The Compound Rubber 110L Mixing Chamber Rubber Kneader Machine Adopts Pneumatic Or Hydraulic Downward Pressure

110L Rubber Kneader Introduction:

110L rubber kneading machine usually refers to 110L pressurized internal mixer, and its advantages and disadvantages are as follows:
Advantages
Large production capacity: Compared with small kneading machines, the capacity of 110L internal mixing chamber can accommodate more rubber raw materials and compounding agents, and the amount of rubber mixing each time is large. It is suitable for medium-sized and above rubber product manufacturers, which can effectively improve production efficiency and meet certain production requirements.
Good mixing effect: Working in a closed, pressurized and temperature-controlled environment, the special design and rotational movement of the rotor subject the rubber and various compounding agents to strong shearing, stirring and friction, and can fully mix and plasticize rubber raw materials and various additives of different types and hardness, so that the material dispersion is high, ensuring the quality of the mixture is excellent, and improving the performance and quality stability of rubber products.
High degree of automation: Generally equipped with advanced electronic control systems, such as PLC devices, with complete and reliable automatic control monitoring, alarm and other functions and necessary interlocking protection functions, can accurately control parameters such as mixing temperature, time, pressure, etc., reduce the error and labor intensity of manual operation, easy and reliable operation, and also help to ensure the consistency of product quality.
Good environmental performance: Fully enclosed structure design, good sealing effect, effectively prevents dust flying and rubber leakage, which is safe and greatly improves the working environment, reduces environmental pollution and waste of raw materials, and meets environmental protection requirements.
The equipment is sturdy and durable: The mixing chamber, rotor, pressure weight and other components usually adopt a jacketed structure, which can be used to pass medium, steam, heat transfer oil, water for heating or cooling to meet various rubber mixing process requirements. The rotor peaks and end faces are surfacing wear-resistant hard alloys. The surfaces of the mixing chamber, rotor, and pressure weight that are directly in contact with the material are polished and hard chrome plated, which are bright, wear-resistant and corrosion-resistant. The machine is sturdy and durable, with a low failure rate and low maintenance cost.

Disadvantages
High equipment cost: Compared with small kneading mills or other simple rubber mixing equipment, the 110L rubber kneading mill has a complex structure and high manufacturing precision requirements. Therefore, the purchase cost of the equipment is high, and the initial investment requirements for the enterprise are large, which may bring certain economic pressure to some small enterprises or enterprises with limited funds.
High energy consumption: Since a large amount of power is required to drive the rotation of the rotor and the pressurization of the top bolt, as well as to maintain the operation of the heating or cooling system, the energy consumption during operation is relatively high, which increases the energy cost of production.
Not suitable for small-scale production: Its large capacity and design are designed to meet the production needs of a certain scale. If it is used for small-scale production, it may lead to low equipment utilization, increased cost of each rubber refining, and frequent changes in formulas and cleaning equipment will also increase the complexity and cost of operation.
Difficult to maintain: The structure is complex and contains multiple systems and components, such as electrical control systems, hydraulic systems, transmission systems, etc. Once a fault occurs, it is difficult to maintain and requires professional technicians to repair it, and the maintenance cost is relatively high.
Large installation and floor space: The volume is large, the installation requires a large space, and the requirements for the installation foundation are also high. A special site is required for installation and commissioning, which may be inconvenient for some companies with limited space.

Technical Parameters:

How to choose?

To choose a rubber kneading machine that suits your production needs, you need to consider the following aspects comprehensively:

A.Production scale

1.Output demand: Determine the required output of rubber products according to the company's production plan and market orders. If the output is large, a large-capacity kneading machine should be selected, such as 110L, 250L or even larger capacity equipment to improve production efficiency; if the output is small, such as laboratory research and development or small batch production, a small kneading machine, such as 3L, 5L, etc., can be selected.
Batch stability: For large-scale continuous production, it is necessary to select a kneading machine with stable performance and high reliability to ensure the consistency of the quality of each batch of products; for small batch and multi-variety production, you can choose equipment with higher flexibility to facilitate rapid formula change and equipment cleaning.

B.Rubber material characteristics
2.Viscosity: Different rubber materials have different viscosities, such as natural rubber has a relatively low viscosity, while butyl rubber has a higher viscosity. For rubbers with higher viscosity, it is necessary to select a kneading machine with larger torque and stronger mixing capacity to ensure that the rubber and compounding agent are fully mixed.
3.Hardness: Harder rubber requires greater shear force and pressure to achieve a good mixing effect, so a kneader with a higher rotor speed and a larger upper bolt pressure should be selected; for softer rubber, the parameter requirements of the equipment can be appropriately reduced.
4.Heat sensitivity: For heat-sensitive rubber, a kneader with precise temperature control function needs to be selected to avoid problems such as scorching or performance degradation of the rubber due to excessive temperature during mixing.

