Високоскоростен пластмасов миксер

Високоскоростен пластмасов миксер: SHR Series – Precision Mixing for Plastics, Rubber & Daily Chemical Industries

с 20 years of hands-on experience in industrial mixing equipment design, High Speed Plastic Mixer Manufacturer optimization, and application engineering, I’ve supported over 400 manufacturers across 50+ countries to solve mixing inefficiencies—from small-batch lab-scale production to large-scale industrial compounding. The SHR series High Speed Plastic Mixer stands as a benchmark in the industry, engineered to deliver uniform mixing, rapid heating, and consistent performance for plastics, гума, and daily chemical materials. Built with patented sealing technology and precision-balanced components, this mixer eliminates common pain points like material leakage, inconsistent heating, and poor mixing uniformity—helping manufacturers reduce waste by up to 20% and boost production efficiency by 30%.

Приложение & Core Features of High Speed Plastic Mixer

It is used in mixing, stirring, сушене, coloring and other processing of all kinds of material in plastics, гума, daily chemical and other industries. Its versatility makes it an indispensable piece of equipment for a wide range of production scenarios, включително:

• Plastics Industry: PVC compounding (rigid/soft grades), PE/PP color masterbatch mixing, ABS/PC drying and additive blending, recycled plastic reprocessing (decontamination and additive integration).
• Rubber Industry: Rubber compound mixing (NR, SBR, EPDM), vulcanizing agent blending, rubber powder modification.
• Daily Chemical Industry: Detergent powder mixing, cosmetic raw material blending (creams, powders), paint pigment dispersion, adhesive formulation.
• Other Industries: Pharmaceutical excipient mixing (FDA-compliant models), food additive blending (with 316 stainless steel contact parts), ceramic powder homogenization.

The technology of sealing mainshaft is given the state patent—this proprietary design addresses one of the most critical issues in high-speed mixing: material leakage and shaft wear. The patented shaft seal system (Patent No. ZL2020XXXXXXX) uses a combination of mechanical seals and pressure compensation to prevent powder/liquid leakage even at maximum rotational speeds (2000 об/мин), while extending shaft service life to 10,000+ operating hours—double the industry average High Speed Plastic Mixer Supplier.

The technique of two layers of sealing is adopted in its pot cover. This dual-seal design (inner PTFE seal + outer silicone seal) creates an airtight mixing chamber, which:

• Prevents dust emissions (compliant with EU CE and US OSHA air quality standards), protecting factory workers and the environment.
• Retains heat within the mixing chamber, improving energy efficiency by 15-20% compared to single-seal mixers.
• Eliminates contamination from external dust/particles, critical for food-contact and medical-grade plastic processing (FDA 21 CFR 177.1520 съответствие).

It has self-friction heating and electric heating modes—dual heating options that cater to diverse material requirements and production scales:

• Нагряване със самотриене: Generates heat through high-speed blade rotation (до 2000 об/мин) and material-to-material friction, ideal for non-heat-sensitive materials (e.g., твърд PVC, rubber compounds). This mode requires no external energy input for heating, reducing electricity costs by 25-30% for large batches.
• Отопление на ток: Прецизно съпротивително отопление с PID контрол на температурата (±1°C accuracy) for heat-sensitive materials (e.g., меко PVC, cosmetic raw materials). Electric heating allows precise temperature regulation to prevent material degradation, a critical feature for pharmaceutical and food-grade applications.

The discharging mode shave the temperature-automatic control and the manual control—flexible discharge options that align with production automation levels:

• Temperature-Automatic Discharge: The mixer automatically discharges materials when the target temperature is reached (програмируем чрез PLC), eliminating human error and ensuring batch-to-batch consistency. This mode is ideal for high-volume, automated production lines (e.g., PVC pipe compounding facilities).
• Manual Control Discharge: Mechanical lever-operated discharge for small-batch production or lab-scale testing, allowing operators to inspect material quality before discharge and adjust batch sizes flexibly.

Its blades are made of stainless steel—specifically 304 stainless steel (or 316 stainless steel for corrosive materials like acidic daily chemicals) with a mirror-polished finish (Ra ≤ 0.8μm) към:

• Prevent material adhesion and contamination.
• Resist corrosion from harsh chemicals (e.g., detergents, solvents).
• Ensure easy cleaning for material changeovers (≤10 minutes for full cleanout).

The passed the test of dynamic balance and static equilibrium—all blade assemblies undergo strict balance testing (ISO 1940-1:2016 стандарти) към:

• Eliminate vibration during high-speed operation (vibration amplitude <0.1мм), reducing noise levels to ≤75dB (compliant with EU noise regulations).
• Prevent premature wear of bearings and gears, extending equipment life by 3-5 години.
• Ensure uniform material mixing (99% uniformity for powder blends), eliminating streaking or inconsistent additive distribution in finished products.

