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Updated Criterion Checklist To Select Your Two-Roll MillInside
Machinery
World
Rubber & Tyre Knowledge On-The-Go Special S...
Two-Roll Mixing Mills have been in existence since the
time mixing of rubber started for various applications.
It is still...
4
File Image: A Mill Working Inside A Factory (Source: Wiki).
Special Supplement - Rubber Machinery World | SEP 2015
| MIX...
Special Supplement - Rubber Machinery World SEP 2015|
5
MIXING MILL
A Story Of Woes To Wows!!
Mixing Mills have been in
ex...
Special Supplement - Rubber Machinery World SEP 2015|
File Image Of An Operator working on a Mixing Mill at Dunlop Factory...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
Mixing & Compounding
Operation:
When mixing on a mil...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
Explains Amardeep Singh Bharaj, “Rubber Mixing mills...
Special Supplement - Rubber Machinery World SEP 2015|
Modern mills now have peripherally
drilled rolls for better cooling ...
www.pelmar.com
Your PartnerWorld-Wide
For Rubber AndTire
Machinery
• PRE-OWNED • NEW • REFURBISHED
Are you seeking affordab...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
for granted. Any mismatch can
lead to recurring prob...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
Stock Blender:
In a discussion and exchange
of thoug...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
improves precision and
facilitate faster nip setting...
AMCL MACHINERY LIMITED
SERVICE TO THE NATION FOR FOUR DECADES
For all your enquiries please contact:
AMCL MACHINERY LIMITE...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
These passages allow a pre-
defined circulation of t...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
Automation and Integration
All your mechanical
impro...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
Explains, Ashutosh
Chincholikar, Business Head
of Sm...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
other machinery like
mixer and batch-off is easy
and...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
We often recommend our customers to
get the machines...
Special Supplement - Rubber Machinery World SEP 2015|
| MIXING MILL |
22
normal when the rebuilders
strip out the machine ...
KELACHANDRA MACHINES
(MFRS. OF RUBBER INDUSTRIAL MACHINERY)
Chingavanam - 686 531, Kottayam, Kerala. India.
Phone Off: +91...
Two-Roll Mill:
Questionnaire cum Checklist To Select Your Right Machinery
Ever been in a situation, where you
wanted to bu...
Rubber And Tyre Machinery
Now Has An Online Address
http://rubbermachineryworld.com
FREE Access On All Your Devices
- Powe...
Special Supplement - Rubber Machinery World SEP 2015|
Criterion Please Answer Descriptively if needed
Production Requireme...
27
Special Supplement - Rubber Machinery World SEP 2015|
Criterion Please Answer Descriptively if needed
Mill Speed: (RPM/...
Special Supplement - Rubber Machinery World SEP 2015|
Criterion Please Answer Descriptively if needed
Any other inputs you...
A Story
Every Has....Machinery
Every Has...Technology
And
As A , You Denitely Have...Equipment Supplier
Which One is Your...
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©2015 – ePublished by Rubber Machinery Worl...
Mixing Mill - A story of woes to wows!!
Mixing Mill - A story of woes to wows!!
Mixing Mill - A story of woes to wows!!
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Mixing Mill - A story of woes to wows!!

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Two-Roll Mixing Mills have been in existence since the time mixing of rubber started for various applications. It is still a sacred machinery for the rubber processors. This feature is a true reflection of what this popular rubber machinery has morphed

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Mixing Mill - A story of woes to wows!!

