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Hard Tooth Surface Reducer Water Cooling Two Roller Rubber Mixing Mill For Manufacturing Rubber Products Factory
What are the sizes of rubber mixing mills?
16-inch mixing mill for rubber mixing equipment. Mixing mills can be divided into: laboratory 6-inch mixing mill, 10-inch mixing mill, 12-inch mixing mill, 14-inch mixing mill, 16-inch mixing mill, 18-inch mixing mill, 22-inch mixing mill, 24-inch mixing mill, 26-inch mixing mill according to the size of the machine. Mixing mills can be divided into: automatic rubber turning mixing mill, hydraulic baffle mixing mill, electric adjustable mixing mill, hydraulic adjustable mixing mill, variable frequency speed mixing mill, etc. according to the degree of automation.
The three basic processes of rubber mixing mills:
The rubber mixing mills basically have three processes in the mixing process: wrapping the rollers/eating powder/turning.
The first process is: wrapping the rollers
During mixing, there may be four situations in which the raw rubber on the rollers of the mixing mills
The first situation occurs when the roller temperature is too low or the rubber is hard. The rubber stays at the accumulated rubber and slides, and cannot enter the roller gap, or can only become fragments when forced into.
The second situation occurs when the rubber is in a highly elastic state, with both plastic flow and appropriate highly elastic deformation. After the rubber passes through the roller gap, it only wraps on the front roller, which is conducive to mixing operations and dispersion of compounding agents in the rubber.
The third situation occurs when the temperature is too high, the fluidity of the rubber increases, the intermolecular force decreases, and the elasticity and strength decrease. At this time, the rubber cannot wrap the roller tightly and become a bag-like shape, and the rollers are removed or broken, and mixing operations cannot be performed.
The fourth situation occurs when the temperature is higher, the rubber changes from a highly elastic state to a viscous flow state, the elasticity and strength almost disappear, and the rubber is difficult to cut. Therefore, the mixing temperature should be controlled to keep the rubber in a state that is conducive to mixing.
The second process is: powder eating
The powder eating stage refers to the process of mixing the compounding agent into the rubber.
After the rubber is wrapped around the roller, in order to mix the compounding agent into the rubber as soon as possible, a certain amount of accumulated rubber should be retained at the upper end of the roller gap.
When the compounding agent is added, due to the continuous flipping and replacement of the accumulated rubber, the compounding agent is brought into the wrinkle groove of the accumulated rubber and then into the roller gap.
In the process of eating powder, the amount of accumulated rubber must be moderate. When there is no accumulated rubber or the amount of accumulated rubber is too small, on the one hand, the compounding agent can only be rubbed into the rubber by the shear force between the rear roller and the rubber, and cannot penetrate into the rubber and affect the dispersion effect; on the other hand, the powdered compounding agent that is not rubbed into the rubber will be squeezed into pieces by the rear roller and fall into the receiving tray. If it is a liquid compounding agent, it will stick to the rear roller or fall on the receiving tray, causing mixing difficulties.
If there is too much accumulated rubber, part of the rubber will rotate and roll at the upper end of the roller gap and cannot enter the roller gap, making it difficult for the compounding agent to mix in. The amount of accumulated rubber is often measured by the contact angle (or bite angle), and the contact angle is generally taken as 32-45.
The third process is: refining
The third stage of mixing is refining.
Due to the high viscosity of rubber, the rubber only flows circumferentially along the rotation direction of the open mill roller during mixing, without axial flow, and the rubber flowing along the circumferential direction is also laminar. Therefore, the rubber layer close to the surface of the front roller at about 1/3 of the thickness of the rubber sheet cannot flow and becomes a "dead layer" or "sluggish layer".
In addition, the accumulated rubber on the upper part of the roller gap will also form a partial wedge-shaped "reflow zone". The above reasons all cause uneven dispersion of the compounding agent in the rubber.
