In modern industries process for high-viscosity materials, like rubber compounds, silicone sealants, polymer, adhesives, master batches, chemical pastes, ceramic and pharmaceuticals etc, manufacturers are facing increasing demands for higher efficiency, uniformity, and productivity. As these high-viscosity material are heavy compounds ,they are very sticky and dense , so mixing these heavy compound material for ordinary sigma mixer is a hard work .
That is why advanced sigma mixer with extruder become more and more popular .
A sigma mixer with extruder an advanced industrial kneading and mixing machine designed to handle high-viscosity, dense, and sticky materials ,it integrate the function of mixing and extruding ,it becomes a high-efficiency mixing and discharge system, capable of improving productivity, consistency, and automation ,thus this high-viscosity mixing equipment has been a new trusted solution for achieving homogeneous mixing.
In this blog, let us learn the advantages of a sigma mixer with extruder compared to a standard sigma mixer and why many manufacturers are shifting to this new model sigma kneader mixer with extrusion function.
Advantages of Sigma Mixer with Extruder
1. Efficient Discharge of High-Viscosity Materials
For Ordinary Sigma Mixer:
As when the mixed material is completed , the ordinary sigma mixer need to discharge manually .For high-viscosity materials, as they are very sticky , so usually clings to the mixing chamber walls and blades, which cause higher material loss ,especially for expensive rare material . What is more, the clearing time would take longer.
While for Sigma Mixer with Extruder
As this advanced equipment is equipped with an extrusion screw ,which cab continuously pushes out the mixed material after the mixing process through a discharge port.
Since it feature with PLC control , this PLC-Controlled vacuum sigma kneader for high-viscosity is actually run automatically, from the mixing ,clean, and complete discharge, all are automatic process , reducing material waste and save labor time cost.
Advantage: Compared to standard sigma mixer ,it can enhance the working efficiency up to 30–40% , faster discharge and less than 1% material residue .
2. Enhanced Homogenization During Mixing
A sigma mixer with extruder is an advanced industrial kneading and mixing machine, it doesn’t just knead and mix the material, but also they homogenize the compound material through the extrusion screw and can achieve several purpose as follows:
* Continuous shearing force from the extrusion screw improves particle dispersion.
* Eliminates micro-lumps in high-viscosity batches.
* Compared to Produces ordinary sigma mixers, it can produce a more uniform mixture and finished products
This is specially very critical for plastics, chemical adhesives, rubber, and specialty polymers where consistent material properties are critical.
3. Cleaner and Safer To Operate
Ordinary sigma mixers often require operators to manually deal with these high-viscosity , sticky, hot, or chemical-heavy products.
While sigma mixers with extruders can discharge the material automately, which minimize operator contact with hazardous or heated materials. Also ,it can decrease the operation time and prevent the risk of chemical or other toxic material , reduced exposure to fumes, burns, and chemical risks.
4. Enhance Productivity
Since the sigma mixer with extruder feature with extra extrusion function ,its cost is accordingly higher. But their applied material is a little different , ordinary sigma mixer may meet with the needs of basic applications and low-viscosity products. But a sigma mixer with an extruder can handle high-viscosity, high-density, or sticky materials.
Except that , with a sigma mixer with extruder equipment ,it also offer the following significant operational advantages :
* Improved homogenization
* Increased productivity
* Reducing batch times
* Minimizing material losses
* Faster and cleaner discharge
* Lower labor and material costs
* Safer and more efficient processing
For manufacturers , if you are aiming to scale up production and increased productivity, the ROI is faster than sticking with traditional sigma mixers.
If your companies are producing rubber compounds, adhesives, hot melts, battery pastes, silicone sealants ,masterbatches, chemical pastes, or specialty polymers, upgrading to an advanced sigma mixer with extruder can boost output quality and overall efficiency.