  1. 1. Updated Criterion Checklist To Select Your Two-Roll MillInside Machinery World Rubber & Tyre Knowledge On-The-Go Special Supplement http://rubbermachineryworld.com A New Generation Mill FilePictureFromWiki MIXING MILL A Story Of Wows!!Woes To
  2. 2. Two-Roll Mixing Mills have been in existence since the time mixing of rubber started for various applications. It is still a sacred machinery for the rubber processors. Hence, we had to think thrice or even more before we decided to write a feature on this machinery. The theme ‘The Story of Woes To Wows!!’, I think, is a true reflection of what this popular rubber machinery has morphed into. Modern mixing mills are rich in features, safe and automated as compared to ancestors. (This edition’s cover page sums up this contrast well!). Our first attempt at a concise Knowledge On-The-Go special supplement was a success. Thanks to each of you - esteemed readers and supportive advertisers, for reposing faith in our abilities. It’s fascinating to us, when you take your valuable time to pen us your comments and shower generous words of appreciation. The immediate result is what you see here - our team is emboldened. We redesigned the cover of our special supplement to differentiate our look, articulate our approach better and more importantly, reinforce our commitment to you. At Rubber Machinery World, we understand your information requirements and hence our efforts to share authentic information on this portal to help you source your machinery wisely is serious, I reassure you. In this edition, we have also included from our portal, an updated checklist to help you select the right mill. As always, I welcome your feedback on rubbermachineryworld@gmail.com. BestRegards Prasanth Warrier | Editor’s Note | Most Popular Rubber Machinery We redesigned the cover of our special supplement to differentiate our look, articulate our approach better and reinforce our commitment to you. 3 rubbermachineri rubbermachineryworld +Rubbermachineryworld1 grp/home?gid=8252803 rubbermachineri Special Supplement - Rubber Machinery World SEP 2015|
  3. 3. 4 File Image: A Mill Working Inside A Factory (Source: Wiki). Special Supplement - Rubber Machinery World | SEP 2015 | MIXING MILL |
  4. 4. Special Supplement - Rubber Machinery World SEP 2015| 5 MIXING MILL A Story Of Woes To Wows!! Mixing Mills have been in existence since the time mixing of rubber started for various applications. Interestingly, the world's first rubber factory was established near Paris in 1803. A Two-Roll Mill is the oldest and simplest type of rubber mixing machinery. You could use these machines for different processes such as mixing, sheeting, plasticizing and warming of the rubber. Some applications include using as Dump mills below an internal mixer for compoundi- ng and sheeting-out; Warm-up and feed mills for calendars and extruders; Re-mixing Plain compounding and Mixing. Despite its versatility, they were extremely painful to work with. Because a basic mixing mill operation is dirty and provides a poor working environment that is equally polluted. Lengthy mixing cycle Prasanth Warrier | MIXING MILL |
  5. 5. Special Supplement - Rubber Machinery World SEP 2015| File Image Of An Operator working on a Mixing Mill at Dunlop Factory leads to higher time consumed. As a supervisor, your productivity from this equipment is dependent on your operator skill. Cutting down hot rubber many times, rolling the sheets and feeding them back into the nip gap of the mill rolls is a physically demanding task for the operator. And from a quality perspective, you could have batch-to-batch variations creating undesired headache. Veteran compounders who have worked on mixing mill will closely relate their painful experiences to the above statements. Nothing could be farther than the truth as the file picture on this page clearly articulates the woes of a mixing mill operator inside a plant. 6 | MIXING MILL |
  6. 6. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | Mixing & Compounding Operation: When mixing on a mill, you place the polymer between the rolls. It is processed until the polymer forms an even belt around one of the rolls with a certain amount of excess compound on the top crevice where the rolls meet. You then add fillers, plastici- zers and other chemicals gradually to the “mixing zone” between the rolls. Some chemicals fall down into the tray below the mill rolls and your operator must then collect it and feed back into the mixing mill again. Finally, when you have inco- rporated all the non-curative ingredients, curing agents and accelerators are added. The total mixing time often is upto at least 30 minutes for a batch size of approx 100 kg. Opinion varies even today. While everyone agrees that good compounding requires good dispersion, some argue that good dispersion come only with internal mixers. While other users claim that for a particular recipe, there’s no better equipment than mixing mill. Says, Amardeep Singh Bharaj, Director (Sales) of leading rubber machinery manufacturer, Bharaj Machineries Pvt Ltd, “A rubber mixing mill is no more just a mere machine with two rolls moving and rubber going in, coming out with flaws like running on high torque and consuming