Top 10 Internal Mixer Brand & Manufacturers

What is an Internal Mixer?

An internal mixer is a type of industrial equipment used mainly in the rubber and plastics industries. It is designed to mix and blend different materials such as rubber compounds, plastics, and additives to achieve a homogeneous mixture. The mixer consists of a chamber with two rotors that rotate in opposite directions. These rotors knead and mix the materials placed inside the chamber, ensuring thorough blending and dispersion of all components.

History of Internal Mixer

The development of internal mixers can be traced back to the early 20th century. As the rubber and plastics industries grew, there was a need for more efficient mixing equipment. The first internal mixers were relatively simple in design but laid the foundation for modern, highly efficient machines. Over the years, with technological advancements in motor design, rotor geometry, and control systems, internal mixers have become more powerful, precise, and capable of handling a wide variety of materials and mixing requirements.

Purpose of Internal Mixer

• Rubber Industry: In the rubber industry, internal mixers are used to blend natural and synthetic rubbers with various additives such as fillers (like carbon black), accelerators, and antioxidants. This is crucial for the production of tires, conveyor belts, seals, and other rubber products. The mixing process ensures that the rubber compound has the desired physical and chemical properties, such as strength, elasticity, and resistance to wear and tear.
• Plastics Industry: For plastics, internal mixers are used to mix different types of resins with additives like colorants, stabilizers, and reinforcing agents. The homogeneous mixture is then used to manufacture a wide range of plastic products, including pipes, injection - molded parts, and thermoformed sheets. The mixing process helps to improve the quality and performance of the final plastic products.

Principle of Internal Mixer

Internal mixers operate based on the rotation of two rotors inside a closed mixing chamber. The rotors have a specific shape and design that allows them to cut, fold, and knead the materials. As the rotors turn in opposite directions, they create a shearing action that breaks down the materials and distributes the additives evenly throughout the base material. The chamber is usually heated or cooled to control the temperature of the mixing process, as the mixing of some materials can generate heat due to friction. The mixing cycle is carefully timed to ensure that the materials are thoroughly mixed without over - or under - mixing.

Features of Internal Mixer

• Thorough Mixing: Internal mixers are known for their ability to achieve a high degree of mixing homogeneity. The complex rotor movements and shearing action ensure that even small particles and additives are evenly distributed throughout the material, resulting in a consistent quality of the final product.
• Variable Speed and Torque Control: Modern internal mixers come with the ability to control the speed and torque of the rotors. This allows operators to adjust the mixing process according to the specific requirements of the materials being mixed. For example, different materials may require different mixing speeds and torques to achieve the best results.
• Temperature Control: As mentioned earlier, the ability to control the temperature inside the mixing chamber is a crucial feature. This helps to prevent overheating of the materials, which could lead to degradation or premature curing in the case of rubber compounds. Some mixers also have cooling systems that can quickly dissipate heat generated during the mixing process.
• Automation and Data Recording: Advanced internal mixers are equipped with automation features such as programmable mixing cycles and automatic loading and unloading of materials. They can also record data such as mixing time, temperature, speed, and torque, which is useful for quality control and process optimization.

Types of Internal Mixer

• Tangential Internal Mixer: In a tangential internal mixer, the rotors are arranged in a tangential position inside the mixing chamber. The rotors have a wing - like shape that creates a strong shearing action as they rotate. Tangential internal mixers are widely used in the rubber and plastics industries due to their efficient mixing capabilities.
• Intermeshing Internal Mixer: Intermeshing internal mixers have rotors that interlock or mesh with each other. This design provides a different mixing action compared to tangential mixers. The intermeshing rotors can offer more efficient dispersion of additives and are often used for materials that require a high - degree of homogeneity, such as high - performance rubber and plastic compounds.[!--empirenews.page--]

Precautions for using Internal Mixer

• Safety Guards: Ensure that all safety guards around the internal mixer are in place and properly functioning. The moving rotors can cause serious injuries, so it's essential to prevent access to the mixing chamber during operation.
• Material Loading and Unloading: When loading materials into the mixer, make sure they are added in the correct order and quantity. Some materials may react violently if not properly introduced. During unloading, ensure that the mixer has come to a complete stop and the pressure inside the chamber has been released.
• Regular Maintenance: Regularly maintain the internal mixer to keep it in good working condition. Check the rotors for wear and tear, clean the mixing chamber to remove any residue, and lubricate the moving parts as per the manufacturer's instructions. Malfunctioning of the mixer due to poor maintenance can lead to inconsistent mixing and product quality issues.

Things to consider when purchasing Internal Mixer

• Material and Mixing Requirements: Consider the types of materials you will be mixing, such as rubber or plastics, and the specific mixing requirements. For example, if you need to mix a high - viscosity rubber compound with a large amount of fillers, you may need a mixer with a higher torque and larger capacity.
• Mixing Capacity and Output: Determine the volume of material you need to mix in a single batch and the overall production output you require. Choose an internal mixer with an appropriate mixing chamber size and rotor speed to meet your production needs.
• Precision and Control Features: If you require a high level of precision in the mixing process, look for a mixer with advanced control systems such as variable speed and torque control, temperature control, and automation features. These features can help you achieve consistent and high - quality mixing results.
• Budget and Cost - effectiveness: Set a budget for the internal mixer and consider the long - term cost - effectiveness. This includes the initial purchase cost, operating costs (such as energy consumption and maintenance), and the expected lifespan of the machine. A more expensive mixer with better performance and durability may be a more cost - effective option in the long run.

Terms of Internal Mixer

• Rotor Design: The shape and configuration of the rotors play a crucial role in the mixing process. Different rotor designs, such as tangential or intermeshing, affect the shearing action, mixing efficiency, and the quality of the final mixture.
• Shearing Action: The force exerted by the rotors that causes the materials to be cut, folded, and kneaded. The shearing action is responsible for breaking down the materials and ensuring the even distribution of additives.
• Mixing Cycle: The sequence of operations, including the time and speed of rotor rotation, temperature control, and material addition, that is used to achieve the desired mixing result. The mixing cycle is usually determined based on the specific materials and the product requirements.
• Homogeneity: The degree to which the different components of the mixture are evenly distributed throughout the material. A high level of homogeneity is essential for the quality and performance of the final product.