Mixer High and Low Temperature Cold Mixer

Mixer – High and Low Temperature Cold Mixer: SRL Series for Precision Plastic Mixing

With 19 years of expertise in plastic processing Compounding Machine Plastic Manufacturer equipment design and application engineering, I’ve collaborated with 350+ प्लास्टिक उद्योग भरका निर्माताहरू - प्याकेजिङ्ग देखि मोटर वाहन सम्म - लगातार सामग्री गुणस्तर र उत्पादन दक्षताको लागि मिश्रण प्रक्रियाहरू अनुकूलन गर्न. SRL श्रृंखला उच्च र कम तापमान चिसो मिक्सर (तातो / चिसो मिश्रण इकाई) आधुनिक प्लास्टिक कम्पाउन्डिङको आधारशिलाको रूपमा खडा छ, समान मिश्रणको लागि महत्वपूर्ण आवश्यकतालाई सम्बोधन गर्दै, तापमान नियन्त्रण, र PVC जस्तै थर्मोप्लास्टिकको डिगासिङ, PE, PP, र ईन्जिनियरिङ् रेजिन (ABS, पीसी). आयातित युरोपेली प्रविधिमा निर्मित र विश्वव्यापी उत्पादन आवश्यकताहरूको लागि परिष्कृत, यो मिश्रण एकाइ स्वचालित उद्धार, दोहोर्याउन सकिने कार्यसम्पादन जसले म्यानुअल मिक्सिङको असंगतिलाई हटाउँछ र उत्पादनको फोहोरलाई कम गर्छ 15%.

आवेदन & SRL श्रृंखला उच्च/कम तापमान चिसो मिक्सर को मुख्य विशेषताहरु

SRL श्रृंखला मिश्रण एकाइ मिश्रण को लागी लागू हुन्छ, colouring and drying of various resin such as poly、PE、PP、PVC polypropylene, poly chloride etc. and in the process of drying and volatilization of engineering plastics such as ABS PC etc before forming and processing as well as in the mixing of phenolic resin. Its versatility makes it an essential piece of equipment for both small-batch specialty compounding and large-scale industrial production, supporting applications including:

• PVC pipe/profile compounding (rigid and soft grades)
• PE/PP film/sheet production (color masterbatch integration)
• Engineering plastic pre-processing (ABS/PC drying and degassing)
• Phenolic resin mixing for automotive interior components
• Recycled plastic compounding (drying and additive blending)
• Masterbatch production (high-concentration color/additive mixing)

एकाइले तातो मिश्रण र कूल मिक्सिङलाई सँगै जोड्छ—एक दोहोरो-चरण डिजाइन जसले प्लास्टिक मिक्सिङको मुख्य चुनौतीहरू समाधान गर्छ।: अपूर्ण homogenization, अति तापबाट थर्मल गिरावट, र जमघट (क्लम्पिङ) ताप पछिको सामग्री. तातो मिश्रण पछि सामग्रीहरू स्वचालित रूपमा चिसोको लागि कूल मिक्सरमा प्राप्त गर्न सकिन्छ, बाँकी ग्यासहरू निस्कन्छ र एग्लोमेरेटहरूबाट बच्न सकिन्छ. कम्पाउन्डिङ मेसिन प्लास्टिक आपूर्तिकर्ता तातोबाट चिसो मिश्रणमा यो निर्बाध संक्रमणले सुनिश्चित गर्दछ कि सामग्रीहरूले उनीहरूको संरचनात्मक अखण्डता कायम राख्छ जबकि उच्च-गुणस्तरको एक्सट्रुसनको लागि आवश्यक समान स्थिरता प्राप्त गर्दछ।, इंजेक्शन मोल्डिंग, वा मोल्डिङ प्रक्रियाहरू झटका.

यो इकाई आयात गरेर विकास गरिएको हो, र उन्नत विदेशी प्रविधि अवशोषित. PLC नियन्त्रण अपनाएर, यसले उच्च स्वचालित स्तर सुविधा दिन्छ. राम्रो मिश्रण प्रभाव. पूर्ण कार्य, कम्प्याक्ट संरचना र सुन्दर उपस्थिति. यो प्लास्टिक मिश्रण को लागी एक आदर्श उपकरण हो. PLC नियन्त्रण प्रणालीले सबै परिचालन प्यारामिटरहरूलाई केन्द्रीकृत गर्दछ (मिश्रण समय, तापमान, गति, डिस्चार्ज समय), मानव त्रुटि घटाउने र ब्याच-टु-ब्याच स्थिरता सुनिश्चित गर्ने - चिकित्सा उपकरण निर्माण जस्ता विनियमित उद्योगहरूको लागि महत्वपूर्ण (FDA 21 CFR 177.1520 अनुपालन) र मोटर वाहन घटक उत्पादन (IATF 16949 मापदण्डहरू).

