Internal Mixer

Internal mixer is used for mixing, master-batch and final mixing for various rubbers. It is also an indispensable in all solid tyre industries.

It consists of internal mixing chamber, two rotors, discharge pressure device, rotor sealing device, reducer, lubrication unit, temperature control unit, electrical control unit, etc.

This machine is used can achieve the best dispersion effect through correct machine model selection. Rotor design and selection is quite important for the product performance, both intermeshing rotors and tangential rotors are available basing on different processing requirement to select. (Intermeshing design is to rotate rotors in opposite directions at the same speed, but tangential design is to rotate at different speed to keep batch circulating.) The clearance between rotors and the surface of chamber wall produces intensive shearing of the batch. After mixing well, a discharge door on the bottom will be opened to unload the mixture. 

But, what's the difference of internal mixer (also called banbury mixer) and kneader mixer? How to choose to use banbury mixer or kneader mixer? 

The most obvious difference is material dropping position. For the banbury internal mixer, the compound drops from the bottom. For the kneader mixer, the compound drops from front side (turnover type discharging door), and the maximum tilting angle is 140°.

The banbury internal mixer generally has a relatively high speed, a large transmission power, high production efficiency, high quality of the rubber compound, but it occupies a large space and cost is high. Banbury mixer is suitable for the production of high-end rubber products and the industries with a huge demand of rubber compound, such as big tire factories and conveyor belt factories. The core components include rotor, mixing chamber, left and right side plates and ram are forging and casting, but these parts are welded and jacketed for kneader machine. 

For the kneader mixer, it has smaller size, easy to install, and the equipment is very cheap, so it is favored by some small and medium-sized enterprises, but the production efficiency is far lower than banbury internal mixer, and the quality of the mixed rubber is also not good as banbury mixer.

The rotors of the internal mixer is integrally cast, and then welded together with two sections of round steel, so it is with high strength. The kneader's rotors, two wings are welded to the surface of the round steel.

The service life of banbury internal mixer is much higher than kneader mixer. Most of the kneaders can be used around 10 years assuming it is used 8-10 hours per day. Banbury mixer can be used at least 20 years. 

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