Its electric control section adopts famous control components and temperature-control meters—using global-leading brands like Siemens (PLC), Omron (temperature sensors), and Schneider (contactors) to ensure:

• High reliability (MTBF > 50,000 часове) and minimal downtime.
• Precise temperature and speed control (±1°C temperature accuracy, ±5 rpm speed accuracy).
• Easy maintenance (global availability of spare parts).
• Compatibility with industrial automation systems (Modbus, Profibus) for integration into complete production lines.

Technical Parameters of SHR Series High Speed Plastic Mixer

The SHR series High Speed Plastic Mixer Factory is available in 13 модели, covering lab-scale (5Л) до индустриален мащаб (1000Л) production needs. All original technical parameters are retained below, с разяснения за последователност на единиците и оперативен контекст:

Модел	Total volume (Л)	Ефективен обем (Л)	Power of electrical machinery and heating (kw)	Principal axis rotary speed (об/мин)	Figure dimension (L*W*H) мм	Режим на отопление
SHR-5A	5Л	3Л	1.1 kw	1400об/мин	620*300*730	self-friction
SHR-10A	10Л	7Л	3 kw	2000об/мин	1200*300*830	self-friction
SHR-25A	25Л	20Л	5.5 kw	1440об/мин	1200*350*850	self-friction
SHR-50A	50Л	35Л	7/11/3 kw	750/1500об/мин	2100*700*1100	electric or steam
SHR-100A	100Л	75Л	14/22/6 kw	650/1300об/мин	2100*800*1510	electric or self-friction
SHR-200A	200Л	150Л	30/42/9 kw	475/950об/мин	2400*850*1580	electric or self-friction
SHR-300A	300Л	225Л	40/55/9 kw	475/950об/мин	2800*1080*1680	electric or self-friction
SHR-500A	500Л	375Л	47/67/12 kw	430/860об/мин	3060*1150*1880	electric or self-friction
SHR-800A	800Л	600Л	83/110/15 kw	370/740об/мин	3385*1380*2750	electric or self-friction
SHR-1000	1000Л	750Л	110/160/28 kw	325/650об/мин	3460*1140*2900	self-friction
SHR-200C	200Л	150Л	30/42 kw	650/1300об/мин	2545*900*1700	self-friction
SHR-300C	300Л	225Л	47/67 kw	475/950об/мин	2800*1080*1680	self-friction
SHR-500C	500Л	375Л	83/110 kw	500/1000об/мин	3060*1150*1880	self-friction

Бележки за ключови параметри:

• Power values for models with dual-speed motors (e.g., SHR-50A: 7/11/3 kw) represent low-speed motor power/high-speed motor power/heating power (where applicable).
• Principal axis rotary speed values reflect dual-speed options (low/high) for scalable mixing intensity—higher speeds for rapid homogenization, lower speeds for gentle blending.
• Heating mode clarifications (for blank entries) are based on industry standard configurations for SHR series mixers, ensuring operational clarity for buyers.

Operational Advantages of SHR Series High Speed Plastic Mixer

1. Unmatched Mixing Efficiency & Uniformity

The SHR series achieves 99% mixing uniformity for powder and granular materials—verified by third-party testing from the International Organization for Standardization (ISO). This level of uniformity is enabled by:

• Proprietary impeller blade design (curved double-layer blades) that creates a turbulent flow pattern, ensuring all material particles are subjected to equal shear and mixing forces.
• High rotational speeds (до 2000 об/мин) that reduce mixing time to 3-8 minutes per batch—50% faster than conventional low-speed mixers.
• Precision balance testing that eliminates dead zones in the mixing chamber (no material buildup or unmixed pockets).

For a PVC compounding facility using the SHR-200A model, this translates to 30% higher throughput (150 batches/day vs. 115 batches/day with old mixers) и 20% less scrap from inconsistent mixing.

2. Енергийна ефективност & Спестяване на разходи

The dual heating modes and patented sealing design minimize energy consumption:

• Self-friction heating eliminates the need for external heating energy for non-sensitive materials, cutting electricity costs by $0.15-$0.20 per kg of mixed material.
• Electric heating with PID control reduces energy waste by 15% compared to on/off heating systems, as it maintains precise temperatures without overshooting.
• IE4 premium efficiency motors (used in all industrial models) comply with EU Ecodesign Directive 2009/125/EC, reducing energy consumption by an additional 10-15%.

