High Viscosity Kneader & Screw Discharge Kneader

High Viscosity Kneader

The kneader has fast mixing speed, high precision, no mixing blind zone, high filling coefficient, sealed operation, and convenient maintenance. It can be divided into a kneading part, base part, hydraulic system, transmission system, vacuum system, electric control system, etc. The kneader has the advantages of high vacuum, uniform mixing, and so on.

The kneader is a strong shearing action produced by a pair of Σ paddles that cooperate and rotate so that the semi-dry state or rubber-like viscous plastic material reacts quickly to obtain uniform mixing and stirring.

The kneader is mainly composed of five parts: the kneading part, the base part, the hydraulic system, the transmission system, and the electric control system. The hydraulic system uses a hydraulic station to control the large oil cylinder to complete the opening and closing functions. The hydraulic system uses a hydraulic station to control the oil cylinder to complete functions such as turning over the cylinder and opening the cover. The detailed parameters can be arbitrarily selected and requested by the user. Convenient and reliable. The transmission system is composed of a motor, reducer, and gear, and the motor is matched according to the model of the kneader.

The transmission part of the kneader is the synchronous speed of the motor. After passing through the elastic coupling to the reducer, the fast pulp is driven by the output device to make it reach the specified speed. The speed can also be adjusted by the frequency converter.

The kneader has two Σ-shaped paddles. The speed of the two paddles is different. Different speeds can be set according to different processes. The most common speed is 42/28 rpm.

The kneader can be designed as heating or non-heating according to the needs. The heat exchange methods usually include electric heating, steam heating, circulating hot oil heating, circulating water cooling, etc.

The discharge methods of the kneader include hydraulic cylinder dumping, ball valve discharge, screw extrusion, etc. The cylinder body and the paddle and material contact parts are made of SUS304 stainless steel to ensure product quality.

The structural characteristics of the kneader

1. The kneader generally adopts a through chassis for easy installation.

2. The helical gear or hard tooth surface reducer is used to make the transmission with the main engine stable, with low noise and long service life.

3. The stirring paddle and the inner wall of the mixing tank are made of SUS304 stainless steel or SUS316L stainless steel to ensure the purity of the product.

4. The shaft sealing structure is advanced and the sealing effect is good. The unique design of the balance structure of the vacuum box ensures that no black material will be ground out.

5. Integrated electrical control (main engine operation, hydraulic cylinder turning, hydraulic cover opening, and constant temperature control), temperature control, and temperature display, which is convenient for operation and process control.

Type of kneader impeller

1. The fishtail-type impeller is suitable for the operation of the kneader for cellulose materials.

2. The Z-type stirring paddle is also called the simple stirring paddle. It has a simple shape and is used to disperse and mix the pigment in the resin under the condition of high viscosity.

3. The cutting-type stirring paddle is a strong stirring paddle, which is suitable for the kneading operation of ultra-high viscosity substances under the condition of high power and heavy load. When cutting-type stirring paddles are used, most of them adopt a tangential arrangement of two paddles.

Applicable materials: rubber, iron oxide, magnetic recording materials, etc.

4. The Σ-type stirring paddle is a general type. It is suitable for the kneading operation of external substances that must have a large movement in the kneader and the tank. It is mainly used for the arrangement of the two paddles overlapping, especially for the extrusion dehydration operation. In some cases, it is suitable to use a Σ-type stirring impeller.

Applicable materials: chewing gum, chocolate, glass glue, sealant, hot melt glue, butyl glue, manhole cover, carbon material, etc.

Kneader performance

The mechanical packing of the kneader has reliable sealing, no foreign matter pollution, reliable stirring paddle shaft seal, no air leakage in a vacuum, wear resistance, automatic oil lubrication, no oil leakage, forced heating and cooling under pressure, large heat exchange area, high heat transfer coefficient, No time delay, no inertia, no steam leakage, no scalding, oil steam heating, efficient and rapid cooling, kneading at room temperature, controllable temperature rise, no abnormal noise, no noise, maintenance-free, no overhaul, low motor temperature, no fasteners Loosening,the kneading cylinder can be opened, remove and take out the kneading paddle screw cleaning, ATEX, explosion-proof, FDA, GMP, dumping and dumping of the cylinder, discharge of the cylinder, discharge of the ball valve, screw extrusion, dual-purpose of turning over and down, kneading cylinder The wall is hardened and wear-resistant, hardened and wear-resistant non-stick kneading paddle-fin rotor, the screw should be wear-resistant, hollow heating and cooling kneading paddle-wing rotor, hollow heating and cooling extrusion screw, the coupling is permanently on the center line, no deformation ,shockproof.

