Rubber & Tyre Machinery World - Collectors Edition - Dec 2015

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

As 2015 draws to a close, reflecting on your progress
is a sure way to move ahead. Because, though you
cannot change your past, by learning from the ‘misses’
and building confidence from your ‘hits’, you can
‘plan’ for greater success in 2016.
2015 has been an exciting year for RUBBER
MACHINERY WORLD. A passion that started out on
Valentine’s Day is now a well regarded Knowledge
Portal on Rubber & Tyre Machinery touching 40k
hits with a fast growing base of readers across 5
continents.
My sincere thanks to you for your encouragement
and feedback on our efforts to broaden the reach of
information through various themes including
‘Know A Leader - In 10 Questions’ and forging unique
partnerships in expos and shows. This in turn helps
us reach out to a larger brotherhood of equipment
buyers in Rubber & Tyre Industry and help them
make informed-purchase decisions.
In this issue, we reciprocate your love, appreciation
and time. We compiled the 3 most-read topics on our
portal into a single ‘collector’s edition’ that I hope
will find space in your digital library - either as
favorite bookmarks or valuable PDF downloads.
As always, I welcome your feedback on
rubbermachineryworld@gmail.com.
Happy Holidays, Merry Christmas and A Prosperous
New Year. May all your dreams turn into reality and
all your efforts into great achievements in 2016.
Best Regards
Prasanth Warrier
| Editor’s Note |
Happy New Year 2016
In this issue, we
reciprocate your
love, affection and
time by creating a
single ‘collector’s
edition’ of the top
sought topics in ‘15.
3
rubbermachineri
rubbermachineryworld
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Rubber & Tyre Machinery World DEC 2015|
Cover Page Wooden Sign Image Source: Gallery Yopriceville

4
| BEST OF 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)

| BEST OF 2015 |
1) Theoretical Equation
The thumb rule is the theoretical equation
W= NV x SG x FF, where
W - Batch Wt [kg];
NV - Net Mixer Volume [dm³];
SG - Specific Gravity (density) of the mixed
batch [kg/dm³]; and
FF= Fill Factor.
Generally, most mixer manufacturers share
this calculation with you. But remember,
what they give you is only a theoretical
number. This is only a starting or reference
point and you need to arrive at your own
mixing batch weight for your compound
recipes, following some of the other tips
stated below.
2) Net Mixer Volume (NV)
Since Internal mixer has a fixed volume
mixing chamber, knowledge of the net
volume (in liters) is required. This can be
obtained from the manufacturer directly
or in some cases from their literature for
their various models.
When the mixer is used regularly (or if you
have procured a used-mixer) the effective
volume increases due to wear on the rotors
and mixing chamber. If not compensated
for this inside wear, your batch volume
will be effectively too small leading to
insufficient ram on the compound, poor
dispersion and longer mixing times.
Annual measurements of chamber are
recommended to update your batch
weight correctly.
Excessively worn out mixers will have to be
rebuilt or reconditioned (Read our posts on
mixer rebuilding – Top 25 Things You Should
Know to Discuss with Mixer Rebuilder and 17
Essential Questions to Select the Right
Rebuilder for your Internal Mixer)
3) Guesstimate the Fill Factor (FF)
If you have a Tangential Mixer (aka Banbury)
then your FF can range between 0.70 - 0.85.
And for a Intermeshing Mixer (aka Intermix),
your FF can range between 0.62 and 0.70.
Knowledge of the fill factor is necessary
because an under-filled mixing chamber
results in the ram bottoming out too soon.
This reduces the pressure on the rubber stock
and increases the mixing time. An over-filled
chamber leads to unmixed ingredients
staying in the mixer throat. This creates a
mess under the mixer when the batch is
dumped.
For example, NR-rich compounds in an
intermeshing mixer has a fill factor of around
0.65 while for the same compound in a
two-wing tangential mixer, it is about 0.75.
This compound will have an increased FF of
about 0.78 for a tangential mixer with
our-wing rotors. Each polymer also has its
ideal fill factor and that varies again with
Mooney viscosity and filler system.
For example, NR-rich compounds
in an intermeshing mixer has a
fill factor of around 0.65 while for
the same compound in a two-wing
tangential mixer, it is about 0.75.
6

