Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.
Upcoming SlideShare
×

Rubber & Tyre Machinery World - Collectors Edition - Dec 2015

In this concluding issue of 2015, we chose to reciprocate your appreciation and feedback in the most apt manner. So, we compiled the 3 most-read topics on our portal into a single ‘collector’s edition’ for your quick reference always.

See all

Related Audiobooks

Free with a 30 day trial from Scribd

See all
• Full Name
Comment goes here.

Are you sure you want to Yes No
Your message goes here
• Be the first to comment

Rubber & Tyre Machinery World - Collectors Edition - Dec 2015

1. 1. Machinery World Rubber & Tyre Knowledge On-The-Go Special Supplement http://rubbermachineryworld.com 3 Most-Read Topics of 2015COLLECTOR’S EDITION: 4 Internal Mixer Batch Weight Calculation 20 Tandem Mixing Technology14 Single-Stage or Two-Stage Mixing? Pg. 24 | Recruit For These Top 15 Skills In Your Mixer (or Kneader) OperatorAlso Inside
3. 3. 4 | BEST OF 2015 | Rubber & Tyre Machinery World DEC 2015| Internal mixer is standard rubber machinery for volume mixing in both tire industry and non-tire rubber industry. When you use one, your most elementary requirement is to calculate the batch weight for your respective mixer model. Because when mixing rubber compounds, you should under-stand that different compounds based on the same polymer might require different batch weights. And different polymers will almost certainly require different batch weights. Here's 7 quick tips for you to fix the batch weight for your rubber mixing. 7 Quick Tips About Batch Weight Calculation For An Internal Mixer Image: Internal Mixer With Hydraulic Ram (Bainite)
5. 5. | BEST OF 2015 | Rubber & Tyre Machinery World DEC 2015| Fill factor of a mixer depends on the age of the machine, wear and tear of the rotors and chamber, the rotor type, rotor speed, rotor friction ratio, nature of elastomer, ratio of elastomers/ fillers, mixing sequence, kind of polymers, fillers and individual SG of the ingredients in your recipe, viscosity of ingredients, etc. Generally, the lower the compound viscosity, the fill factor is higher. Hence, we initially guesstimate the FF before stabilizing on the figure later on through actual trials. 4) Estimate the Specific Gravity (SG) of your Compound You can estimate the density of your compound by multiplying the quantity of each ingredient with its individual density (you can get this figure in any compounding handbook or ingredient supplier literature). Sum up your individual results and then divide this number by the total sum (usually phr). The result will give you the estimated density of the compound. (Mathematically, this is the weighted average calculation). For example, lets consider a sample recipe as shown below (I got this recipe from a web search). Calculating, the SG of this Compound mix is arrived at 1.16 (=179.3/155). Image: Kobelco Make Internal Mixers Mathematically, this is the weighted average calculation. 8
8. 8. 14 | BEST OF 2015 | Rubber Tyre Machinery World DEC 2015| Should You Do Single-Stage Mixing or Two-Stage Mixing? Image: Bosch Rexroth Have you encountered this often dilemma, “Should I do single-stage or two-stage mixing for my compound; which machinery to use?” – do not be surprised! You are not alone. Single-stage mixing is considered for productivity reasons (and cost- effectiveness). While Two-stage mixing gives a better dispersion of the finer size blacks. And interestingly, for some compounds with high levels of blacks, even three or more mixing-passes may be necessary. Rubber mixing as a subject would have been quite simpler, if we could answer this topic effortlessly. Unfortunately, it is not! Single-stage mixing in an internal mixer is a cost-effective solution but difficult for all compounds. If the compounds have high filler loadings, you may be forced to mix in two-stages due to the high amount of shear and heat generated in the mixing cycle. If you use peroxide cures or are mixing expensive FKM, then you must be even more worried of the batch temperature. Most experts feel two-stage mixing, with short time spans for each of the mixing stages, is helpful.
