High-intensity mixer vs flip-style mixer: How Modifier Plants Can Overcome Four Major Pain Points for Precise Selection?
In the production process of modified plastics, the mixing procedure may seem simple, but it plays a decisive role in the quality of the final product.When faced with various types of mixing equipment on the market, how can a modification factory make the most suitable choice?The article will provide an in-depth analysis.The difference between high-speed mixers and flip-type mixers, and provide a practical selection guide.。
01
Challenges and difficulties in the mixing process of modified plastics
Response Plan
Pain Point 1: Uniformity Problem
When adding a small amount of color masterbatch or functional additives, traditional mixing equipment struggles to achieve ideal uniform distribution due to differences in density and particle size between materials, resulting in color inconsistency and unstable performance in the product.
Optimize mixing process parameters: precisely adjust the mixing machine's speed, time, and filling coefficient according to different material characteristics. For example, for materials with significant density differences, adopt a mixing strategy that starts at a low speed and then shifts to a high speed.
Adopt a stepwise feeding method: first add the main raw material in a large proportion, and then gradually add small proportion additives. It is recommended to feed in the order of base material → filler → functional additives → color masterbatch.
Use dispersing aids: For additives added in very small amounts, they can be pre-dispersed with a resin carrier, and it is recommended to control the carrier proportion at 5-10%.
Pain Point 2: Temperature Control
Some engineering plastics and functional additives are sensitive to temperature. The heat generated by mechanical friction during the mixing process may cause material degradation, affecting product performance.
Choose equipment with precise temperature control: prioritize mixers equipped with cooling jackets and temperature sensors.
Optimize mixing time: Determine the shortest effective mixing time through experiments while meeting uniformity requirements.
Adopt low-temperature mixing process: For particularly sensitive materials, choose equipment that controls the material temperature change within the range of 0.6-1.5℃/minute.
Pain Point 3: Cleaning and Maintenance
The traditional mixer has a complex internal structure with many cleaning dead ends, which can easily lead to cross-contamination during formula changes, affecting product purity.
Select equipment for structural optimization: choose a mixer with an internal smooth design and no dead corners.
Establish standardized cleaning procedures: Develop cleaning specifications for product changeovers, including three steps: dry cleaning → wet cleaning → verification.
Use dedicated cleaning materials: equip with plastic special cleaning agents and resin cleaning materials.
Pain Point 4: Balancing Efficiency and Energy Consumption
Prolonged mixing time, high energy consumption, and low equipment utilization rate are factors that directly affect production costs and delivery schedules.
Reasonably match equipment capacity: select a mixer capacity that matches the production batch size, and it is recommended to maintain equipment utilization at 70-85%.
Energy Consumption Monitoring and Management: Establish an energy consumption monitoring system to optimize equipment operating parameters in real-time.
Intelligent Upgrade: Implement an automated control system to achieve full-process automation from feeding to mixing to conveying.
02
Comparison of Features between High-Speed Mixer and Flip-Type Mixer
In addition to the comparison of advantages and disadvantages mentioned above, price is also a major factor for modification factories when selecting equipment.The investment cost of a high-speed mixer is relatively low, while the initial investment cost of a flip-type mixer is high.。
03
How to Choose a Mixer for a Modified Plastic Factory
Based on material characteristics
Choose formulations that require heating to promote dispersion, such as certain filling modifications and compatibilizer use scenarios.High-speed mixerIt is a more suitable choice. Its friction-generated heat characteristics can promote the dispersion of additives and improve mixing efficiency.
For heat-sensitive materials, such as certain engineering plastics and functional additives, a flip-type mixer with a combination of large and small blades. Low-temperature mixing characteristics can better protect material performance and avoid degradation risks.
Consider production scale
Mass continuous production is more suitable for high-speed mixers.Its processing power is strong, and the return on investment is high.The multi-variety, small-batch production model is more suitable for the flip-type mixer.Due to its quick and clean material changeover, it can effectively enhance equipment utilization and reduce the risk of cross-contamination between different formulations.
Focus on operating costs
High-speed mixers have high energy consumption and their components need to be replaced relatively frequently; although tilt mixers have a higher purchase cost, their long-term operational costs may be more advantageous.
Technology Upgrade Roadmap
When selecting equipment, it is important to consider the company's development plan for the next 3-5 years. Will new production lines be introduced? Will the product types expand? Does the equipment need to be compatible with various process requirements? Additionally, after-sales service and technical support systems also impact the decision-making process for equipment selection.
【Copyright and Disclaimer】The above information is collected and organized by PlastMatch. The copyright belongs to the original author. This article is reprinted for the purpose of providing more information, and it does not imply that PlastMatch endorses the views expressed in the article or guarantees its accuracy. If there are any errors in the source attribution or if your legitimate rights have been infringed, please contact us, and we will promptly correct or remove the content. If other media, websites, or individuals use the aforementioned content, they must clearly indicate the original source and origin of the work and assume legal responsibility on their own.
Most Popular
-
List Released! Mexico Announces 50% Tariff On 1,371 China Product Categories
-
Dow, Wanhua, Huntsman Intensively Raise Prices! Who Controls the Global MDI Prices?
-
Clariant Unveils Cost-Cutting Plan Details, Plans to Shut Down Multiple Plants
-
New Breakthrough in Domestic Adiponitrile! Observing the Rise of China's Nylon Industry Chain from Tianchen Qixiang's Production
-
Nissan Cuts Production of New Leaf EV in Half Due to Battery Shortage
