Rebuilding an internal mixer can be less expensive than purchasing a new machinery. Your production downtime can also be reduced by proper planning because of faster turnaround times on rebuilds.

Depending on the condition of the internal mixer; they could be rebuilt, remanufactured or upgraded.

Rebuilding a mixer requires expertise in mechanical aspects and knowledge of its functioning. Rebuilders’ knowledge of hydraulic, lubrication, pneumatic, electrical, control, and cooling systems are equally important if you plan to upgrade.The rebuilding process will require your mixer (and its components) to be disassembled, cleaned, inspected, and repaired (or replaced as is required).

Hence, an expert rebuilder follows these steps.

• Disassembly, cleaning, and inspection.
• Estimation on the scope of rebuild and guidance to upgrade the mixer components (in case of old designs and brands) to improve performance.
• Rebuilding or remanufacturing mixer components to original dimensions, clearances and tolerances.
• Ordering of the required electrical, control, hydraulic, lubrication, pneumatic, and cooling system parts.
• Reassembly of the mixer and painting.
• Documentation and manuals for installation, spares, maintenance (and operations in case of upgrading the mixer)
• Inspection, testing and mechanical recertification.
• Installation and Startup support at site.
• After-market service and spares support.

There are a significant number of details within each of the steps outlined above, that needs extensive expertise. Hence, I suggest that you ask yourself the following 17 questions (that needs a “yes” answer) to decide on your choice of a mixer rebuilder (reputed companies recognize the importance of these questions and will provide you full details. Most would even display documentary evidence during your discussions).

1. Is the company well-established in the industry?
2. Does the company have drawings to rebuild and remanufacture your mixer to specifications?
3. Does the company have design capabilities to upgrade, modify or custom-design your mixer components to new/improved specifications?
4. Can the company service your mixer?
5. Does the company have competent personnel for field service?
6. Can the company provide installation support?
7. Does the company have the required engineering infrastructure to remanufacture your mixer components? What are its manufacturing capabilities?
8. Can the company extend service and spares support throughout the life of your mixer?
9. Does the company have the required testing (like pressure, steam, hydrostatic, ultrasonic, etc) facilities for your mixer and its components?
10. Does the company supply installation and parts manuals?
11. Can the company ensure final mixer dimensions match the existing dimensions available at your site?
12. Does the company provide you verification of inspection reports, test certifications of critical components?
13. Are they confident of their internal quality processes and systems?
14. Do they agree for a third-party inspector for final inspection and validation?
15. How does the company go about determining the scope of rebuild?
16. Does the company display transparency when sharing – which components are rebuilt? Which are remanufactured? which are upgraded designs?, etc.
17. Does the company have the expertise or resourcefulness to guide you on electrical, control, hydraulic, lubrication, pneumatic, and cooling systems?

Plan a visit to research and evaluate your prospective companies well. Because a mixer rebuild can cost your pocket at least 50% or more of a new machinery price depending on its condition. Select the right rebuilder to restore your internal mixer to its original capacity, maintain them well (Recommended Maintenance Schedule For Internal Mixer) for longer life and thus maximise your ROI.

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