The XK-550 Type Rubber Mixing Mill With A Production Capacity Of 100kg Per Batch,

Here's a detailed breakdown of what this system is, how it works, and its role in a rubber manufacturing plant.

Overview: The "One-Two Punch" of Rubber Mixing

This setup is a two-stage mixing process:

1. Stage 1: The 110L Kneader (Intermixer) - For intensive mixing, blending, and plastication.

2. Stage 2: The XK-550 Open Mixing Mill - For final mixing, homogenization, and sheet-down.

This is a more modern and efficient alternative to using only a large open mill for the entire mixing process, which is more labor-intensive, time-consuming, and less consistent.

1. The 110L Rubber Kneader (The Workhorse)

• Function: This is a batch-type internal mixer. It performs the initial, high-intensity work of incorporating various ingredients (polymers, fillers, oils, chemicals) into a uniform mass.

• How it Works: It consists of a sealed, jacketed chamber with two counter-rotating, intermeshing rotors. The shearing and kneading action inside the closed chamber ensures thorough dispersion of carbon black, silica, oils, and other additives.

• Key Features:

  • Capacity: 110 Liters. This volume refers to the total chamber volume. The typical "fill factor" is 0.6 to 0.75, meaning the actual batch weight of rubber compound is usually between ~65 kg and 80 kg.

  • Efficiency: It mixes much faster than an open mill for the initial stage, saving time and energy.

  • Quality: Provides superior dispersion of powders, leading to a more consistent compound.

  • Environment: Enclosed design contains dust and fumes, improving the working environment.

2. The XK-550 Open Mixing Mill (The Finisher)

• Function: This machine receives the masterbatch from the kneader for final mixing, homogenization, cooling, and forming into sheets.

• How it Works: It consists of two parallel, counter-rotating rolls. The friction between the rolls (different speeds and temperatures) generates high shear stress, which further blends the compound and adjusts its viscosity.

• Key Features:

  • Size: The "550" typically refers to the roll diameter in millimeters (550mm or ~22 inches). The roll length (e.g., 1500mm) determines the batch size capacity.

  • Capacity: Rated for 100 kg per batch, which is well-matched to the output of the 110L kneader (after accounting for the kneader's fill factor, multiple kneader batches might be combined on the mill for a single final batch).

  • Versatility: It is used for:

    • Dumping: Receiving the hot mass from the kneader.

    • Blending: Mixing different masterbatches or adding sensitive curatives (like sulfur) that cannot withstand the high heat of the kneader.

    • Sheeting: Forming the mixed compound into a continuous, uniform sheet of specific thickness for easy handling and feeding to the next process (e.g., calendering or extrusion).

    • Cooling: The large surface area of the water-cooled rolls helps bring down the compound temperature.

The Typical Workflow in a Plant

1. Weighing: All raw materials (natural/synthetic rubber, carbon black, zinc oxide, stearic acid, process oils, antioxidants, etc.) are precisely weighed according to the recipe.

2. Loading & Mastication: Rubber is loaded into the kneader first to soften it (mastication).

3. Intensive Mixing: Powders and liquids are added in a specific sequence to the kneader. The machine runs for a set time or until a target energy/temperature is reached.

4. Dumping: The mixed "masterbatch" is dumped from the kneader, often directly onto a conveyor that feeds the XK-550 mill.

5. Final Mixing on the Mill: The operator works the compound on the mill, repeatedly cutting and folding the sheet to ensure final homogenization. At this stage, curatives (sulfur, accelerators) are added.

6. Sheeting & Cooling: The final compound is passed through the mill rolls to form a smooth sheet. This sheet is then run through a cooling system (e.g., a cooling water bath or festoon cooler) to prevent premature vulcanization.

7. Storage/Feeding: The cooled sheets are stacked or cut for storage or directly fed to downstream processes like extrusion, calendering, or molding.

Advantages of This Combination

• High Productivity: The kneader handles the slow, intensive part quickly, while the mill handles the finalizing and sheeting.

• Excellent Compound Quality: Achieves good dispersion and consistency, which is critical for product performance.

• Labor Optimization: Reduces the heavy manual labor required if the entire mix were done on an open mill.

• Process Control: Allows for precise control over mixing temperature, time, and energy input.

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• Technical parameters

• model	XK-450	XK-550	XK-560
  roller diameter	450mm	550mm	560/510mm
  roller working length	1200mm	1500	1500
  front roll linear speed	24.5	27.94	27.87
  frictio ratio of roller	1:1.27	1:1.22	1:1.2
  motor	55	110	90
  Batch capacity	25-50	50-60	50-60
  machine size	5200*2380*1770	5900*2680*2080	6500*2300*2000
  machine weight	about 12000 kg	27000 kg	19500 kg

Industries and Applications

This specific setup is commonly found in plants manufacturing:

• Tire Components (tread, sidewall, inner liner)

• Automotive Rubber Parts (hoses, belts, gaskets, seals)

• Industrial Rubber Products (conveyor belt covers, rubber linings, rollers)

• Footwear (soles)

• Dense, technical rubber products requiring high-quality mixing.

In summary, the 110L Kneader + XK-550 Open Mill is a robust, industry-standard combination that provides an excellent balance of productivity, quality, and versatility for a serious rubber product manufacturing facility.

Qingdao Beishun Environmental Protection Technology Co., Ltd. is engaged in Environmental protection machinery, rubber machinery R & D and manufacturing enterprises, located in the west coast of Qingdao ---- Jiaonan city, Qingdao Economic and Technological Development Zone, adjacent to the former Bay near Qingdao Port and International Airport Jiaodong airport, excellent geographical location.

The company gathered a large number of the industry's outstanding technical and management personnel, advanced machining, heat treatment equipment and sophisticated detection equipment. With high-quality service, advanced equipment and strong technical force as the basis, through constant innovation and development, Beishun Environmental Protection Technology machinery has many customers at home and abroad to establish a stable business relationship, and gradually establish a brand in the same enterprise.

Companies adhere to the "first-class quality to gain market confidence, quality service to win customer satisfaction, continuous improvement of enterprise development seek to establish a corporate brand management excellence" business philosophy, in terms of quality, brand and work hard to achieve the strategic goals of common development.

Qingdao Beishun Environmental Protection Technology Co., Ltd. will carry forward the "realistic, innovative, rigorous and efficient" business style, good governance, integrity first, with a high sense of responsibility "in customer service, service to the community", with industry colleagues mutual benefit, for a better tomorrow.