SRL शृङ्खला मिक्सरहरूको प्रमुख परिचालन विशेषताहरू

1. लचिलो ताप मोडहरू

तताउने मोड: इलेक्ट्रिक हीटिंग वा आत्म-घर्षण. दोहोरो तताउने विकल्पहरूले विभिन्न सामग्री आवश्यकताहरू र उत्पादन स्केलहरू पूरा गर्दछ:

• इलेक्ट्रिक हीटिंग: PID तापमान नियन्त्रणको साथ सटीक प्रतिरोध ताप (±2°C शुद्धता) अति तताउने संवेदनशील सामग्रीहरूको लागि (जस्तै, नरम पीवीसी, ABS). सानो ब्याच उत्पादन वा विशेष रेजिनहरूको लागि आदर्श जहाँ सटीक तापमान नियमन गैर-वार्तालाप योग्य छ।. Electric heating also eliminates the risk of contamination from oil/gas heating systems, making it suitable for food-contact plastic processing.
• Self-Friction Heating: Generates heat through the high-speed rotation of mixing blades (सम्म 1800 आरपीएम) and material-to-material friction—cost-effective for high-volume production of non-heat-sensitive materials (जस्तै, कठोर पीवीसी, PE). This mode reduces energy consumption by 20-25% compared to electric heating for large batches (≥200kg), as it leverages the material’s own kinetic energy rather than external power.

2. Customizable Discharging Modes

Discharging mode: Manual or pneumatic. The discharge system is engineered for ease of use and minimal material waste:

• Manual Discharge: Mechanical lever-operated discharge gate for small-scale production (SRL-Z 50/100, 100/200 मोडेलहरू). Ideal for facilities with low throughput or frequent material changeovers, as it allows operators to inspect mixed materials before discharge and adjust batch sizes flexibly.
• Pneumatic Discharge: Air-powered discharge gate (8 bar operating pressure) for automated, उच्च मात्रा उत्पादन (SRL-Z 200/500 को 800/1600 मोडेलहरू). The pneumatic system ensures fast, complete discharge (≤30 seconds per batch) with minimal material retention (<0.5% of batch volume), reducing waste and downtime between batches. It can be integrated with conveyor systems for direct transfer to extruders/injection molders.

3. Advanced Mixing Blade Design

The SRL series uses a proprietary double-helix blade design (imported from German engineering specifications) that ensures 360° material circulation within the mixing chamber:

• High-speed rotating blades (सम्म 1800 rpm in heat mixer) create a turbulent flow pattern, breaking up agglomerates and ensuring uniform distribution of additives (स्थिरताहरू, प्लाष्टिकाइजर, flame retardants) at the particle level.
• Cool mixer blades operate at lower speeds (50-180 आरपीएम) with a spiral design that gently agitates materials during cooling, preventing clumping while maximizing surface area for heat dissipation and degassing.
• Blades are constructed from wear-resistant alloy steel (40Cr) with a surface hardness of HRC 58-60, extending service life to 8,000+ operating hours—3x longer than standard carbon steel blades—even when mixing abrasive filled compounds (जस्तै, 50% calcium carbonate-filled PVC).

4. Integrated Degassing System

A built-in vacuum degassing port (optional for all models) and atmospheric vent in the cool mixer removes moisture, volatile organic compounds (VOCs), and air bubbles from materials:

• Critical for hygroscopic engineering plastics (ABS, पीसी) – eliminates surface defects (bubbles, pinholes) in finished products.
• Reduces VOC emissions by 90% compared to open mixing systems, complying with EU REACH and US EPA air quality standards.
• Automated degassing timing (programmable via PLC) ensures consistent results across batches.