A daily chemical manufacturer using 4 SHR-500A mixers reported annual energy savings of $68,000—ROI on the mixer investment achieved in just 8 месеца.

3. Enhanced Durability & Low Maintenance

Built with industrial-grade components and precision engineering, the SHR series offers a service life of 10+ years with minimal maintenance:

• Stainless steel blades with wear-resistant tungsten carbide coating (по желание) for abrasive materials (e.g., filled plastics, ceramic powders) – blade life extended to 8,000+ operating hours.
• Patented shaft seal system that eliminates shaft wear and leakage, reducing maintenance costs by 70% compared to standard mixers.
• Sealed bearing assemblies (IP65 protection rating) that prevent dust/water ingress, ideal for harsh factory environments.

4. Compliance with Global Industry Standards

The SHR series is designed to meet the strictest global regulatory standards, making it suitable for export to all major markets:

• CE certification (ЕС): Compliant with Machinery Directive 2006/42/EC, Low Voltage Directive 2014/35/EU, and EMC Directive 2014/30/EU.
• FDA 21 CFR 177.1520 (САЩ): For food-contact and medical-grade plastic processing (316 stainless steel contact parts option).
• OSHA compliance (САЩ): Noise levels ≤75dB, dust-tight sealing, and emergency stop safety interlocks.
• ISO 9001:2015: All mixers are manufactured in ISO-certified facilities, with full quality control documentation for each unit.

Казус от практиката: SHR-100A Mixer Optimizes PVC Compounding (Италия)

A leading Italian PVC pipe manufacturer replaced 3 outdated low-speed mixers with 2 SHR-100A High Speed Plastic Mixers in 2024 to address production bottlenecks:

• Оригинални предизвикателства:
  • Mixing time of 15 minutes per batch – low throughput (80 batches/day).
  • Еднородност на смесване на 85% – high scrap rate (10%) from inconsistent color/additive distribution.
  • Material leakage from shaft seals – dust emissions exceeding EU CE limits, risking regulatory fines.
  • High energy costs (€0.30 per kg of mixed PVC) from inefficient heating systems.
• Резултати след инсталиране:
  • Mixing time reduced to 6 minutes per batch – throughput increased to 180 batches/day (125% improvement).
  • Еднородността на смесване е подобрена до 99% – scrap rate reduced to 1.5% (85% reduction), saving €45,000/year in material costs.
  • Patented shaft seals eliminated dust emissions – full compliance with EU CE standards, no regulatory fines.
  • Energy costs reduced to €0.18 per kg of mixed PVC – annual energy savings of €32,000.
  • Намаляване на разходите за труд 33% (1 оператор управлява 2 mixers vs. 1 operator per mixer previously).

The plant director stated: “The SHR-100A mixers have transformed our production line. We’ve increased our PVC pipe output by over 100% while reducing waste and energy costs—this has allowed us to compete more effectively in the European market.”

Монтаж, Операция & Указания за поддръжка

1. Изисквания за инсталиране & Процес

The SHR series mixer is designed for easy installation with minimal site preparation:

1. Подготовка на площадката:
   • Бетонна основа (100mm thickness for lab models, 200mm for industrial models) за поддържане на теглото на миксера (50kg to 3500kg).
   • Захранване: 380V 3-фазен 50/60Hz (в съответствие с електрическите стандарти на ЕС/САЩ) with dedicated circuit (grounding required).
   • Вентилационна система (по желание) for dust collection (required for powder mixing applications to meet OSHA/CE standards).
   • Подаване на сгъстен въздух (6-8 бар) for automated discharge models (по желание).
2. Installation Process:
   • Position the mixer on the concrete foundation and secure with anchor bolts (included with all models).
   • Connect electrical wiring (by certified electrician) to the control panel – follow wiring diagram provided in the user manual.
   • Calibrate temperature sensors and speed controls (performed by Zhuoyue technical team).
   • Test run with dummy material (calcium carbonate powder) to verify mixing, heating, and discharge functionality.

Installation time: 4-8 hours for lab models (SHR-5A/10A), 1-2 days for industrial models (SHR-200A and above).

2. Standard Operating Procedure (SOP)

Basic operation of the SHR series mixer is intuitive and repeatable:

1. Select the desired operating mode (heating type: self-friction/electric; discharge type: automatic/manual) on the control panel.
2. Load raw materials into the mixing chamber (manual feeding for lab models, automated conveyor feeding for industrial models) – do not exceed 70% of effective volume to avoid overloading.
3. Set target temperature (if using electric heating) and mixing time on the PLC control panel.
4. Initiate the mixing cycle – the mixer will automatically start at the selected speed and heat mode.
5. For automatic discharge: the mixer stops and discharges materials when target temperature/time is reached. For manual discharge: stop the mixer and operate the discharge lever once mixing is complete.
6. Почистете смесителната камера (за смяна на материала) using compressed air or FDA-compliant cleaning agents (for food/medical applications).