10. 10. | BEST OF 2015 | Rubber Tyre Machinery World DEC 2015| One school of thought advocate an open two-roll mill for second-stage mixing because the dispersion of the batch and the mastication is higher (than an internal mixer). Open mills, though slower, are safe for short scorch compounds. A traditional mixing line comprises of an internal mixer above a dump mill then one (or two) mill before the batch off cooling line. Internal mixers are high-capacity rubber compounding machinery. Hence they need to be supported by open mills with advanced features to keep pace with production. The rotors of these mixers operate at high-speed to maximise dispersion of the bulk ingredients and dump the batch at high temperatures. Curatives, blowing agents, etc are added on the open mill and final homogenization happens on the last mill before batch off. Also, adding the cure system on downstream mill eliminates the batch contamination problem from ‘leftover's’ trapped (between the rotor end plates and ends of the rotors) in the internal mixer. These open mills are recommended to have peripherally drilled rolls to take out heat of the compound before adding heat sensitive curatives. Single-stage mixing in an internal mixer is a cost-effective solution but difficult for all compounds. Image From Web 16
12. 12. | BEST OF 2015 | Open mill mixing is operator dependent and hence quality of compound varies from beginning of shift to end of shift. As compared to rubber mixing in a closed environment, the probability of ‘fly loss’ is high in open mills. Hence, an alternate school of thought propagates second-stage mixing also performed in an internal mixer. This can be at a lower speed, energy and dump-temperature configuration setting on mixer. Single-stage mixing in an internal mixer is possible, when you mix and drop the batch within 120 degree Celsius. The present range of internal mixers have advanced designs to effectively control batch temperature. With many designs and rotor geometries for faster mixing, accompanied by quicker cooling features, mixers like tandem mixers allow traditional two pass to be reduced to single pass cycle.As a side note, if you opt for single-stage mixing with internal mixer; the Intermeshing Type Mixer has the best quality and efficiency. Single-stage mixing is not always cheaper and two-stage mixing is not always better. The best way to decide is to make a cost- benefit analysis between the two processes for the different polymers that you work with. Quantify how much of your product defects are linked to poor dispersion. Analyzing them, you have your customized solution to mix effectively. Summarizing, there is no one best way for all compounds. Your mixing process has to be designed to the polymer; depends on the viscosity of the elastomers used, the quantity of filler, mixing temperature, machinery employed, time at every stage of mixing and desired physical properties for the end use product. If you get your ‘desired’ characteristics in a single-stage mixing, adopt it or wisely opt for two-stage mixing. RMW Confirms as Know More At: http://rubbermachineryworld.com/ Machinery World Rubber Tyre Know A LEADERIn 10 Questions Rubber Tyre MM RUBBER Rubber Machinery WorldKnow Your Supplier Rubber Machinery Accessories KENYA: MYANMAR:June 8-10, 2016 July 8-10, 2016 Aug 5-7, 2016 Feb 22-24, 2017SRI LANKA: VIETNAM: KNOWLEDGE PARTNER for http://rubbermachineryworld.com INFORMATIONONEQUIPMENT,TECHNOLOGY,INNOVATIONSUPPLIERS 18
13. 13. 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
14. 14. | BEST OF 2015 | Rubber Tyre Machinery World DEC 2015| 9 Things About Tandem Technology Your Boss Wants To Know In Rubber Mixing Image: HF Mixing Group 20
16. 16. | BEST OF 2015 | Rubber Tyre Machinery World DEC 2015| 5. The mixer below must be intermeshing type to enable self-feed without pressure and work without a top ram. The finals rubber mixing function is usually a shorter process than the masterbatch stage. This means that the tandem mixer has an idle time after the discharge and before receiving the next hot masterbatch. This idle period with the discharge door open allows the tandem mixer to cool. 6. The final mix compound is then dumped into a two-roll mill or a dump extruder and processed in the normal way. 7. When the two tasks of dispersion and distribution are separated, your compound weight is relatively smaller in the larger lower machine. Hence, you can operate this ramless mixer at a higher speed. This improves the quality of your mix because your compound is moved around the mixing chamber more number of times. 8. Excellent cooling water circulation to the mixers is a must in tandem mixing technology. 9. HF Mixing Group expert, Dr Harald Keuter, emphasize that a Tandem mixer improves your throughput rate by up to 25 per cent when compounding with carbon black compounds and can rise up to 100 per cent with silica compounds. Hence you can cut costs and increase output with this technology. Depending on your choice of mixing line, say for a mixing room with five tandem mixing lines and production of approx. 100,000 tonnes of rubber compound annually, he says you save up to one million euros per year. (...And that’s lot of money!!) The population of tandem mixers is higher in the tire industry while its economy of operations is tempting the non-tire rubber industry as well. The population of tandem mixers is higher in the tire industry while its economy of operations is tempting the non-tire rubber industry as well RMW SUBSCRIBE TO OUR WEEKLY NEWS DIGEST FREE http://rubbermachineryworld.com/newsletters/ 22
