How Sigma Mixer with Extruder Processes High-Viscosity Materials Efficiently

In modern material industrial production, the demand for efficient, precise, and automated mixing solutions is growing rapidly.

When dealing with high-viscosity materials such as rubber compounds, silicone sealants, adhesives, plastics masterbatches, chemical pastes, gum compounds, resins, and polymer blends ,ceramic or pharmaceuticals etc , traditional mixing equipment ,like ordinary sigma mixer , is usually hard to mix these very stick and high-density material ,and achieve uniformity, quick processing, and efficient discharge.

This is where the sigma mixer with extruder becomes an trusted solution ,
This sigma mixer with extruder feature with a high-efficiency mixing and discharge system ,it integrate both the function of mixing with extruding and is capable of homogeneous mixing for high-viscosity material like rubber ,plastic ,master batch and pharmaceucals
, improving productivity, consistency, and automation greatly.

In this blog, we’ll explain how the sigma kneader mixer machine works, its working principle , and why it’s perfect for high-viscosity applications.

1. Introduction to Sigma Mixer with Extruder

A sigma mixer with extruder is an advanced mixing equipment,  it adopts two counter-rotating to knead and mix high-viscosity, dense, and sticky materials.
Different from an ordinary sigma mixer, which mainly relies on manual or tilting discharge, this sigma mixer with extruder machine integrates an extrusion screw at the bottom of the mixing chamber.

This upgraded PLC-Controlled Sigma Mixer with Extruder equipment combines intensive mixing, vacuum degassing, and extrusion discharge under intelligent PLC system control, which ensure consistent product quality and higher efficiency, this this sigma mixer are especially useful for continuous or semi-continuous production lines. Due to its strong capability of achieve uniformity, quick processing, and efficient discharge , this High-performance polymer mixing sigma kneader becomes an indispensable solution for manufacturers in industries like rubber, silicone, chemicals, food, and pharmaceuticals.

Key Components of Sigma Kneader with Extruder Machine:

* Twin Sigma Blades — Used for mixing, kneading, and shearing.
* Sigma Mixing Chamber — Designed for intensive kneading and blending under heavy loads.
* Vacuum system – for degassing and removing air bubbles
* Extrusion Screw / Auger — Pushes material out after mixing and seamless automatic discharge from discharge port.
* Discharge Port / Nozzle — Directs mixed material into molds, extruders, or containers.
* PLC Control System — Equipped with PLC system for smart monitoring and real-time process adjustments, which allow the sigma knead mixing machine run the whole procedure automatically , from the mixing process , heating/cooling, to discharge at the end .
*Jacketed Chamber (Optional) — For some special application or material , it can be also equipped with jacketed system to control heating or cooling for temperature-sensitive materials.

2. Working Principle: Step-by-Step Process

Step 1. Raw Material Feeding

The raw ingredients , such as rubber, silicone, resins, sealant or adhesives etc.are loaded into the mixing chamber manually or via an automated feeding system.

A variety of are parameter, including the material ratio, mixing time, and temperature etc can be parameter on the PLC settings . The PLC-controlled systems can monitor several parameter ,such as blade speed , torque levels and chamber temperature ,thus with the PLC controlled system .
Any parameter deviation triggers automatic adjustments for stable quality. Therefore , it ensure the precise dosing and repeatable batch quality of this high-viscosity mixing equipment .

Step 2. Intensive Kneading & Mixing

Inside the mixing chamber of the jacketed sigma kneader mixer machine with PLC , there are two counter-rotating sigma blades rotating at different speeds in opposite direction, generating intense kneading, shearing, and stretching forces.

Through this rotating blade action ,it can ensures uniform dispersion of fillers, pigments, plasticizers, or additivee and also reach 3 purpose as follows:

* Homogeneous blending of multiple ingredients
* Even dispersion of fillers, additives, and pigments
* Efficient processing of ultra-high viscosity compounds (up to 10 million cps)

For these temperature-sensitive materials, the jacketed chamber provides heating or cooling via steam, hot oil, or chilled water automatically to adjust its temperature .

Step 3. Vacuum System (Optional)

When this sigma kneader with extruder feature with vacuum system ,
For these materials required bubble-free results , such as ceramic ,pharmaceuticals , silicone sealants, EVA resins, or hot-melt adhesives, the vacuum system would be activated automatically . In vacuum environment , it can removes trapped air and moisture from the mixture. Also , the vacuum system can enhances the mechanical strength and surface finish of the final product.

Step 4: Extruding & Discharge Automatically

Unlike ordinary sigma mixers, after the mixing process is completed , it need manual to discharge the processed compound material, the PLC-controlled sigma kneader with extruder can push the processed material in batch through a screw conveyor automatically and continuously, the material would be directly sent into molds, sheets, or storage containers ,which greatly reduced the loss of material and shorten the discharge times.This is very essential for high-viscosity materials, as they are too stick and difficult to remove from the chamber manually.

3. Ordinary Sigma Mixer VS With Extruder

A PLC-controlled Sigma Mixer with Extruder is not just an upgrade, it is very essential for manufacturers handling high-viscosity materials. Its special feature of intelligent automation, continuous extrusion, and precise control make it far better than conventional sigma mixers.

If you are in the high-viscosity materials industries ,like rubber, silicone, chemicals, food, or pharmaceuticals , investing a sigma mixer with extruder is a very essential equipment ,as this mixing machine is capable to mix, homogenize, degas, and automatically extrude materials , it would save much of your time, improves quality, and maximizes productivity.