high units of electricity and majorly breakdowns due to Bushes and Gears.” It is in this context that we track the modernizat- ion or technology impro- visations in mixing mills. Modernization And Technology Changes With evolving times, the manufacturers have devised ways to address 8 the shortfalls of working with mixing mills. Says, Eldad Eilam, Co-CEO of Pelmar Engineering Limited, leading world- wide suppliers of rubber and tyre machinery, “The industrial mixing mill may have not significantly changed over time from design point of view. Yet, it has introduced many mechanical improvements and electrical upgrades to meet the on-going demand coming from customer for enhanced processing, safety and automation.” It is said familiarity breeds contempt. And, hence this could be a reason why we consider two-roll mills as a low technology product and automatically assume that anybody can manufacture them. Is this true? A Mixing Operation On A Mill
  7. 7. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | Explains Amardeep Singh Bharaj, “Rubber Mixing mills today are very smart and energy-efficient machines providing highest levels of quality as required. The whole perception has changed. Rubber mixing mills, being the heart of rubber factory in terms of providing rubber to ancillary equipments like calendars/extruders /moulding presses, is taken very seriously in terms of Rubber Mixing mills today are very smart and energy-efficient machines providing highest levels of quality as required. The whole perception has changed. Amardeep Singh Bharaj Director (Sales) Bharaj Machineries Pvt. Ltd. Image: A 60" Mixing Mill With Advanced Features, Controls, and Automation from Bharaj Machineries. 9
  8. 8. Special Supplement - Rubber Machinery World SEP 2015| Modern mills now have peripherally drilled rolls for better cooling and temperature control, bearings with minimal friction, compact operator friendly design which also saves space, simple base frame for easy installation, and hydraulic nip adjustment for safety of machine parts in the event of overload | MIXING MILL | of roll ratios for better mixing quality, Rolls temperature controlling systems for high level quality controlling of compounds, improved safety features like emergency brakes /auto reversing systems for operator safety, precise button operated nip gap adjustment systems for perfect sheet thickness, variable speed drives for hard to process compounds and fully automated mixing cycles through PLC and energy graphs to analyse the power consumption which makes the user smart and competitive to know where one stands.” Philip Thomas Managing Director Kelachandra Machines 10 Adds Philip Thomas, Managing Director of Kelachandra Machines, “Modern mills now have peripherally drilled rolls for better cooling and temperature control, bearings with minimal friction, compact operator friendly design which also saves space, simple base frame for easy installation, and hydraulic nip adjustment for safety of machine parts in the event of overload”. Kelachandra Machines manufactures rubber industrial machinery. There are instances today in the industry where two-roll mills are not meeting the expectations of the customers. The fault lies on either side – end users failed to draft the technical specifications properly and manufacturers failed to understand the expectations properly. After all a two-roll mill is only a two-roll mill, isn't it? How complicated can it be? The fact that each component going into the mill needs to maintain the physical and dimensional integrity is taken
  9. 9. www.pelmar.com Your PartnerWorld-Wide For Rubber AndTire Machinery • PRE-OWNED • NEW • REFURBISHED Are you seeking affordable and durable machinery? For tire production, tire retreading, tire recycling, hoses, automotive parts, flooring and covering, conveyor belts manufacturing and other technical rubber goods. Discuss with us for your requirements of - Single Machinery - Spares - Complete Lines -Turnkey Solutions You may choose from our varied stock in of17 locations USA, Europe, Middle-East and India that includes Mixers, Mills, Calenders, Cutters and Splicers, Extruders, Curing Presses,Tire Building Machines (TBM),Testing and Finishing Equipment, Injection Molding Machines as well as Laboratory equipment. Through our in Germany, UK,8 fully owned subsidiaries USA, Italy, India, China, Spain and Turkey; we provide you with any type of rubber machinery, tire equipment and engineering services. Subscribe to our Newsletters for the latest inventory catalogue and best equipment deals. For more info, visit Or email us at silbiger@pelmar.co.il
