In the world of industrial processing, handling high-viscosity and heavily filled materials ,especially for chemical material , it is always not so easy to process. That’s where the chemical dispersion kneader comes into play—especially for 110-litre model dispersion kneader, which are widely used and offers an ideal balance between batch capacity and performance. But how exactly does this dispersion kneader machine process chemical compound materials?
Here ,let us explore the whole procedure that how does dispersion kneader work for chemical ,
from raw material loading to final discharge in the end, and explain why a dispersion kneader is so essential for high-quality compound production.
🔄 What Is a Chemical Kneader?
Firstly ,let us know what is chemical kneader ?
A chemical kneader, also known as a dispersion kneader or banbury intensive mixer, it is a mixing machine specially designed for processing highly viscous or plasticized materials. It is widely used in various industries for the production as follows:
* Rubber and elastomer compounds
* Silicone rubber compounding for electronics and automotive use
* Sealants and adhesives
* Pigmented plastics and masterbatches
* Hot-melt resins
* Adhesive blending for hot-melt glues
* Battery pastes and specialty chemicals
* Heavy filler-loaded sealants for construction
Key Features:
* Twin Z-blade mixing for strong shearing and folding action
* Hydraulic tilting or bottom discharge for easy material removal
* Temperature-controlled jacket for heating or cooling
* Heavy-duty gearbox and motor for continuous operation
* Vacuum sealing option for moisture-sensitive or air-free mixing
* Wear-resistant chamber liners for long service life
⚙ How a 110-Litre Dispersion Kneader Works ?
1. Raw Material Feeding
Firstly ,the raw materials such as base chemical , polymers, resins, fillers, plasticizers, catalysts, and additives are fed into the 110-litre mixing chamber. The dispersion kneader can be equipped with a hydraulic or pneumatically operated feeding cover ,so that ensure the safe and efficient loading for raw material.
2. Sealing and Safety
Once the raw materials are fed in the mixing chamber , the chamber is then sealed tightly to ensures safe, dust-free material to load, and also the sealed lid protects volatile or sensitive ingredients from external contamination to pollute environment. As your specific needs ,the chamber can be tailored as vacuum setting ,which can eliminate moisture and air bubbles, so extremely useful when mixing moisture-sensitive compounds.
3. Mixing Begins: Twin Z-Blades in Action
The kneader’s twin count Z-blades begin to rotate at differential speeds ,which therefore generate intense kneading and shearing forces for the compound material ,so that create homogeneous compound mixture.
The purpose of mixing not only mix the compound material evenly and homogeneously , but also it helps to develop the desired physical characteristics ,such as viscosity, elasticity, thermal stability of the mixture.
4. Temperature Control
Throughout the mixing process, thermal jackets around the mixing chamber allow for precise heating or cooling.
5. Discharge of Finished Compound
The mixing time rely on the specific material ,usually ,it take about 30 to 90 minutes . Once the mixing process is complete, there are two main discharge options:
* Hydraulic tilting: The entire chamber tilts to pour out thick or sticky compounds
* Bottom discharge valve: Allows for controlled release of flowable materials
✅ Why Use a 110-Litre Chemical Kneader?
The 110-litre dispersion kneader is the perfect mid-range capacity ,as it is not too small for industrial production, but also not too large for lab or pilot-scale operations. It offers:
* High mixing uniformity
* Stable temperature control
* Durability for abrasive or chemically aggressive materials
* Batch-to-batch consistency
In conclusion , whether you are in the chemical, rubber, plastic, or battery industry, the 110-litre chemical dispersion kneader is essential equipment ,which ensures uniform mixing, high throughput, and reliable results.
If you want to learn more about dispersion kneader ,we ,here ,at Simptek ,are very happy to help you.