Tech Team · Kintek Solution

Mixing rubber compounds is a precise process that requires specialized equipment and careful attention to detail. Whether you're using an open-mill or an internal mixer, each method has its own unique advantages and procedures.

5 Key Steps for Perfect Rubber Compound Mixing

Types of Mixing Equipment

• Open-Mill Mixing: This method uses a mixing mill with two rolls rotating in opposite directions at different speeds. The shearing forces created by the rolls mix the rubber with various additives.
• Internal Mixer: This involves a closed chamber with a pair of rotors rotating relative to each other. It's ideal for larger batch sizes and offers better control over the mixing process.

Steps in Open-Mill Mixing

1. Preparation: Adjust the roll distance, turn on the power and water circulation, and feed the rubber material onto the rolls.
2. Addition of Additives:
   • Add small materials and carbon black or filler sequentially.
   • Add liquid softener after the initial mixing phases.
3. Temperature Control: Monitor and adjust the temperature to ensure it drops below 110°C before adding sulfur.
4. Finalizing: Cut the rubber material to ensure even distribution of additives.

Steps in Internal Mixer Operation

1. Preparation: Calculate the mixing amount based on the chamber capacity and fill factor, and weigh the raw materials accurately.
2. Preheating: Turn on the power and heating switches, check all systems, and preheat the mixer.
3. Feeding and Mixing:
   • Load the raw rubber into the mixer.
   • Add small materials, carbon black or filler, and finally the liquid softener in sequence.
4. Monitoring: Ensure all systems are functioning correctly and monitor the mixing process for quality control.

Quality and Efficiency Considerations

• Open-Mill: Suitable for small batch sizes and simple mixing processes.
• Internal Mixer: Offers higher efficiency, better control over the process, and is ideal for larger batch sizes and more complex mixing requirements.

Additional Processing Steps

• Compounding: Involves measuring and mixing raw rubber with other ingredients to form a compound ready for further processing.
• Extrusion: Post-mixing step where uncured rubber is forced through a die to create shaped sheets or profiles, which are then cut into slugs or pellets.

By understanding these key points, a lab equipment purchaser can make informed decisions about the type of mixing equipment and processes best suited for their specific rubber compound mixing needs. This ensures efficiency, quality, and consistency in the final product.

Continue Exploring, Consult Our Experts

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