  10. 10. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | for granted. Any mismatch can lead to recurring problems resulting in downtime and causing loss of production. Informs Eldad Eilam, “In terms of processing, new drive technologies, coupled with peripherally drilled rolls are used to enable processing of a broader range of elastomeric compounds by better control of the temperature and ability to make different compound characteristic by easily changing the friction.” Let's examine a few developments these leaders are speaking of. Drives The new mills that are manufactured today adopt compact direct drive where the gearbox output shaft is coupled directly to the roll. Bull gear-pinion that consumed more power, made noise and vibration has become obsolete. There are also uni-drives where two output shafts from the same gear-box drive the two rolls. The external connecting gears are absent here making the mills appear more aesthetic and compact. Then, there are independently driven rolls where each roll is connected to an individual gearbox taking power from individual motors. The advantage is that variable friction ratio can be obtained for different recipes. A hydraulic drive is another upgrade that saves power though comes with higher initial capital investment. 12 Image: Different Configurations of Independent Drive
  11. 11. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | Stock Blender: In a discussion and exchange of thoughts on this subject recently on LinkedIn platform, veteran compounders have vouched on the “immense value” a stock blender provides to a mixing mill. Not surprising, as Eldad Eilam adds “Use of a stock blender reduces dependence on operator skills; provide better and consistent productivity to achieve the desired batch-to- batch uniformity”. A main disadvantage in mixing on a two-roll mill is that the process is dependent on your operator skill. A Stock blender enhances efficiency and productivity through reduced operator fatigue because this accessory eliminates the demanding task of cutting down hot rubber many times, rolling the sheets and feeding them back into the nip gap of the mill rolls. The operator also benefits from a safe work environment. The Stock Blender is an add- on accessory mounted on top of an open two-roll mill. 13 It aids in rubber blending by pulling the mix compound from the front roll of the mill and guiding it to the nip gap between the two mill rolls. A stock blender helps in homogeneous mixing and repeatability of the mixing operations. They are also used on pre-warming mills before feeding the rubber sheet to a Calender. Nip-gap Adjustment: A motorized / hydraulically actuated nip-gap adjustment Image: CE Certified 6"x13" Lab Mill with Variable Friction Ratio, VSD, Digital Nip-Gap display and Temperature Controlling Mechanism (By Bharaj Machineries) Image: 84" Mixing Mill With Stock Blender from Kelachandra Machines.
  12. 12. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | improves precision and facilitate faster nip setting for multiple recipes. This can further be automated to have 'preset nip gaps 'obtained at the press of a button on the operator panel. Nip Gap can be controlled / measured in electronic devices. Informs Sugundhan Nagendhran, Solutions Head of Base Automation Technologies Private Ltd, “We can monitor the nip gap with suitable sensor installed in the machine.” Stock Guides The movement of stock guides can be made pneumatically or hydraulically actuated for faster movement and precision. The shape of the stock guides in such uses may be modified to make the rubber flow always to the centre of the rolls so that the compound does not seep sideways prolonging the mixing process further. Rolls Roll selection for a mixing mill is of decisive importance for the quality of many high-tech products manufactured by the rubber industry. Generally, these rolls are made of Chilled Cast Iron (CI) through a process of vertical casting. Chilled CI has greater resistance to deflection and uniform heat transfer characteristics. Depending on the presence or absence of alloy, the hardness of the outer working (chill) zone could be in the range of 460-650 HV with a thickness 12-20 mm. As these rolls operate at high speeds, precise concentricity with proper balancing of rolls is a pre- requisite for efficient utilization of material and energy. The surface quality of the rolls is crucial for the products to be produced. The smoother and more precise the rolls, better the product. Viscous deformation of the rubber compounds occurs between the rolls of mills during mixing and mastication. This generates heat that needs to be removed through effective cooling. Hence, water circulation passages for cooling are an essential feature of the roll design in rubber mills. 14 We can monitor the nip gap with sensor installed in the machine. Sugundhan Nagendhran Solutions Head Base Automation Technologies Pvt Ltd A Lab Mill From Pelmar
  13. 13. AMCL MACHINERY LIMITED SERVICE TO THE NATION FOR FOUR DECADES For all your enquiries please contact: AMCL MACHINERY LIMITED Works: Plot No.A1/1, MIDC, Butirobi-441122, Nagpur Mumbai office: 202, Ackruti Centre Point, MIDC Central Road, Andheri (East), Mumbai-400 093. Contact person: Mr. S.H. Mehta Mobile No. +91-9004697430. Email: Website: www.amcl.inshmehta@amcl.in • Rubber Mixer – 76" liter and 270 liter. • Mixing Mills – 16", 22", 26" and special sizes • Hot feed extruders – 6" and 8" • Rubber Calenders – 2/3 rolls. • Bias Tyre Building machine – RB1/RB3 • Automatic LCV Tyre Building Machine – RB1619 • Automatic Truck Tyre Building Machine-RB2022 • Mechanical Tyre Curing Presses – Scooter to Truck size • Bladder Curing Presses • Tube Splicers Product Range
