rubber dispersion kneader a friend in knead

DISPERSION

KNEADERYour Friend In ‘Knead’

Machinery World

Rubber & Tyre Knowledge On-The-Go Special Supplement

http://rubbermachineryworld.com

For many years, open mill mixing has been the

preferred form of mixing rubber. But then

technology has been evolving.

Thus came mixers and the major considerations had

always been cost. Since last twenty five years, the

Kneaders have become the most commonly used type

of 'mixer' in the rubber industry.

This popularity, prompted us to showcase Kneaders

specifically in this Knowledge On-The-Go Special

Supplement.

Though developed initially for mixing thermoplastics,

Dispersion Kneaders have a unique place in the

elastomer mixing industry. Users love the ease of

cleanliness on this machine especially when they have

to change the colour of their compounds frequently.

Dispersion Kneader is energy efficient, maintenance

friendly, labour and time saving machinery that offers

consistent quality of rubber mix compound at higher

output as compared to an open mixing mill – thus

making it truly for your rubberYour Friend in 'Knead'

processing plant...

I hope you agree and find this special supplement

informative.

As always, I welcome your feedback on

[email protected].

BestRegards

Prasanth Warrier

| Editor’s Note |

Your Friend In ‘Knead’ Is A True

Friend Indeed

Since last twenty

five years, the

Dispersion Kneaders

have become the

most commonly used

type of 'mixer' in the

rubber industry.

3

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Special Supplement - Rubber Machinery World NOV 2015|

4

| DISPERSION KNEADER |


Image: Hevea Engineering Works (HEW) Make Rubber Dispersion Kneader



5

DISPERSION

KNEADER

For many years, open mill mixing has been the

preferred form of mixing rubber. But then

technology has been evolving, your customers

expectations growing - sustaining quality without

compromising on cost, reducing wastage,

extracting more out of available time has all been

additional challenges that you come across in day-

to-day operations.

Thus came mixers and the major considerations

had always been cost.

In the world of rubber mixing, when 'purists' refer

to 'mixer', they either mean a Tangential Rotor

Type (Banbury®) Mixer or a Intermeshing Rotor

Type (Intermix®) Mixer.

While 'practitioners' have a third category viz.

Rubber Dispersion Kneader.

When discussing with the practitioners (mostly in

Asia) you will hear the terms 'Kneader Banbury',

'Kneader Mixer', 'Kneader Intermix', 'Intensive

Mixer Kneader', 'Internal Mixer Kneader',

'Dispersion Mixer', 'Tilt Mixer' etc.

So, what is this dispersion kneader?

Prasanth Warrier

Your Friend In ‘Knead’

6



To start with, a kneader

means a machine that

specializes in kneading

substances, something

to a dough form.

I suspect it originates

from Germany when

Heinz List, a pioneer of

modern industrial

processing technology,

first developed a

kneader reactor to

process high viscosity

materials.

Nilesh Parikh, Director

of Microquick

Engineers, says “In

Kneader, the production

of compound increases by

40 to 50 per cent than that

of mixing mill. The batch

preparation time could be

between 10 to 15 minutes.

The compounding takes

place normally with a

mastication time of 3 to 5

minutes and filler

compounding time of 7 to

10 minutes.”

Applications of Kneader

Though developed initially

for mixing thermoplastics,

Dispersion Kneaders have

a unique place in the

elastomer mixing industry.

Image: Bharaj Make 110 Liters Kneader For Export to USA.

Users love the ease of

cleanliness on this machine

especially when they have

to change the colour of their

compounds frequently.

Informs Kulwant Singh

Manpotra, Director of

Modern Machines,

manufacturers and

exporters of Rubber

Machinery “Kneaders are

easy to operate, ensure

uniform dispersion of

compounds and can be

employed in a wide

assortment of material

mixing ranging from low

viscosity adhesives to high

viscosity rubber.”

Dispersion Kneaders have

efficient cooling mechanism

through jacketed

construction. This, in turn,

improves the mixing

dispersion and prevents

your rubber compound

from scorching by

facilitating low

temperature mixing.

