In the chemical , rubber and other materials industry, achieving uniform mixing and dispersion of high-viscosity materials is essential. One kind of dispersion kneaders are among the most reliable mixing machines which are widely used for blending, kneading, and dispersing complex formulations.
The processing weight of a kneader machine is one of the most important performance indicators. Whether you are producing silicone rubber, ceramic paste, adhesive, sealants or chemical compounds, understanding why actual batch weight differs from the theoretical capacity and how to increase batch weight , undoubtedly can enhance your production efficiency and capability.
1. The Factors That Inflence the Batch Processing Weight of a Kneader
1.1. Chamber Volume vs. Material Density
The standard capacity of industrial dispersion kneader are usually 25L , 35L, 55L, 75L, 110L and 150L, which is based on chamber volume, but the actual batch weight depends heavily on the density of the processing material. Usually ,the material can be seperate high- density material and low-density material.
* High-density materials are usually these metal powders, aluminum powder , ceramics material etc. As these high-density material can fill into the mixing chamber more weight in the same volume.
* Low-density materials are usually referred to these foamed rubber, EVA ,polymer etc , which take up more space but less weight in the same volume .
Thus ,for these two kinds of material , in the same volume ,its batch weigt is different.
1.2. Filling Coefficient
Since two blades in the mixing chamber need to rotate to shear , mix and stir the compound material . Thus kneaders‘ chamber cannot be filled 100% full, its filling coefficient is typically 0.6–0.8 ,so that the two blades rotate and for materials to move freely. And also . overfilling reduces mixing efficiency and may effect the motor overload ,then damage the kneader machine .
1.3. Blade Type & Speed
There are mainly common two blade designs: Sigma blades and Z-blades .
Sigma blades are also named as sigma impeller or sigma mixer, which are ideal for high-viscosity compound material but may require more space for material flow, this sigma blade keader is very used for mixing, kneading and blending of solid & semi solid materials. It’s often used in a side-by-side tangential or overlapping arrangement.
While Z blade resembles “Z” style. The Z blade kneader feature masticator blades and can process high density with higher torque. ,which is widely used in a wide range of materials, from low to high viscosity. This Z blade kneader is particularly effective for dispersing and mixing high-viscosity substances like pigments in resins.
1.4. Temperature Control
It is the fact that excessive heat would be generated when the material are mixed and blender in the chamber , it can cause some checical raction , such as premature curing or expansion, thus reducing density. So a kneader equipped with jacket system can control precisely the heating/cooling ,which can inflence the stability and consistency of material.
How to Increase the Processing Weight of a Kneader
Choose the Right Kneader Capacity Accooding To Your Actual Needs
If your production needs exceed your current kneader’s processing weight, then you need to consider upgrading to a larger chamber volume kneader machine .
Optimize Blade Design
You may need to consider customized sigma or Z-blades ,which can effectively improve the production efficiency , output capacity ,material circulation etc.
Vacuum Systems Kneader
A vacuum kneader is a specialized mixing machine which is specially designed to process high-viscosity materials under a vacuum environment. Vacuum kneaders remove entrapped air and moisture, increasing net material density.
Maintain Temperature Stability & Consistency
The jacktet system can control the temperature , it can prevent material expansion or early curing and thus can allow more material to be processed per batch.
In conclusion , the processing weight of a kneader is not a fixed number , it depends on material properties, machine design, and process control etc .
By understanding these influencing factors and selecting the right size kneader machine , manufacturers may increase their production output but not need to purchase a larger machine.
At Simptek , we custom and provide both lab-scale kneader and industrial kneaders for you . Here , optimized chamber design, customizable blades, and advanced vacuum/temperature control systems can be tailored , your maximize batch weight and mixing efficiency can be reach at Simptek.