  14. 14. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | These passages allow a pre- defined circulation of the cooling agent (mainly water) and ensure that the temperature can be kept within a prescribed tolerance over the entire face length of the rolls. Two designs are normally available – centrally cored rolls and peripherally drilled rolls. Peripherally drilled rolls are possible for diameter greater than 150mm (or 6 inches). The efficiency of heat transfer is relatively higher in the case of peripherally drilled rolls than in centrally cored rolls due to close proximity of the water channels to the roll surface. In peripherally drilled rolls, the passages for heat exchange are provided approximately 25mm under the roll surface and can vary nominally between manufacturers. The manufacturing processes and costs involved in producing a peripherally drilled rolls is relatively high, hence they are priced higher than cored rolls. Your choice of peripherally drilled or cored rolls depends on the quality of rubber processing required in mixing mills and the marketability of your rubber products for a price 16 The efficiency of heat transfer is relatively higher in the case of peripherally drilled rolls than in centrally cored rolls. that profitably covers your investment. Safety Various safety devices have also been improved and implemented in new mills with special attention to operator protection in mind. Sugundhan Nagendhran, cites “Whenever the emergency switch is pressed, the mill will rotate in the reverse direction (half circle) to avoid hazards of crushing the hand.” Image: Mixing Mill Rolls (Courtesy: Web)
  15. 15. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | Automation and Integration All your mechanical improvements and add-ons will benefit you best when they are automated, integrated and safe. Depending on your requirement a high level of customization is possible. Amardeep Singh Bharaj, says “Automated PLC features helps to analyse mixing cycles and productions time and this makes the machine self sufficient and not labour intensive.” While Sugundhan Nagendhran adds “Normally, in the mixing mill the sheeting time of the compound is left to the operator; excess sheeting of the compound will lead to compound scorch; while less sheeting will lead to improper mixing. To avoid this, the sheeting mixing time can be monitored as per the recipe sequence and once the sheeting time is reached the system will raise the alarm to stop and guide the operator to take the compound.” Today, there is integration possible between the Master Batch (MB) sheet addition and Finals chemical addition into the mixing mill. Explains Sugundhan further, “This means adding the Final Batch (FB) chemicals at the right time and right step is very crucial in the mixing. The FB mixing system is integrated such a way that, the system will monitor the sheeting time and record the KW consumed and it will indicate the correct step to add the FB chemical to the mill. To ensure the 100% addition of chemical, the event of taking the chemical bag from the weighing scale is recorded and a photo- sensor will be deployed above the mill to ensure the operator have dropped the chemical at the right step and time.” When you are considering a mixing mill in a mixing room, there are major developments. Image: Mixing Mill With Hydraulic Drive at PTE, Germany Automated PLC features helps to analyse mixing cycles and productions time and this makes the machine self sufficient and not labour intensive. 17
  16. 16. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | Explains, Ashutosh Chincholikar, Business Head of Smart Controls India Ltd, “Mixing Mill Automation today has gone a sea change as compared to what was available few years back. Earlier, recipe-based weighing and mixing was considered something ultimate. But now we talk of a Mixing Room Automation. This means it has moved to a fully integrated system that integrates the Carbon Handling System, Mixer upstream, Mixer, Mills and the Batch off. Not only that, we also have the labs integrated in this solution as well. Further, we have Advanced Process Control giving greater efficiency and better batch to-batch uniformity in spite of the varying properties of the Raw Material.” This has helped the users in terms of a more efficient and integrated system that can be completely managed from one room. Ashutosh Chincholikar probably knows the best on automation and integration, because Smart Controls India Ltd is pure integrators and their solutions are based on state of the art products from Siemens. He further adds, “We have an ability to integrate almost any kind of control system with our Mixing Line Controls that is based on Siemens platform. The biggest advantage we offer is that we are not machinery suppliers. Yet we 18 understand the Mixing Machinery very well, be it Mixers or Upstream or Mills or batch off. We possess good skills on IT integration as well. So the Mixing solution can be connected to the business platforms like SAP or Oracle.” Mixing mill integration with Mixing Mill Automation today has gone a sea change as compared to what was available few years back. Earlier, recipe- based weighing and mixing was considered something ultimate. But now we talk of a Mixing Room Automation. Ashutosh Chincholikar Business Head Smart Controls India Ltd.