The mechanical packing of the kneader has reliable sealing, no foreign matter pollution, reliable stirring paddle shaft seal, no air leakage in a vacuum, wear resistance, automatic oil lubrication, no oil leakage, forced heating and cooling under pressure, large heat exchange area, high heat transfer coefficient, No time delay, no inertia, no steam leakage, no scalding, oil steam heating, efficient and rapid cooling, kneading at room temperature, controllable temperature rise, no abnormal noise, no noise, maintenance-free, no overhaul, low motor temperature, no fasteners Loosening,

Kneading effect

Shearing, mixing, kneading, crushing, stirring, vulcanization, re-polymerization, even mixing, strong pressure, tension, shearing force, no dead angle, three-dimensional radiation mixing action, refining to improve powder properties, maintaining powder particle size, strong shearing The shear force acts on the rheology of the powder adhesive to make the mixture have certain compatibility and fluidity. Macroscopic homogeneity, and microscopic homogeneity, improve mixing uniformity, each powder is fully coated with adhesive, without destroying the microstructure molecular chain of the material.

Kneading material

High viscosity, high consistency, high specific gravity, high elastic plastic material.

Kneader structure

Double kneading paddle-fin rotor, extrusion screw, saddle W-shaped kneading cylinder box, box cover, end plate, seal, stirring shaft, shaft head, bearing, motor, gearbox, reducer.

Kneader sealing method

Mechanical seals, dynamic and static, packing, packing.

Suitable industry

Food: chewing gum, gum base, xylitol, sandwich, powder, liquid, two-color, multi-color chewing gum, bubble gum, sheet, almond nut shape, dragee, functional chewing gum for medicine, nicotine chewing gum, chewing gum base, food gum Base, calcium carbonate, talc, gummosis, gummies, styrene-butadiene rubber, gelatin, paraffin, esters, emulsifiers, gum arabic solution, glycerin, massecuite, flavors and fragrances vanilla aromatherapy, health care products, sports and outdoor high energy Food, candy, chocolate, FDA, food grade 316L all stainless steel, GMP.

Screw Discharge Kneader

The structure of the kneader

The screw kneader can be made into four types: ordinary type, pressure type, vacuum type, and high-temperature type. According to the material, it can be divided into carbon steel kneader, stainless steel kneader, and special material kneader. According to the place of origin and quality, it can be subdivided into the kneader machine. The temperature adjustment method adopts jacket, steam, heat transfer oil heating, water cooling, and other methods, and adopts hydraulic cylinder turning and covering the opening. The discharge methods include hydraulic pressure, cylinder dumping, ball valve discharge, screw extrusion, hydraulic flap discharge, etc. The cylinder body and the part of the paddle in contact with the material are made of stainless steel, alloy steel, manganese steel, and other materials to ensure product quality.

Working principle of screw discharge kneader

When working, the motor is driven by the reducer to the driving paddle, the driven paddle is driven by the gear, and the propeller of the stirring paddle drives the material to accumulate both in the axial direction and in the radial direction; it is used for high-speed accumulation and low-speed accumulation; It not only performs extrusion movement, but also performs separation movement, so that the materials are fully kneaded, kneaded, blended and mixed evenly, and the physical and chemical reactions of the materials are accelerated.

Stirring paddle for screw kneader

1. The fishtail-type impeller is suitable for the kneading operation of cellulose materials.

2. The Z-type stirring paddle is also called the simple stirring paddle. It has a simple shape and is used to disperse and mix the pigment in the resin under the condition of high viscosity.

3. The cutting type stirring paddle is the toughest stirring paddle, which is suitable for the kneading operation of ultra-high viscosity materials under the condition of high power and heavy load. When cutting-type stirring paddles are used, most of them adopt a tangential arrangement of two paddles. Applicable materials: rubber, iron oxide, magnetic recording materials, etc.

4. The Σ-type stirring paddle is the most general type. It is suitable for the kneading operation of external substances that must have a large movement in the kneading and tank. It is mainly used for the arrangement of the two paddles overlapping, especially for the extrusion dehydration operation. In some cases, Z is suitable for using Σ-type stirring paddles.

How to Improve the Efficiency of Screw Kneader

1. The characteristics of the material (particle size, adhesion, shape, density, fluidity, water content, surface roughness, agglomeration tendency, etc.)

a. When the particles with uniform size are kneaded, the dense one tends to the bottom of the device.

b. When the density is similar, the bottom of the tendon is small and nearly spherical.

c. The higher the viscosity and the higher the temperature, the easier it is to agglomerate or agglomerate, and it is not easy to disperse evenly.

2. The discharge method of the kneading equipment:

a. Hydraulic turning cylinder discharge

b. Bottom discharge ball valve

c. Screw extrusion material

3. The inner surface roughness of the kneader (mirror polishing, fine polishing, rough polishing)

4. The amount of material in the container:

a. Too much, less kneading space;

b. Too little, low productivity, generally 30% – 50% is appropriate.

5. The speed of the paddle of the kneader: the speed of the paddle is different for the kneader of different specifications.