| BEST OF 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

| BEST OF 2015 |
5) Know your Internal Mixer
Knowing your internal mixer – its
capabilities, design features like rotor
(tangential or intermeshing), ram
(pneumatic with dedicated air supply at
the plant or hydraulic), variable speed
capabilities of the motor, SCADA, PLC,
automation and control features, etc.
Rotor speeds are critical because you can
use higher speeds at the initial mix and
then reduce the rotor speed to allow the
batch to “knead” well. This will allow you
to get both your dispersion and
distribution tasks of mixing right. Hence,
when selecting a mixer explore variable
speed drives since it give you advantage in
your mixing process.
Similarly, think of ram pressure. If your
ram pressure is too high you will cause
excessive heat build up and poor flow of
ingredients across the rotor tips. In
intermeshing mixers, this will also cause
internal pressure within the mixing
chamber and might cause mixer failure.
If ram pressure is too low, then you will
not get the ingredients down into the
rotors and this will result in poor mixing.
6) Watch the Ram Action
After the above reference calculations are
done and mixing initiated; watch the ram
action during the mix. The ram should
start high, move up and down about an
inch or two and bottom out when mixing
is complete. Good mixing practice dictates
that when the ram bottoms out about 30-45
seconds before the batch is dumped, you
can be assured that the chamber is properly
filled and mixed compounds will be of high
quality.
You need to observe the position of the ram
by watching the tell-tail rod attached to the
top of the ram. Hence, this requires more of
practice and experience than theoretical
knowledge.
If you have a good mixing system with
controls and feedback features, you can
correlate the position of the ram with the
current and rise in temperature – these are
important to get an optimized batch size and
high quality of mix.
7) Optimize Your Mix Batch Size (...Do Not
Maximize)
The key to successful mixing is optimizing
your mix batch size, and not maximizing.
And good mixing is a form of art.
Most mixer users want to get the most out of
their internal mixer (quite natural!) and they
test its capabilities to the full. Finally, when
they get poor mixing, they wonder if they
have done the right investment!
If you try to take your batch size to the upper
limits of the mixer's “capacity” as specified in
The key to successful mixing is
optimizing your mix batch size,
and not maximizing. And good
mixing is a form of art.
10

| BEST OF 2015 |
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the manufacturer's manual (that is usually
a peak magical figure) and you have raw
material variations such as particle size or
bulk density changes in your fillers, this
can lead to poor mixing (dispersion and
distribution of ingredients).
The right batch size will be smaller, but
your internal mixer throughput is
increased by shorter mixing time and thus
more batches in the same period. Thus,
optimizing your batch weight will allow
you to get consistent batch quality and
repeatability that are of paramount
importance to your (or your customers')
downstream processes.
The key factors that will influence your
mixing optimization are compound
formulation, ram pressure, mix procedure,
mixing speed and rotor design.
Each mixer is different and it would be
very difficult to determine the optimized
fill factor without actually conducting
several mixing trials. Experience is a key to
good mixing.
Summarizing, when mixing rubber
compounds, different compounds require
different batch weights. These 7 tips will
help you calculate the optimized batch
weight for your compounding recipes on
an internal mixer quicker.
The key factors that will
influence your mixing
optimization are compound
formulation, ram pressure, mix
procedure, mixing speed and
rotor design.
RMW
12

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.

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| BEST OF 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

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| 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/
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Rubber Tyre Know A
LEADERIn 10 Questions
Rubber Tyre
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RUBBER Rubber
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18

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

| BEST OF 2015 |
9 Things About
Tandem
Technology
Your Boss Wants
To Know In
Rubber Mixing
Image: HF Mixing Group
20