8



Their varied applications

include

- Oil seal, Body seal, Belt,

Gasket, Hose, Tube for

Automobiles

- Rubber for Electric

wires

- Conveyor Belts & Power

transmission belts

- Rubberized Rolls

- Rubber based products

like Plug, Cap, Glove,

Dental for Medical line

- Sporting goods like

rubber ball, etc

Construction of Kneader

The construction comprises

of a hopper with ram,

mixing chamber with dust

seals, pressure lid, rotors

(blades), tilting mechanism

to facilitate discharge,

gearbox, motor-controls.

Operating Principle of a

Dispersion Kneader

The concept of mixing

inside Kneader is

essentially a carry forward

of what happens in Two-

Roll mills. This means that

there is friction between

two rotors (similar to rolls

in mills) to aid mixing.

However, here it happens in

a closed environment.

Introduction of ram pressure

forces the material into the

chamber and hence the

rotors. The Kneader with its

uniquely designed rotors,

rotor blades, mixing chamber

and pressure lid allows for

thorough material flow and

controlled shear mixing

within the mixing chamber.

Nilesh Parikh says, “The

differential rotation of

rotors; Helical, Wide width

of rotor wings and clearance

of rotors gives excellent

pressing/shear/tear/folding/

stretching/smear of

ingredients of compound.

This leads to the best

kneading effect and

promotes the uniform

dispersion of fillers”.

The production of compound increases

by 40 to 50 per cent than that of mixing

mill.

Nilesh Parikh

Director, Microquick Engineers

Image From Web

10



Highest quality mixing with minimum

time has been a major push force for

regular technology developments.

Kneaders have come a long way. They

have evolved from shabby mixing rooms.

Amardeep Singh Bharaj

Director (Sales)

Bharaj Machineries Pvt. Ltd.

Evolution and Technology

Developments in Kneader

Since last twenty five years,

the Kneaders have become

the most commonly used

type of 'mixer' in the rubber

industry.

“Highest quality mixing with

minimum time has been a

major push force for regular

technology developments.

Kneaders have come a long

way. They have evolved from

shabby mixing rooms and

are respectfully placed in

air-conditioned areas” says

Amardeep Singh Bharaj,

Director (Sales) of leading

rubber machinery

manufacturer, Bharaj

Machineries Pvt Ltd.

He further adds, “Efficient

dust proof systems and

technology has made the

compounding room a

matter of pride. Hydraulic

rams and lid designs for

controlled dispersion effect,

automatic stage mixing

features for consistent

compound, PLC controlling

systems with energy-

efficient variable frequency

drives.”.

Image: Bharaj Make 75 Liters Kneader For Japanese Co.

12



Rotors

Traditional Kneaders have

two counter rotating rotors

with each rotor having two

wings affixed on it.

The two wing rotors rotate

at different speeds

facilitated through

connecting gears. The wings

move your rubber material

from one portion of the

chamber to the other while

also providing material

movement along the rotor

axis.

Conventional Kneaders

have a one piece rotor

design which includes a

rotor shaft with two long,

high and narrow wings

welded on the shaft.

Water cooling is provided

through a passage in the

rotor shaft and small

jackets in each wing in

traditional kneaders. This

cooling method is not

sufficient for single pass

mixing.

Explains Amardeep Singh,

“In terms of mixing

technology and usage, there

is major development

happening in the Kneader

rotor. Rotor designs have

changed with cooling

channels for better and

quick mastication. For

example, Bharaj has

specially developed

tri-blade rotors where

mixing with highest

quality dispersion effect

is achieved with a 15%

reduction in the mixing

time.”

Opines Tom C. Abraham,

Director of the leading TSR

processing machinery

manufacturer Hevea

Engineering Works Pvt.

Ltd. “Introducing

peripheral cooling to the

rotor improves the mix

quality”.

Hevea Engineering Works

has recently launched their

Image: Microquick Engineers.

Image of Rotors

For example, Bharaj Machineries has

specially developed tri-blade rotors

where mixing with highest quality

dispersion effect is achieved with a 15%

reduction in the mixing time.

Amardeep Singh Bharaj

Director (Sales)

Bharaj Machineries Pvt. Ltd.

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range of Kneaders, expand-

ing their engineering

competence from TSR

processing machinery.

Validates Tom C. Abraham

on their unique advantage

to benefit customers “We

have our own rubber

processing unit where we

test our machinery. We

continuously innovate and

improve our machinery

based on our experience

and customer feedback.”