18. 18. 24 | BEST OF 2015 | Rubber Tyre Machinery World DEC 2015| Top 15 Skills Required For an Internal Mixer (or Kneader) Operator Rubber Mixing is a capital and energy- intensive operation. And mixing machinery are the mother equipment. This could be an Internal Mixer (Banbury or Intermix) or Rubber Dispersion Kneader depending on the size of your organization and/or products manufactured. Hence, the cost of errors or omissions is very high when compounding a batch in a mixer. You need a skilled operator. Ever pondered on the skills that make a mixer operator successful? Here is the list of top 15 skills for you to look out in your next successful batch mixer (or kneader) operator hire. 1. Control of Operations Your mixer operator should be able to adjust ram pressure, control the mixing process, set parameters and ensure its completion as per SOP (temperature or time or energy as programmed/specified). 2. Monitoring Operations The most important skill of your operator should be to have a keen eye for watching gauges, dials, or other indicators in the control panel or HMI to make sure the mixer is working properly. He has to ensure that the mixer is kept clean, safety features are functional, upstream and downstream equipment along with all accessories (like cooling water, hydraulic/pneumatic system, temperature control unit (TCU), lubrication system, etc) are ready Image: Bainite
19. 19. 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
22. 22. | BEST OF 2015 | Rubber Tyre Machinery World DEC 2015| in a particular circumstance. 10. Repairing Your mixer operator should be able to use the required tools to both repair and assist repair of mixers when needed in the most urgent manner. 11. Time Management Your operator should manage his own time and display sensitivity to the time of other co-workers involved in the mixing room. 12. Mixer Maintenance Performing routine maintenance on mixer and determining when and what kind of maintenance is needed is an important skill that your operator should posses. 13. Active Learning Your operator should display active learning skills. This is because, mixers get upgraded, automation and new controls might get introduced or new methods of mixing could be introduced all of which he might have to learn or get trained in. If you could get an operator who could communicate effectively in writing to you (or his supervisor) or to other departments, then I would say you have a great asset. 14. Writing If you could get an operator who could communicate effectively in writing to you (or his supervisor) or to other departments, then I would say you have a great asset. 15. Complex Problem Solving Your operator should develop skills to identify and solve complex problems when they occur at site and support maintenance department effectively over a period of time. This reduces the downtime of your mixer. RMW Merry X’mas and A Prosperous New Year! Wishes you and your loved ones ahttp://rubbermachineryworld.com INFORMATIONONEQUIPMENT,TECHNOLOGY,INNOVATIONSUPPLIERS Machinery World Rubber Tyre Know A LEADERIn 10 Questions Rubber Tyre MM RUBBER Rubber Machinery WorldKnow Your Supplier Rubber Machinery Accessories 28
23. 23. Email: rubbermachineryworld@gmail.com ©2015 – ePublished by Rubber Machinery World in DEC 2015 Content For Free eDistribution Download INFORMATION ON EQUIPMENT, TECHNOLOGY, INNOVATION SUPPLIERS 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 SPECIAL DIGITAL MAGAZINES With Focus On ONE KEY THEME ...DIFFERENTLY Gives YOU In-depth Info Practical Solution www. .comracsol KELACHANDRA MACHINES ........... And More Know More On EQUIPMENT SUPPLIERS And Their SOLUTIONS For YOU

Be the first to comment

• ArpatChuybunchoo

May. 25, 2017
• khairulanasomar

Mar. 29, 2018
• PawanAggarwal21

Jan. 19, 2020

In this concluding issue of 2015, we chose to reciprocate your appreciation and feedback in the most apt manner. So, we compiled the 3 most-read topics on our portal into a single ‘collector’s edition’ for your quick reference always.

Total views

1,536

On Slideshare

0

From embeds

0

Number of embeds

3

62

Shares

0