Technical Parameters of SRL Series High/Low Temperature Cold Mixer

The SRL series is available in 7 मोडेलहरू, scaled to match production volumes from lab-scale (50L heat mixer) to industrial-scale (800L heat mixer). All parameters are retained below, with clarifications for unit consistency and operational context:

मोडेल	Effective volume (L) (Heat/Cool)	Rotary speed (आरपीएम) (Heat Low/Heat High/Cool)	Motor / heating power (kW) (Heat Low/Heat High/Cool)	Dimension (mm) (L×W×H)	Weight (T)	Mixing/cooling time (min/pot)
SRL-Z 50/100	32/75	750/1500/180	7/11/5.5	2300*1800*1900	2.2T	6-10min/pot
SRL-Z 100/200	75/160	650/1300/180	14/22/7.5	3780*1870*2250	3.2T	6-10min/pot
SRL-Z 200/500	150/320	475/950/130	30/42/11	4850*2240*2470	3.5T	6-10min/pot
SRL-Z 300/600	200/360	475/950/130	40/55/11	4680*2240*2740	3.8T	6-10min/pot
SRL-Z 300/1000	200/640	475/950/110	40/55/15	4980*2500*2740	4.2T	6-10min/pot
SRL-Z 500/1000	375/640	430/860/50	47/67/15	4600*3000*4050	5.6T	6-10min/pot
SRL-Z 800/1600	600/1050	370/720/50	83/110/22	5170*3200*4480	7.5T	6-10min/pot

Key Parameter Notes:

• Rotary speed values reflect low/high speed settings for the heat mixer (adjustable via VFD) and fixed speed for the cool mixer.
• Motor/heating power is split between heat mixer (low/high speed motor) and cool mixer motor – all values comply with IE3 premium efficiency standards (EU Ecodesign Directive 2009/125/EC).
• Mixing/cooling time (6-10min/pot) is a typical range for PVC compounding; ईन्जिनियरिङ् प्लास्टिक (ABS/PC) may require 8-12 minutes for complete drying/degassing.

Operational Advantages of SRL Series High/Low Temperature Cold Mixer

1. Superior Mixing Uniformity

Third-party testing by the China Compounding Machine Plastic Factory Industry Association (CPMIA) confirms that the SRL series achieves 98% mixing uniformity for PVC compounds—12% higher than single-stage mixers. This uniformity translates to:

• Consistent color distribution in finished products (no streaking in film/sheet)
• Uniform mechanical properties (tensile strength, प्रभाव प्रतिरोध) in extruded profiles
• Reduced scrap rates (बाट 8-10% को <2% for most applications)

2. ऊर्जा दक्षता & लागत बचत

दोहोरो तताउने मोड र स्वचालित PLC नियन्त्रणले ऊर्जा प्रयोगलाई अनुकूलन गर्छ:

• स्व-घर्षण तापले बिजुली खपत घटाउँछ 20-25% उच्च मात्रा ब्याचहरूको लागि.
• गर्मी रिकभरी प्रणाली (वैकल्पिक) कूल मिक्सरबाट प्रि-हीट इनकमिङ सामग्रीहरूमा फोहोरको तापलाई कब्जा गर्छ, एक अतिरिक्त द्वारा समग्र ऊर्जा उपयोग कटौती 10%.
• स्वचालित सञ्चालनले श्रम लागत घटाउँछ 50% म्यानुअल मिश्रणको तुलनामा (1 अपरेटरले व्यवस्थापन गर्न सक्छ 2-3 एकै साथ मिक्सरहरू).

SRL-Z प्रयोग गरी मध्यम आकारको PVC पाइप निर्माता 300/600 मोडेलले वार्षिक ऊर्जा बचतको रिपोर्ट गरेको छ $28,000 र $ 45,000 को श्रम बचत - ROI मात्र मा प्राप्त भयो 10 महिना.

3. उच्च स्वचालन & प्रक्रिया पुनरावृत्ति

PLC नियन्त्रण प्रणाली सम्म भण्डारण गर्दछ 50 पूर्व-कार्यक्रमित सामग्री व्यञ्जनहरू (जस्तै, कठोर पीवीसी पाइप कम्पाउन्ड, नरम पीवीसी मेडिकल ग्रेड, ABS मोटर वाहन ग्रेड), अनुमति दिँदै:

• द्रुत सामग्री परिवर्तनहरूको लागि एक-टच नुस्खा चयन (≤15 minutes between recipes).
• Automated batch timing, तापमान नियन्त्रण, and discharge—eliminating human error in mixing parameters.
• Data logging of all batch parameters (तापमान, time, गति) for regulatory compliance and quality control audits.

This level of automation is critical for manufacturers operating in regulated industries (चिकित्सा, खाद्य प्याकेजिङ) where process traceability is mandatory.