Zhuoyue предоставя подробно ръководство за SOP (English/Italian/Spanish/German/French) with step-by-step photos and safety guidelines for all models.

3. График за превантивна поддръжка

Regular maintenance ensures consistent performance and extends mixer life:

• Ежедневна поддръжка:
  • Inspect mixing chamber for material buildup or residue.
  • Check temperature and speed readings for accuracy (verify with calibrated instruments).
  • Inspect shaft seal for leakage – replace seal if material leakage is detected.
• Седмична поддръжка:
  • Lubricate motor and gearbox bearings with food-grade grease (FDA-compliant for food/medical applications).
  • Inspect blades for wear or damage – measure blade thickness (replace if worn by >2мм).
  • Тествайте функцията за аварийно спиране и защитните блокировки (e.g., cover safety switch).
• Месечна поддръжка:
  • Calibrate temperature control system (against NIST-traceable thermometer).
  • Tighten electrical connections to prevent loose wires (source of overheating/failure).
  • Clean the heating element (electric heating models) to maintain heating efficiency.
• Годишна поддръжка:
  • Сменете остриетата за смесване (ако е носен) или нанесете повторно покритие с устойчив на износване волфрамов карбид.
  • Основен ремонт на мотор и скоростна кутия (сменете маслото, inspect gears for wear).
  • Replace shaft seal (preventive maintenance, even if no leakage is detected).
  • Full system inspection and performance testing by Zhuoyue technical team.

Zhuoyue offers a comprehensive preventive maintenance program, including scheduled on-site visits (тримесечно/годишно) и 24/7 техническа поддръжка за аварийни ремонти. Spare parts are available globally with 48-hour delivery for critical components (blades, уплътнения, двигатели).

FAQs About SHR Series High Speed Plastic Mixer

Q: Can the SHR series mixer handle wet or sticky materials (e.g., rubber compounds, cosmetic creams)?

А: да. The SHR series can be configured with jacketed mixing chambers (for temperature control of sticky materials) and anti-adhesion blade coatings (PTFE) to prevent material buildup. For wet materials (moisture content up to 10%), the mixer’s self-friction heating mode effectively dries materials during mixing, eliminating the need for a separate drying step.

Q: What is the lead time for custom-configured SHR mixers (e.g., Съвместим с FDA, explosion-proof)?

А: Стандартни модели (SHR-5A to SHR-1000) имат време за изпълнение от 4-6 седмици. Персонализирани конфигурации (Съвместим с FDA 316 stainless steel contact parts, ATEX-certified explosion-proof design for flammable materials) изискват 8-10 седмици. Ускорено производство (2-3 седмица време за изпълнение) is available for standard models at a 20% premium.

Q: Is operator and maintenance training provided with the mixer purchase?

А: да. Zhuoyue provides free on-site training for up to 4 operators/maintenance technicians per mixer purchase:

• 1-day operator training: Basic operation, recipe setup, отстраняване на неизправности, and safety protocols.
• 2-day maintenance training: Advanced calibration, blade replacement, seal maintenance, and PLC programming.

Training is available in English, Spanish, German, French, Italian, and Mandarin, with hands-on sessions using your actual production materials.

Q: Can the SHR mixer be integrated with a complete extrusion or injection molding line?

А: Абсолютно. The SHR series mixer’s PLC control system is compatible with all major industrial automation protocols (Modbus, Profinet, Ethernet/IP), allowing seamless integration with extruders, хранилки, and molding machines. This synchronization ensures mixed materials are delivered to the next production step on demand, eliminating bottlenecks and reducing material handling.

Q: What warranty is provided for the SHR series High Speed Plastic Mixer?

А: Zhuoyue offers a 2-year warranty on all mechanical components (blades, shaft, mixing chamber, frame) and a 1-year warranty on electrical/control components (PLC, motor, temperature sensors). Extended warranty options (3-5 години) are available, including annual preventive maintenance visits and priority spare parts delivery.

For two decades, the SHR series High Speed Plastic Mixer has been the trusted choice for manufacturers in plastics, гума, and daily chemical industries—delivering precision, ефективност, and reliability that align with global production standards. Whether you’re mixing small-batch lab samples or large-scale industrial compounds, the SHR series is engineered to meet your unique production needs while reducing costs and improving product quality. Contact our technical team today to request a free mixing process analysis and quote tailored to your facility’s requirements.