21
| BEST OF 2015 |
Dr Julius Peter, then Chief Technical Officer
at Continental AG patented his idea of
Tandem Mixing Technology in 1989. His
colleague, G. Weckerle, manager at
Continental Technical Rubber promoted
this technology at his factory in Northeim,
Germany on K2A, K4, K5 and K7 type of
mixers.
Francis Shaw Co had sole world rights
for supply of the intermeshing type
tandem mixers.
Today, HF Mixing Group (Harburg-
Freudenberger Maschinenbau GmbH)
are owners of tandem mixing technology
by virtue of their acquisitions in the
rubber machinery world.
Here are 9 key things about tandem
technology in rubber mixing you should
know to impress your boss.
1. Tandem technology separates the two
main tasks in your rubber mixing process
viz. dispersion and distribution.
Dispersion means breaking down of your
solid materials such as the fillers.
Distribution involves achieving
homogeneity within your rubber mix
compound with its different chemicals
added.
The temperature profile which is
absolutely essential for inducing
chemical reactions during your rubber
mixing process can be better controlled
when these two stages are separated.
2. In Tandem technology you interconnect
two “mixers” in series, a ram type mixer
on top of aramless mixer. Each machinery
is optimised to perform one rubber mixing
task. Ram type mixer does dispersion well
while ram-less tandem mixer does the task
of distribution.
3. Your masterbatch produced in the primary
ram mixer is transferred without
intermediate storage to the ramless tandem
mixer below. Here your batch is cooled and
finals mixed.
At the same time a new masterbatch is
prepared in ram mixer above. The upper
mixer with ram is preferably (but not
necessarily) intermeshing type. As your
masterbatch mixing does not involve the
addition of curatives or accelerators and is
essentially a heating operation, the mixing
cycle may be carried out rapidly without any
need to cool your mixer before the next
mixing cycle.
4. Between the two mixers is a discharge flap
and chute which would be closed at all times
except when the lower tandem mixer
receives the masterbatch dump from above.
In Tandem technology you inter-
connect two “mixers” in series, a
ram type mixer on top of a
ramless mixer. Each machinery
is optimised to perform one
rubber mixing task.

| BEST OF 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
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24
| BEST OF 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

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| BEST OF 2015 |
3, Active Listening
Your operator should be a skilled listener.
He should actively listen to the sounds of
the mixer and its motor during a mixing
cycle; pay full attention to what his
supervisor (or you) or his colleagues on
the mixing room safety are saying, take
time to understand the points being made,
and ask relevant questions.
4. Speaking
Your operator should be able to talk to
you (or his supervisor) to convey
information effectively be it to report data
/problems/incidents as applicable in a
timely manner
5. Reading Comprehension
An operating and maintenance manual is
normally supplied together with the
mixer. This is a crucial document. Again
your compounding process may involve
specific work related instructions or SOP.
Or there could be a training manual in
some instances. Your operator should be
able to understand written sentences and
paragraphs in these documents. Hence,
reading skills is very important for a
successful operator. It is not necessary
(while it is preferred) that they read
English, because you could translate these
documents to your operator's local
language for ease of reading.
6. Troubleshooting, Judgment and
Decision Making
Your operator is the first point of contact
with your mixer in operation. Hence, he
should have the experience or knowledge
on mixers to determine/read the causes of
any operating errors when they occur, judge
the gravity of the error and also decide what
to do about it – whether to reset the mixer, or
escalate to supervisor or raise a service visit
request of the manufacturer's engineer.
7. Critical Thinking
Operating a rubber mixer requires critical
thinking skills because your operator should
use logic and reasoning to identify
alternative solutions, conclusions or
approaches to problems he faces while mixer
is in operation.
8. Quality Control Analysis
Your operator should have basic skills on
quality control with an outlook to meet your
set mix quality parameters in every batch.
This may involve need for appropriate fine
tuning like helping you fix the batch weight,
or sending the sample of specified compound
/batch in specified form to lab for testing.
9. Social Perceptiveness
Emotions could run high in the rubber
mixing room. Your operator should display
‘awareness’ of others' reactions and
understanding of why they react as they do in
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.
26

1.DISPLAYYourProductsRegularlytoBuyers.
2.COMMUNICATEYourCompetenciesDiﬀerently.
3.ATTRACTMoreBuyerstoYourBrandInformatively.
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Rubber Tyre
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| BEST OF 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
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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
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LT - Kobelco Machinery
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AMCL Machinery
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