1. Feeding & Batching Section (Mixer Feeding System)
A mixing line starts with precise batching. The Mixer Feeding System stores, conveys, weighs and feeds the four major material groups into the internal mixer: carbon black is unpacked and pneumatically conveyed into storage silos; raw rubber is guided by the rubber strip feeder and dosed via the rubber scale; oil is heated and kept warm in tanks and metered by the oil injection system; small chemicals (accelerators, antioxidants and other compounding agents) are automatically weighed by the multi-station batching system. Weighing accuracy must reach Class III with dynamic error ≤0.2%FS, and the batching cycle must stay within 120 seconds per batch to match the mixing rhythm.
2. Internal Mixer Mixing Section
The internal mixer is the heart of the line, where rubber and compounding agents are mixed inside the sealed mixing chamber. The choice between shear-type and intermeshing rotors, the ram pressure, and the temperature control and hydraulic systems together determine mixing quality and efficiency. Depending on the rubber type and recipe, multi-stage mixing (first-stage / second-stage) is carried out, with discharge temperature and time of each stage controlled by the process curve.
3. Sheeting & Cooling Section (Downstream System)
The hot compound discharged from the internal mixer must be sheeted and cooled immediately to prevent scorching. An open mill or a twin-screw extruder sheeter forms the compound into sheets; the batch-off cooler cools the sheets continuously with water plus air cooling; variable-frequency speed control is linked to the discharge rhythm; finally the sheets are stacked or conveyed directly to the next process.
4. Environmental Treatment
Dust and VOCs treatment in the mixing workshop has shifted from "optional" to "mandatory". Bag filters control dust during feeding and discharging; mixer exhaust gas is concentrated by a zeolite rotor and then oxidized by RCO/RTO catalytic combustion to achieve compliant emissions.
5. Intelligent Control System
The HopeMixer control system manages recipes, monitors weighing and records batches; the MES connects batching, mixing and quality inspection data at workshop level, enabling production scheduling, traceability and dashboard management. The intelligent control layer upgrades the mixing line from "a stack of equipment" to "data-driven production".
Conclusion
When selecting a mixing line, we recommend deciding the configuration in the order of "process → capacity → workshop → budget". Feel free to contact us for a free turnkey line design.