Intermeshing type of rotors

in Kneader imparts

superior dispersion during

the kneading process. This

advancement is similar to

those observed in

Intermix® Rotors that have

a rotor shaft with two nogs

(small blades) for mixing.

The materials are subjected to

a larger smearing action of

the batch against the rotor tip

to chamber wall as well as the

rotor tip to rotor shaft.

Informs Nilesh Parikh, “The

new kneader has much wider

land width and stubby in

shape. The wide rotor tips

enhance the dispersion effect.”

Intermeshing rotors have a

much larger outside diameter

than conventional kneader

rotors. This allows for more

cooling surface as well as

larger mixing surfaces.

The cooling circuit is

designed inside wing of

rotors and all around mixing

chamber. The result is

quality compounding at less

temperature even at high

rate of production.

Hopper and Feed Area

Conventional Kneaders use

pneumatic pressure to push

the batch down into the

rotors and mixing chamber

with a floating weight (ram).

This pneumatic system is

unreliable and inconsistent.

The pneumatic ram moves

completely uncontrolled and

the ram position is

controlled by the rotor

dragging force as well as the

size of rubber pieces it is

trying to force into the

rotors. The hydraulic ram

exerts positive pressure on

the batch and can be

accurately controlled in the

desirable position which

leads to better batch to batch

consistency.

Introducing peripheral cooling to the

rotor improves the mix quality. We have

our own rubber processing unit where

we test our machinery. We continuously

innovate and improve our machinery

based on our experience and customer

feedback.

Tom C. Abraham

Director

Hevea Engineering Works Pvt. Ltd.

14

Manufacturing, Supply, Erection

and Commissioning of New

- Dispersion Kneaders

- Mixing Mills

- Calenders

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- Extruders

- Hydraulic Presses

Repair Services of Old Machinery.

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is required for mixers

with drop door.

Customization & Automation

A standard Kneader

construction can be usually

considered for all applications.

However, it is the

accompanying automation

that makes this machinery

customized to its users.

Confirms Amardeep Singh,

“As per customer products

and demands, Kneaders are

offered with various

options. For example, in

case of hard to process

rubber compounds heavy

transmissions gearboxes

and motors are used. For

high friction rubbers

temperature controlling

systems are provided to have a

grip on quality by providing

efficient cooling and

maintaining consistent

temperature. Automatic

sequence stage wise mixing

through PLC is also highly

effective.”

A standard Kneader construction can be

generally considered for all applications.

Emphasizes Amardeep

Bharaj, “A Hydraulic system

ensures zero maintenance

compared to geared designs;

enhancing the life of the

equipment with better

mixing and minimum

downtime.”

Adds Tom C. Abraham,

“Earlier the feeding and

discharge were done from

the front side. Now, feeding

is done from the rear side,

and discharge to the front

side, which allows for better

automation and efficiency.”

Discharge Mechanism

Observes Tom C. Abraham,

“In kneaders, hydraulic

tilting mechanism has

largely replaced the worm

gear type mechanism.

Instead of the tilting

mechanism, a drop door

mechanism can be

introduced, which would

allow for better automation

and accessory equipments

such as the skip conveyor

may be eliminated.”

This is particularly

interesting as the kneader

tilts 125-140 degrees to

discharge the batch unlike

a batch mixer that

discharges the batch

through a bottom drop-

door.

However, this drop door

mechanism could dilute

the widely broadcasted

advantage i.e. Kneaders

can be positioned on the

ground level.

While a mezzanine floor

Image: Tilt Discharge Mechanism

(Moriyama Make Kneader)

16



He further recommends the

standard Kneaders for

customers starting new

and/or shifting from

primitive mixing on two-roll

mills, so that they can learn

the art of mixing the

compounds on the Kneaders.

And then improvise with

better upgrades in future.

Explains Ashutosh

Chincholikar, Business

Head of Smart Controls

India Ltd, “Mixing

Automation today has

changed significantly.