  17. 17. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | other machinery like mixer and batch-off is easy and affordable. However there are challenges. Says, Ashutosh Chincholikar, “Lot of decisions at the user end need to be taken correctly. But in general, there are two options available with the user. First option is to engage one single company that takes the total responsibility of supply of all machinery and controls related to Mixing. This includes machinery like Mixer, Upstream, Drives & Motor, Mills and Batch off. This option relieves the user to a very large extent and the responsibility of integration of all the Automation systems lies with this turnkey supplier. Obviously the cost goes high with such option but if we talk of the paybacks, then it's a good option to choose. Second option is to choose an integrator, who also works like a consultant giving detailed configuration of the control systems each machinery supplier should consider. The integrator then supplies the Master Control System that integrates Mixer Controls, Upstream Controls, Mill Controls, Batch off Controls and Drives. This integrator should be a Control System supplier with a very good knowledge of Rubber Mixing Process.” Speaking broadly, second option is more popular and a smart option for you to consider. Should You buy New, Pre-Owned Mixing Mill or Rebuild a Mill? Mixing Mills are critical machinery in any rubber factory. You can have a variety of Moulding machines / Extruders and other ancillary equipments but rubber mixing mills are definitely a prime source 20 or providing semi-finished rubber in technical rubber goods industry. A mixing mill is generally designed for long life. Thus, it is normal when you will choose to upgrade your existing old mill or you observe a substantial demand for Used or Pre-Owned Mixing Mills. How do you decide? Emphasizes Amardeep Singh Bharaj, “We encourage our buyers to invest and buy any capital safety system equipment keeping in mind key factors like Electricity cost, Labour cost and maintenance cost. The machines offered today by Bharaj Machineries are Uni-drive type and only with high quality Anti-Friction roller-bearings Image: 42" Compact Mixing Mill from Pelmar Engineering
  18. 18. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | We often recommend our customers to get the machines fully reconditioned with the most up-to-dated controls and equipped with advance features in order to enjoy additional lifetime assurance of reliability and ensuring its long operational life. which help one save up to 20% power compared to old machines. Lubrication systems are automatic so you don't need skilled labour to maintain and keep an eye on them. Automated PLC features helps to analyse mixing cycles and productions time and this makes the machine self sufficient and not labour intensive. Having the said features will help any buyer get the best ROI in terms of power saved, practically Zero Break-down/ Production losses and Consistent quality output.” Eldad Eilam has a differentiated view and says, “The answer lies on the customer preferences and constraints in terms of budget and delivery time, which may vary subject to scope of the work. We often recommend our customers to get the machines fully reconditioned with the most up-to-dated controls and equipped with advance features in order to enjoy additional lifetime assurance of reliability and ensuring its long operational life.” Philip Thomas articulates, “We usually recommend a mix of reconditioning and new components / upgradation. However, this depends upon the customer's budget and what parts are actually available along with the machine to be reconditioned and what parts are missing. We are working on the possibilities of converting old cored rolls to peripherally drilled and bush bearings to antifriction roller bearings to improve on cooling, power consumption and efficiency of old Mills currently in operation.” In reconditioning, it is also Eldad Eilam Co-CEO Pelmar Engineering Limited 21
