearing industry).

     12) The jacket is equipped with multi-layer diversion reinforcement plates to ensure cylinder strength and uniform heating/cooling.

     13) Frequency converter: Shenzhen INVT (listed company, the world's leading supplier of industrial control and automation products and services).

     14) Electrical control: Jiangsu CHINT (listed company, one of the top ten electrical appliance brands in the world).

Kneader parameters

Application scope

Widely used in high viscosity sealants, silicone rubber, adhesives, BMC inks, pigments, dyes, plastics, rubber, cosmetics and other industries.

Listed below are several representative vacuum kneader application pictures for your reference: