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Dispersion Kneader – Your Friend in ‘Knead’

For many years, open mill mixing has been the preferred form of mixing rubber. But then technology has been evolving.

Thus came mixers and the major considerations had always been cost. Since last twenty-five years, the Kneaders have become the most commonly used type of ‘mixer‘ in the rubber industry.

Kneader-Special-Supplement

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This popularity, prompted us to showcase Dispersion Kneaders specifically in this Knowledge On-The-Go Special Supplement. Though developed initially for mixing thermoplastics, Dispersion Kneaders have a unique place in the elastomer mixing industry. Users love the ease of cleanliness on this machine especially when they have to change the color of their compounds frequently.

Dispersion Kneader is energy-efficient, maintenance-friendly, labor and time-saving machinery that offers consistent quality of rubber mix compound at higher output as compared to an open mixing mill – thus making it truly Your Friend in ‘Knead’ for your rubber processing plant.

I hope you agree and find this special supplement informative.

(Disclaimer: Any pictures and quoted statements in our special supplements including Know Your Supplier editions are shared with us by the respective companies and/or sources are mentioned appropriately. Rubber Machinery World does not independently verify them nor will vouch for their actions, hence will not be liable for any misrepresented data)


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Rubber Dispersion Kneader – The Other “Internal Mixer”

In the world of rubber mixing, when “purists” refer to “internal mixer”, they either mean a Tangential Rotor Type (aka Banbury Mixer) or a Intermeshing  Rotor Type (aka Intermix).

While “practitioners” have a third category viz. Rubber Dispersion Kneader.

When you discuss with the practitioners (mostly in Asia) it is very common to hear the terms “Kneader Banbury”, “Kneader Mixer”, “Kneader Intermix”, “Intensive Mixer Kneader”, “Internal Mixer Kneader”, “Dispersion Mixer”, “Tilt Mixer” etc being used in the same context as an “internal mixer”.

So, what is this dispersion kneader and how is this different from an internal mixer?

Dispersion Kneader

Moriyama Make Dispersion Kneader

To start with, a kneader means a machine that specializes in kneading substances, something to a dough form. I suspect it originates from Germany when Heinz List, a pioneer of modern industrial processing technology, first developed a kneader reactor to process high viscosity materials.

The respective rotor, throat, chamber and floating weight designs are different in a dispersion kneader and batch mixer (or internal mixer) . While a mixer discharges the batch through a bottom drop-door, the kneader tilts 125-140 degrees to discharge the batch. Available in more customized capacities than batch mixer, this machine can be positioned on the ground level. While a mezzanine floor is required for mixers with drop door. For similar capacities, dispersion kneaders use lower power than mixer. The mixing time is higher than an internal mixer and hence production volumes are lower in kneader.

Though developed initially for mixing thermoplastics, dispersion kneaders have a unique place in the elastomer mixing industry. Users love the ease of cleanliness on this machine especially when they have to change the colour of their compounds frequently. These machines are also easy to operate and their varied applications include

  • Oil seal, Body seal, Gasket, Belt, Hose, Tube for Automobiles
  • Rubber for Electric wires
  • Conveyor Belts & Power transmission belts
  • Rubberized Rolls
  • Rubber based products like Plug, Cap, Glove, Dental for Medical line
  • Sporting goods like rubber ball, etc

Moriyama Japan (now merged with Nihon Spindle Manufacturing Co Ltd in 2014) enjoys a leadership status in Dispersion Kneader and continues to innovate regularly. Many regional players co-exist in India, China, and Taiwan catering to different categories of customers in rubber mixing industry.

Over a period of time, these kneader manufacturers have developed designs, features and automation for high quality and optimum mixing performance to position themselves closer to the internal mixer. Hence, the confusing terminologies (that I spoke of in the beginning) needs to be viewed in this context. The only caution being when trying to articulate, discuss and solve rubber compounding issues, it is very important to know exactly which rubber machinery is being used – is it dispersion kneader or internal mixer?

Happy Mixing!


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