  19. 19. Special Supplement - Rubber Machinery World SEP 2015| | MIXING MILL | 22 normal when the rebuilders strip out the machine and find it in satisfactory condition, they will only recommend a minor replacement of components and new painting to provide the mill with new appearance. Future of Mixing Mills: The changes in rubber compounding demands and continuous improvements in processing chemicals will direct the usage in future. While Philip Thomas opines “From the application point of view, in certain cases there is a present trend of replacing a Mill with for example a dump extruder. However, the blending quality in my opinion is better in a Mill”. Mixing mills will continue to be relevant rubber machinery in various product sub-sectors and there would be demand for further automation. Eldad Eilam says, “In the next decades, we foresee improvements meant to the safety and automation aspects of the mill. The level of use will probably be increased and we anticipate technological progress in drive solutions related to the continuous need for improved performance and savings in energy and manpower.” Amardeep Singh Bharaj also views it similarly, “Mixing mills will need to have Variable Friction Ratios, so customers can easily process different rubbers in one machine with easy change in Friction ratios through push of a button. Peripherally Drilled rolls will also be in huge demand as temperatures of rolls need to be controlled keeping in mind the nature of different compounds to be processed on the machine. Safety regulations will be more stringent so the machines will need better safety systems as time demands.” Concluding, Two-Roll Rubber Mixing Mills are available with different attachments and equipment as per the kind of raw material to be blended. They are no more “simple” and a proper planning of the requirements and drafting of specifications can help you acquire optimized technology for your mixing process – removing your “woes” to you exclaiming “wows!”. RMW Mixing mills will continue to be relevant rubber machinery in various product sub-sectors. Image: A Rebuilt Mixing Mill
  20. 20. KELACHANDRA MACHINES (MFRS. OF RUBBER INDUSTRIAL MACHINERY) Chingavanam - 686 531, Kottayam, Kerala. India. Phone Off: +91- 481-2430325. Fax: +91- 481-2430596 e-mail: km1912@gmail.com
  21. 21. Two-Roll Mill: Questionnaire cum Checklist To Select Your Right Machinery Ever been in a situation, where you wanted to buy a two-roll rubber mixing mill but did not know the crucial questions to ask the supplier? Or terrified with the different formats of techno-commercial offer from various suppliers? Or flummoxed by what basic features really are required to meet your mixing operation? Or even more confused to decide on the different features offered on the mil? Yes!! Well, then you need a ready-reference- sheet of selection criteria to consult with the mixing mill supplier and have an intelligent discussion with your machinery salesman. Some criterion on this check list are optional while most are crucial to aid you decide well. After the baseline requirem- ents of your two-roll mixing mill are frozen, insist your potential suppliers to give you a quote focused on these needs. Of course, there are developments in two- roll mill. If your supplier offers additional features, treat them as options or extras to your core requirement. Subsequently, you can compare on various brand factors – including workmanship quality, supplier | SELECTION CRITERION FOR TWO-ROLL MILL | Buying lowest priced mill without focussing on the features you need for your rubber mixing operation will lead you to post-purchase discontent. reliability, product aesthetics & durability, after-sales service and spares support to your market, price and discounts, etc to decide the most suitable supplier. Buying a lowest priced mill without focussing on the features you need for your rubber mixing operation will lead you to post-purchase discontent. Adopt this Two-Roll Mill Selection Questionnaire and avoid buyer's remorse. Image of a Mixing Mill With Stock Blender 24 Special Supplement - Rubber Machinery World SEP 2015|
  22. 22. Rubber And Tyre Machinery Now Has An Online Address http://rubbermachineryworld.com FREE Access On All Your Devices - Power Your Business Forward With Authentic Information On - Equipment & Allied Machinery - Technology - Equipment Suppliers - Read, Absorb & Implement Ideas From - Insightful Interviews Of Leaders - Informative Articles - Special e-Editions & e-Books - Short Updates Curated from the World Of Machinery Every Thursday In Your Inbox - Resourceful Downloads For Day-to-Day Use - Plan For Your Conferences & Expo from event dates - Book Store with Best Rubber Books For Your Quick Buy - Key Documents/Directories to take Powerful Business Decisions Available For Purchase. - Left-Oriented Clean Layout for your easy reading. - Follow Us on Twitter, Google+, LinkedIn & Pinterest. http://rubbermachineryworld.com AUTHENTIC INFORMATION TO SOURCE MACHINERY WISELY Attention: Equipment Buyers & Users JOIN OUR READERS FROM 68+ COUNTRIES SUBSCRIBE TODAY FOR FREE & BENEFIT