Earlier, recipe-based

weighing and mixing was

considered ultimate. But

now we talk of a Mixing

Room Automation. We today

have Advanced Process

Control giving higher

efficiency and better batch-

Mixing Automation has changed

significantly. We today have Advanced

Process Control giving higher efficiency

and better batch-to-batch uniformity in

spite of the varying properties of your

raw material.Ashutosh Chincholikar

Business Head

Smart Controls India Ltd.

to-batch uniformity in spite

of the varying properties of

your raw material.”

This has helped the users

in terms of a more efficient

and integrated system that

can be completely managed

from one room.

Smart Controls India Ltd is

pure integrators and their

solutions are based on state

of the art products from

Siemens. They have an

ability to integrate almost

any kind of control system

with their Mixing Line

Controls based on Siemens

18

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platform. He further adds

“We understand the Mixing

Machinery very well, be it

Mixing Machinery,

Upstream or Batch off. We

possess good skills on IT

integration as well. So the

Mixing solution can be

connected to the business

If the kneader is structurally sound,

reconditioning is okay. Provided the

major components like rotor, chamber,

and bearings etc supports within the

price expectations of reconditioning.

Kulwant Singh Manpotra

Director

Modern Machines

platforms like SAP or Oracle.”

Is Kneader Reconditioning

Recommended?

Reconditioning, timely

maintenance and service is

the most important factor for

longevity of any rubber

machinery's life. And I

suppose, it is the same with

Dispersion Kneaders too.

However, the varying

opinion amongst

manufacturers is interesting.

Nilesh Parikh of Microquick

Engineers does not

recommend reconditioning

because it is expensive to

replace the major

components and he feels

there would be drop in

kneader performance.

While Kulwant Singh

Manpotra of Modern

Machines calls for a cautious

approach. “If the kneader is

structurally sound,

reconditioning is okay.

Provided the major

components like rotor,

chamber, and bearings etc. Image: A Rebuild Kneader (From Web)

20

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supports within the price

expectations of

reconditioning.”

Tom C. Abraham of Hevea

Engineering Works feels

“It is easy to replace/

refurbish the worn out

parts, such as rotor,

chamber etc. So if the

kneader is structurally

sound, reconditioning is OK.

However, it will not be

possible to change the

feeding side, or change

the tilt mechanism with a

simple reconditioning.”

Amardeep Singh of

Bharaj Machineries says

“there are times when due

to continuous running and

fatigue factor of machines,

some parts wear-out

effecting the productivity

of the machine and thus

causing various energy

losses, product quality

issues, increased cycle

times and sometimes

contamination of rubber

with worn out parts.

Upgrading the electrical

features and

reconditioning with

available technology will

ensure that the equipment

runs trouble free with

optimum results.”

When it comes to reconditioning, you

need an expert diagnosis of the condition

of your machinery to evaluate the pros

and cons of refurbishing or upgrading.

The bottom line is that when

it comes to Kneader

reconditioning, you need a

expert diagnosis of the

condition of your machinery

to evaluate the pros and cons

of refurbishing or upgrading.

And then make an informed

trade-off between your costs

versus performance

expectation.

Differences between Kneader

and Mixer

The respective rotor, throat,

chamber and floating weight

designs are different in a

dispersion kneader and batch

mixer (or internal mixer).

Kneaders are available in more

customized capacities than

batch mixer and can be

Image: Modern Machines Make Kneader Working At A Plant.

22

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Phone Off: +91- 481-2430325. Fax: +91- 481-2430596

e-mail: [email protected]



positioned on the ground

level.

For similar capacities,

Dispersion Kneaders use

lower power than mixer.

The mixing time is higher

than an internal mixer and

hence production volumes

are lower in kneader.

Over a period of time,

kneader manufacturers

have developed designs,

features and automation

for high quality and

optimum mixing

performance to position

them closer to the internal

mixer. Yet, a kneader is

different from an 'internal

mixer' and should be

viewed contextually

during your discussions to

avoid the confusing

terminologies corelating

them to mixer (that I

outlined in the start).

Summarizing, Dispersion

Kneader is energy efficient,

maintenance friendly,

labour and time saving

machinery that offers

consistent quality of

rubber mix compound at

higher output as

compared to an open mixing

mill – making it truly your

Friend in 'Knead' for your

rubber processing plant.

RMW

Image: Internal or Batch Mixer (Left) and Dispersion Kneader (Right).

[email protected]

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