TECHNOLOGICAL INNOVATIONS IN RUBBER COMPOUNDING …

1 TECHNOLOGICAL . INNOVATIONS IN RUBBER . COMPOUNDING MACHINES. Mr. S. S. Shetty (Manager - Marketing). Bainite Machines Private Limited Fully Automated Complete Mixing Line The Mixing Room In Mixing Room, lot of automations can be envisaged & achieved by adopting modern technology in electronics & hydraulics systems 1. Feeding Systems Carbon Feeding Systems Chemical Feeding Systems Oil Feeding Systems Weighing & Feeding Conveyors 2. Internal Mixers Tangential Type Intermeshing Type The Mixing Room 3. Downstream Equipment's Mixing Mill Dump- Extruder Twin Screw Sheeter 4. Batch-Off Cooling Manual Batch Off Cooling Unit Fully Automated Batch Off Cooling Unit Batch Off Cooling Unit with Air Conditioners The Mixing Room Mixing Mill Setup The Mixing Room Twin Screw Sheeter Setup Fully Automated Complete Mixing Line (Video).

2 1. Feeding Systems Carbon Feeding Systems- (3-5 Types). Chemical Feeding Systems- (8-16 Types). Oil Feeding Systems- ( 8-16 Types). Weighing & Feeding Conveyors- With Metal Detectors 2. Internal Mixers Types of Internal Mixers Tangential Type Intermeshing Type Mixing Area Capacity of Internal Mixers Tangential Mixer Capacity 25 40 70 80 95 120 160 180 240 270 310 440 620. Rotor 2W 2W 2W 2W 2W 2W 2W 2W/ 2W/ 2W/ 2W/ 4W/ 4W/ 4W/. Type 4W/ 4W/ 4W/ 4W/ 6W 6W 6W. SP4 SP4 SP4 6W/. SP4. Intermeshing Mixer Capacity 25 50 95 150 210 330. Rotor HP5 HP5 HP5 HP5 HP5 HP5 HP5. Type Internal Mixers Rotor Designs #2 Wing Rotors #4 Wing Rotors #Modified 4 # Turbo Rotors Wing Rotors #Staggered #SP4 Rotors #HP5 Rotors #6 Wing Rotors Wing Rotors Two Wing Rotor (Normal Rotation).

3 Turbo Rotor (Normal Rotation). 4 Wing Rotor (Shear Rate Distribution ANSYS Polyflow). 6 Wing Rotor (Normal Rotation). Tangential Rotor (Water Circulation Tip Cooling). HP5 Intermeshing Rotor (Normal Rotation). HP5 Intermeshing Rotor (Particle Distribution ANSYS Polyflow). HP5 Intermeshing Rotor (Water Circulation Spiral Cooling & Nog Cooling). Advanced Hydraulic RAM Operation E Hopper +. A Rapid Movement less than 3 seconds of RAM. up and RAM down Variable Speed Variable Pressure Variable positioning with RAM position indicator Sensing Stock pressure and varying the RAM. pressure accordingly automatically All the above factors can be pre-programmed for different recipes. The Main Mixer Body Heart of the Machine Improved Rotor design by using advanced Simulation tools - ANSYS Polyflow, Solidworks & AutoCAD.

4 Rotor material technology depending upon - # The rough recipes with higher Silica content, # Quick dispersion with homogeneous mixing # Highest dispersion rate in the Master Batch The Main Mixer Body Effective Cooling & Higher Fill Factor Efficient Cooling in Door Top. Efficient Cooling in Drilled Sides Modifications in Floating Weight - For Higher Fill factor Drill Side Chamber (Water Circulation). Door Top (Water Circulation). The Main Mixer Body Heart of the Machine Water cooled Rotor End Plates &. Dust Stops Temperature Monitoring of Bearings & Dust stops Oil Less Dust-stop unit The Main Mixer Body Heart of the Machine Efficient Linear Actuator operations with Toggle type latch for door operations. Modifications in Door Top - For quick dumping action Temperature Control Unit- TCU.

5 TCU Ensure Effective Temperature control during Mixing Cycles. Oil Type TCU up-to 160. Water TCU for up-to 90 . Equipment's The Modern Mixing Mills- Latest Features Hydraulic Nip Adjustment Nip Monitoring through LVDT. Peripherally Drilled Rolls Variable friction Uni-drive Gear Box Enhanced Safety Features Hydraulic Nip Adjustment The Modern Mixing Mills Individually driven rolls & Uni-drive gearbox The Modern Mixing Mills Peripherally Drilled Rolls Water circulation The Modern Mixing Mills- Accessories Movable Stock Guides - Pneumatic / Hydraulic Stock Blender Single Plate Base Vibro Pads VFD Controls Twin Screw Sheeter- All New Features Individually Driven Screws with Intelligent Controls Connecting Gear to ensure Back up screw Position Calendar with Individually driven Rolls Hydraulic / Motorized Nip adjustment Hydraulic Locking arrangement Twin Screw Sheeter Individually Frame Mounted Roll Drives with VFD.

6 Chute with Level Sensors Total Synchronization between Extruder and Calendar from Load Cell Fully auto operations using load cells and sensors Twin Screw Sheeter Hydraulic Nip Adjustment for TSS. Twin Screw Sheeter Calendar movement hydraulically operated for cleaning Twin Screw Sheeter Screw Barrel Water Circulation Old Version Improved New Version 4. Sheet Cooling Manual Batch-off Festooner Arrangement 4. Sheet Cooling Fully Automated Batch Off Cooling Unit Fully Automated Batch Off Cooling Unit Fully automated right from Picking up sheets till Stacking. Auto pick up programme to pick up sheets. Fully Automated Batch Off Cooling Unit First floor hugger conveyor for remixing (Master Batch). Take Away Conveyor for Ground Floor stacking (Finals Batch).

7 Fully Automated Batch Off Cooling Unit Packer Stacker Unit Auto Palletization Unit Total Program integration for Automation & Remote management. Total Integration with Corporate ERP. Automations Auto Packer Stacker Auto Slitter Automations Auto Sampling -Cookie Cutter for Better Sampling Automations Auto Sampling Barcoding System for efficient Tracking Automations PLC. SCADA. HMI. Recipe Management Automations Strip Feeder Lower Initial Cost Convenient Feeding Quicker Mixing Energy Saving Metal Detection System Bainite's Res-O-Lab Bainite's Res-O-Lab Latest Features A Product for RUBBER Industry - R & D Division A Scaled down version of Production Mixer Chamber Volume with total connected load of ~40kW. Fully Enclosed Canopy with all mixer controls on the HMI.

8 All Cylinders operation & control by Hydraulic system Ram Positioning system & Stock Pressure sensing facility Highly efficient, Miniaturized Temperature Control system Temperature is Controlled with TCU. Mixer is equipped with PLC Control & SCADA, which monitors - 1. Energy consumed 2. Batch timings 3. Batch weight 4. Batch Temperature Bainite's Res-O-Lab Latest Features Different thousands of recipes could be recorded & based on the recipe you can vary the various factors like - 1. RAM Pressure 2. RAM Speed 3. RAM Positioning (With Indication). 4. Stock Pressure sensing 5. Rotor Speeds throughout the Mixing Cycle 6. Compound Temperature monitoring throughout the cycle All the factors governing the COMPOUNDING cycle are captured Everything could be displayed on the monitor Mixing cycle history can be stored for future reference The SCADA also keeps a record of the ingredients used Integration with the Corporate's ERP system