  23. 23. Special Supplement - Rubber Machinery World SEP 2015| Criterion Please Answer Descriptively if needed Production Requirement: ___________________ Tons/Hour; ___________________ of 8 hour Shifts/Day What is your expectation from this Mill? (Please tick appropriate boxes)  Warming/Pre-heating (before feeding into next stage)  Mixing (for thorough blending of compound)  Dump Mill (below mixer/kneader)  Sheeting out  Refiner Mill  Cracker Mill (with corrugated rolls for breaking cold rubber sheet)  Others If Others, please specify: Mill Size (Roll Diameter x Length) ___________________ MM x ___________________ MM Type of Mill: (Please tick)  Both Rolls Plain  One Roll Corrugated  Both Rolls Corrugated Roll Type: (Please tick)  Both Rolls Centrally Cored/Bored  Only one Roll Peripherally Drilled  Both Rolls Peripherally Drilled Friction Ratio Required (Optional) Nip Gap Adjustment  Manual  Motorized  Hydraulic | SELECTION CRITERION FOR TWO-ROLL MILL | 26
  24. 24. 27 Special Supplement - Rubber Machinery World SEP 2015| Criterion Please Answer Descriptively if needed Mill Speed: (RPM/MPM) (Please fill and tick) ___________________ RPM; or Roll Surface Speed of ______________ MPM  Variable Speed (VFD) Motor required for different speed Mill Stock Guides (Please tick appropriate boxes)  Fixed  Pneumatic Movement  Motorized Movement  Hydraulic Movement Mill Gearbox / Reducer (Please tick)  Unidrive (Gearbox to have single input shaft/double output shaft)  Semi Unidrive (Connecting Gear on Mill Rolls)  Independently Driven Rolls with Variable Friction Ratio If you have any Service Factor (SF) specifications, note here or discuss with the manufacturer without fail. Accessories/Features Required : (Please tick)  Temperature Control Unit  Stock Blender  LVDT for nip gap measurement  Emergency Stop features  Others If Others, please specify: Details on any major components that are of abrasive or heat sensitive nature in your recipe (Optional) | SELECTION CRITERION FOR TWO-ROLL MILL |
  25. 25. Special Supplement - Rubber Machinery World SEP 2015| Criterion Please Answer Descriptively if needed Any other inputs you wish to share on your need. (For example, brands of electrical, hydraulic components, or lubrication requirements, etc - Optional) This article was first published on Rubber Machinery World Information Portal. You can access the link to original on: http://rubbermachineryworld.com/2015/02/20/two-roll-mixing-mill-criterion-check-list-for- buyers/ RMW Did You Know? Global research from the CMO Council reveals that 88 percent of business buyers believe online content plays a moderate to major role in supplier selection. | SELECTION CRITERION FOR TWO-ROLL MILL | 2. PRODUCT ZONE Edition Promoting One Product At A Time...Differently. 3. KNOW YOUR SUPPLIER Edition Advertising One Supplier At A Time...Differently 1. TECHNOLOGY & INNOVATION Edition Communicating One Technology At A Time...Differently RubberMachineryWorld Technology & Innovation MM RUBBER Rubbe r Machinery World Technology&Innovation ProductZoneRubberMachineryWorld ProductZone MM RUBBER Rubbe r Machinery World Know Your Supplier Rubber Machinery Accessories Pracsol Chemicals Machinery MM RUBBER Rubber Machinery World Special Edition In Conversation With Harish Nene, Chief Executive Ofcer ‘Practical Solutions’ on Equipment Simplified KnowYourSupplierRubberMachineryWorld RubberMachineryWorld Top 25 Things You Should Know to Discuss with Mixer Rebuilder HOW TO SELECT YOUR RUBBER TYRE MACHINERY? Jacob Peled Pelmar Engineering Andreas Limper HF Mixing Group Peter Haan Siemens AG Arul Shanmugavelu LT - Kobelco Machinery Harish Nene Pracsol Rakesh Sharma AMCL Machinery Insightful Advices From 6 CEOs In si de MM RUBBER Rubber Machinery World Special Supplement PLUS BUYERs SPECIAL On One Key Topic At A Time ...............Differently MM RUBBER Rubber Machinery World PromoteYourBrandOn REACH 3X...DIFFERENTLY Only on http://rubbermachineryworld.com Thru Buyer-Oriented Editions To Market Your Equipment Solutions Differently. 28
  26. 26. A Story Every Has....Machinery Every Has...Technology And As A , You Denitely Have...Equipment Supplier Which One is Your’s Today? Promote Your Brand Through Stories on Equipment, Technology, Innovation More With Buyers From Over 68 Countries Only On MM RUBBER Rubber Machinery World Equipment Marketing Redefined Contact: rubbermachineryworld@gmail.com
  27. 27. Email: rubbermachineryworld@gmail.com Website: http://rubbermachineryworld.com ©2015 – ePublished by Rubber Machinery World in Sep 2015 Content For Free eDistribution Download SELL MORE MM RUBBER Rubber Machinery World WHEN BUYERS VISIT FOR AUTHENTIC INFO ON MACHINERY Promote Your Brand On

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