Technical Parameters:
| Parameter/model | XK-160 | XK-250 | XK-300 | XK-360 | XK-400 | |
| Roll diameter(mm) | 160 | 250 | 300 | 360 | 400 | |
| Roll working length (mm) | 320 | 620 | 750 | 900 | 1000 | |
| Capacity (kg/batch) | 4 | 15 | 20 | 30 | 40 | |
| Front roll speed (m/min) | 10 | 16.96 | 15.73 | 16.22 | 18.78 | |
| Roll speed ratio | 1:1.21 | 1:1.08 | 1:1.17 | 1:1.25 | 1:1.27 | |
| Motor power (KW) | 5.5 | 18.5 | 22 | 30 | 37 | |
| Size (mm) | Length | 1104 | 3230 | 4000 | 4140 | 4578 |
| Width | 678 | 1166 | 1600 | 1574 | 1755 | |
| Height | 1258 | 1590 | 1800 | 1800 | 1805 | |
| Weight (KG) | 1000 | 3150 | 5000 | 6892 | 8000 | |
FAQ
A rubber mixing mill is a machine consisting of two counter-rotating rolls that are used to mix, knead, and homogenize rubber compounds. It is commonly used in the rubber industry to prepare rubber for further processing, such as calendering, extrusion, or molding.
The rubber mixing mill works by passing rubber compounds through two rotating rolls. The rolls rotate at different speeds (friction ratio), creating shear forces that mix and homogenize the rubber with additives like fillers, curing agents, and processing aids.
The main components include:
Rolls: Two counter-rotating rolls made of hardened steel.
Frame: A sturdy structure to support the rolls.
Drive System: Motor and gearbox to power the rolls.
Adjustment System: To control the gap between the rolls.
Cooling System: To regulate the temperature of the rolls.
Safety Devices: Emergency stops and nip guards.
The friction ratio is the speed difference between the two rolls. Typically, the front roll rotates slower than the back roll, creating shear forces that help mix the rubber compound effectively. Common friction ratios range from 1:1.1 to 1:1.4.
Rubber mixing mills are primarily used for natural rubber, synthetic rubber, and rubber compounds. They can also process materials like EPDM, SBR, NBR, and silicone rubber, along with additives like carbon black, silica, plasticizers, and curing agents.
Efficient mixing and homogenization of rubber compounds.
Flexibility in processing different rubber types and formulations.
Ability to handle small to medium batch sizes.
Cost-effective for small-scale production.
Requires skilled operators for optimal results.
Limited batch size compared to internal mixers.
Longer mixing times for large batches.
Heat generation can affect rubber properties if not controlled.
Regularly lubricate moving parts.
Check and adjust roll alignment.
Inspect and replace worn-out rolls.
Clean the rolls and machine after each use.
Monitor the cooling system to prevent overheating.
Always use nip guards to prevent hand injuries.
Avoid loose clothing or jewelry that could get caught in the rolls.
Use emergency stop buttons in case of emergencies.
Train operators on proper handling and safety procedures.
Rubber Mixing Mill: Uses two rolls to mix rubber compounds; suitable for small to medium batches; requires manual feeding and cutting.
Internal Mixer: Uses rotors inside a closed chamber; suitable for large batches; faster and more automated but less flexible for small-scale production.
Consider factors such as:
Roll size and capacity.
Friction ratio.
Power and speed requirements.
Cooling system efficiency.
Material compatibility.
Budget and production needs.
The temperature of the rolls is usually maintained between 40°C to 70°C (104°F to 158°F), depending on the rubber compound and processing requirements. Excessive heat can degrade the rubber.
Yes, modern rubber mixing mills can be equipped with automation features like programmable logic controllers (PLCs), automatic roll gap adjustment, and feeding systems to improve efficiency and consistency.
Uneven mixing due to improper roll gap or friction ratio.
Overheating of rubber compounds.
Roll wear and misalignment.
Inconsistent batch quality due to operator error.
Rubber mixing mills are used in industries such as:
Tire manufacturing.
Rubber sheet production.
Hose and belt manufacturing.
Footwear and rubber goods production.
If you have more specific questions about rubber mixing mills, feel free to ask!