Overhaul & Upgrade Solution for Aging Mixing Lines
Automation upgrade and capacity recovery for existing mixing lines: new Mixer Feeding System / small chemicals batching, control system replacement and environmental retrofit — with minimized downtime.
Application Scenarios
Suitable for mixing lines that have been in service for many years: mainly manual batching, large weighing errors, non-compliant dust and environmental performance, aging control systems with high failure rates and noticeable compound quality fluctuation.
We provide a systematic upgrade without replacing the main mixers: with minimized downtime as the goal, the retrofit is implemented module by module, giving priority to production continuity.
Solution Configuration
Retrofit modules (can be implemented standalone or combined):
- Mixer Feeding System addition/upgrade: carbon black pneumatic conveying, oil systems, rubber weighing & feeding systems retrofitted to existing internal mixers
- Small chemicals batching retrofit: manual batching → semi-automated batching (4–6 g) → fully automated batching (1 g readability), in steps according to budget
- Control system replacement: HopeMixer intelligent control system replaces aging electrics — full upgrade of recipes, traceability and alarms
- Environmental retrofit: workshop dust collection upgrade + VOCs treatment (RCO/RTO)
- Digital catch-up: basic MES modules go live (traceability + dashboards)
Free on-site survey (domestic) or video survey (overseas) before retrofit, with a retrofit plan and phased quotation provided.
Solution Value
- Efficiency gains without replacing mixers: feeding automation upgrade improves both batching cycle and weighing accuracy
- Minimized downtime: modular construction plan, staged cutover, fast switching
- Environmental compliance: dust collection and VOCs treatment retrofitted to meet current emission standards
- Old equipment renewed: HopeMixer replaces legacy controls, failure rate drops significantly
- Data from scratch: batch records and traceability system go live, quality management becomes evidence-based
Implementation Process
Solution Design
Tailored system engineering based on site requirements.
Equipment Manufacturing
In-house fabrication with strict quality control.
Installation & Commissioning
On-site installation and full-line commissioning.
Acceptance & Delivery
Performance verification, operator training and handover.
After-sales Maintenance
Responsive spare parts supply and lifelong technical support.