C.Process requirements
5.Mixing uniformity: If the quality and performance requirements of rubber products are high, a kneader that can achieve high mixing uniformity needs to be selected, such as equipment with special rotor design, good sealing performance and reasonable stirring speed, to ensure that the rubber is evenly mixed with various compounding agents.
Temperature control accuracy: The production process of some rubber products has strict requirements on mixing temperature, such as high-temperature vulcanized rubber needs to be mixed within a specific temperature range. At this time, a kneader equipped with a high-precision temperature control system should be selected to accurately control the temperature in the mixing chamber.
6.Automation degree: Large-scale production usually requires a high degree of automation to improve production efficiency and product quality stability. You can choose a kneading machine equipped with advanced PLC control system, automatic feeding and unloading device, etc.; for small production or laboratory research, a manual or semi-automatic controlled kneading machine may be more suitable and more flexible to operate.

D.Equipment performance and quality
7.Rotor design: Rotors of different shapes and structures have a great influence on the mixing effect of rubber. Common rotors include two-sided, four-sided, six-sided, etc. The appropriate rotor type should be selected according to the rubber material and process requirements. For example, a two-sided rotor is suitable for general mixing, while a four-sided or six-sided rotor is more suitable for high-viscosity rubber or mixing processes that require high dispersion.
Transmission system: The stability and reliability of the transmission system directly affect the operating efficiency and service life of the kneading machine. Transmission components such as high-precision gears and bearings, as well as transmission devices with good lubrication and cooling systems should be selected to ensure smooth operation and low noise of the equipment.
8.Sealing performance: Good sealing performance can not only prevent the leakage of rubber and powder, reduce raw material waste and environmental pollution, but also ensure the stability and safety of the mixing process. Kneading machines with advanced sealing technology and high-quality sealing materials should be selected, such as equipment with sealing rings made of materials that are resistant to high temperature, wear-resistant, and have a small thermal expansion coefficient.

E.Energy consumption
Power consumption: The main motor power of the kneading machine is large, and the energy consumption during operation is high. When selecting equipment, the motor power should be reasonably selected according to the production scale and process requirements to avoid excessive or too small power configuration that leads to energy waste or unstable equipment operation.
Heating and cooling methods: Different heating and cooling methods also have an impact on energy consumption. Steam heating costs are relatively low, but a stable steam supply system is required; electric heating is easy to operate, but the energy consumption is high. The appropriate heating and cooling method should be selected according to the actual situation of the enterprise to reduce energy costs.

F.Maintenance and maintenance
Replacement of wearing parts: The rotor, sealing ring, top bolt and other parts of the kneading machine are wearing parts and need to be replaced regularly. When selecting equipment, you should understand the service life and replacement difficulty of wearing parts, and choose equipment that is easy to replace and maintain to reduce maintenance costs and downtime.
Difficulty of cleaning and maintenance: Although the fully enclosed kneading machine has good sealing performance, it is relatively difficult to clean and maintain. If the formula or color needs to be changed frequently during the production process, equipment that is easy to clean and maintain should be selected, such as a kneading machine with an automatic cleaning device or easily removable parts.
G.Budget and cost
Equipment procurement cost: The prices of rubber kneading machines of different brands, models and specifications vary greatly. The equipment with high cost performance should be selected according to the company's budget and production needs. Under the premise of ensuring the performance and quality of the equipment, the procurement cost should be reduced as much as possible.
Operation cost: including energy consumption, replacement of wearing parts, maintenance and other costs. When selecting equipment, the operating cost of the equipment should be comprehensively considered, and equipment with low energy consumption, simple maintenance and long life of wearing parts should be selected to reduce long-term operating costs.

H.After-sales service
Technical support: Select equipment suppliers with professional technical teams and rich experience, who can provide timely and effective technical support during equipment installation, commissioning, training and use, to help enterprises solve problems encountered.
Accessories supply: Ensure that the equipment supplier can provide original genuine accessories in a timely manner to ensure the normal operation and maintenance quality of the equipment.
Maintenance response time: Understand the supplier's maintenance response time and after-sales service commitment, and select suppliers who can respond and solve equipment failures in a short time to reduce equipment downtime and production losses.

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.