Application example:
Rubber
compounding
inline masterbatches
& blends
Problem:
I need a true inline compounding system to produce and let-down rubber masterbatches of various compounds.
Solution:
Developed by a team with decades of experience in rubber compounding and extrusion design, a combination of Maelstrom's UML and DCL inline machines can efficiently disperse and blend all of the ingredients for a wide range of rubber masterbatches and compounds. Maelstrom can integrate these machines into a complete compounding system with dosing feeders, instrumentation, drives and controls for a complete inline compounding solution.
Application example:
Rubber
compounding
inline masterbatches
& blends
Problem:
I need a true inline compounding system to produce and let-down rubber masterbatches of various compounds.
Solution:
Developed by a team with decades of experience in rubber compounding and extrusion design, a combination of Maelstrom's UML and DCL inline machines can efficiently disperse and blend all of the ingredients for a wide range of rubber masterbatches and compounds. Maelstrom can integrate these machines into a complete compounding system with dosing feeders, instrumentation, drives and controls for a complete inline compounding solution.
Internal mixers such as the Banbury® and the Intermix® have long been the standard solution for rubber masterbatch preparation and compounding in most applications. However, they both have the inherent drawbacks of batch mixers with large internal volumes and relatively small machine surface areas in contact with the product. These features limit the efficiency of the machines and make temperature control difficult, often requiring multiple mix cycles with cooling periods in between.
Is it possible to masterbatch and compound in a true inline process system with high efficiency and good temperature control?
A combination of UML inline ultra mixer and DCL inline blending mixer offers compounders a flexible and efficient way of producing masterbatch and compounds inline. The addition of a high-accuracy dosing system for ingredients and good temperature control ensures consistent quality across the system and an efficient mixing process without the need for multiple passes.
The UML provides exceptional levels of extensional stressing and radial shear for excellent dispersion of powdered ingredients whilst the DCL adds inter-cavity transfer action for low-stress blending, including a degree of back-mixing. The use of these two machines in series provides effective process control in a small-footprint package.
A key difficulty experienced with many inline compounding systems is the dosing and distribution of trace quantities of ingredients in the mix. In many applications, Maelstrom's high accuracy dosing solution combined with controlled back-mixing in the process eliminates this problem to achieve consistent, high quality results.
Robust, reliable and easy to maintain, a UML/DCL system also has a relatively small internal volume, meaning that product changeovers and cleaning cycles can be quick, with minimal wastage.
Want to know more?
Contact us today to discuss your application or to book a free demo or trial.
Banbury® and Intermix® are registered trademarks of Farrel Corporation, USA.