4. Compact Design & Space Efficiency

Despite its full functionality, the SRL series features a compact, integrated design that saves factory floor space:

• Heat and cool mixers are mounted on a single frame (no separate installation required).
• Smallest model (SRL-Z 50/100) occupies just 4.14 m² (2300×1800mm) – ideal for small workshops or lab settings.
• Optional vertical design for larger models (SRL-Z 500/1000, 800/1600) reduces floor space by 30% compared to horizontal alternatives.

केस स्टडी: SRL-Z 200/500 Mixer Optimizes ABS Compounding (जर्मनी)

A German automotive component manufacturer implemented the SRL-Z 200/500 high/low temperature cold mixer in 2024 to replace outdated single-stage mixers for ABS compounding (used in interior trim components):

• Original Challenges:
  • Mixing uniformity of 85% – inconsistent color and mechanical properties in finished parts.
  • High scrap rate (12%) due to material agglomeration and moisture-related defects.
  • Manual operation requiring 2 operators per mixer – high labor costs.
  • Non-compliance with IATF 16949 (lack of process data logging).
• Results After Installation:
  • Mixing uniformity improved to 98% – 100% pass rate for color/mechanical property testing.
  • Scrap rate reduced to 1.8% – annual material savings of €32,000.
  • Labor costs cut by 50% (1 operator manages 2 मिक्सरहरू) – annual savings of €58,000.
  • Full compliance with IATF 16949 (data logging and recipe traceability).
  • उत्पादन थ्रुपुट बढेको छ 25% (छिटो ब्याच समय र परिवर्तनहरू).

प्लान्ट इन्जिनियरिङ् प्रबन्धकले उल्लेख गरे: "SRL-Z मिक्सरले हाम्रो कम्पाउन्डिङ प्रक्रियालाई रूपान्तरण गरेको छ - हामी अब लगातार उत्पादन गर्छौं, न्यूनतम फोहोर संग उच्च गुणस्तर ABS यौगिकहरू, र हाम्रो अडिट तयारी स्वचालित डाटा लगिङ द्वारा सरलीकृत छ. कम्प्याक्ट डिजाइनले अतिरिक्त एक्स्ट्रुजन लाइनहरूको लागि मूल्यवान भुइँ ठाउँ पनि खाली गर्‍यो।

स्थापना, सञ्चालन & मर्मत दिशानिर्देशहरू

1. स्थापना आवश्यकताहरू & प्रक्रिया

SRL श्रृंखला मिक्सर न्यूनतम साइट तयारीको साथ सीधा स्थापनाको लागि डिजाइन गरिएको हो:

1. साइट तयारी:
   • कंक्रीट आधार (150मिमी मोटाई) मिक्सर वजन समर्थन गर्न (2.2T देखि 7.5T).
   • बिजुली आपूर्ति: 380V 3-चरण 50/60Hz (EU/US विद्युतीय मापदण्डहरूसँग अनुरूप).
   • संकुचित हावा आपूर्ति (6-8 बार) वायमेटिक डिस्चार्ज मोडेलहरूको लागि (वैकल्पिक).
   • वेंटिलेशन प्रणाली (degassing को लागी) - स्थानीय वायु गुणस्तर नियमहरूसँग अनुपालन.
2. स्थापना प्रक्रिया:
   • कारखाना पूर्व-एकत्र फ्रेम डेलिभर गरिएको छ र जग मा स्थित छ (मोडेलहरूको लागि क्रेन आवश्यक छ >3T).
   • इलेक्ट्रिकल तार र एयर लाइन जडान (यदि लागू हुन्छ) प्रमाणित इलेक्ट्रीशियन / प्राविधिकहरू द्वारा.
   • तापमान सेन्सर र PLC नियन्त्रण प्रणाली को क्यालिब्रेसन (Zhuoyue प्राविधिक टोली द्वारा प्रदर्शन).
   • डमी सामग्री संग परीक्षण रन (क्याल्सियम कार्बोनेट) मिश्रण प्रमाणित गर्न, तताउने, र डिस्चार्ज कार्यक्षमता.

स्थापना सामान्यतया लिन्छ 1-2 साना मोडेलहरूको लागि दिन (SRL-Z 50/100, 100/200) र 2-3 ठूला मोडेलहरूको लागि दिन (SRL-Z 500/1000, 800/1600).

2. मानक सञ्चालन प्रक्रिया (SOP)

SRL श्रृंखला मिक्सर को आधारभूत सञ्चालन एक दोहोर्याउन योग्य पछ्याउँछ, स्वचालित कार्यप्रवाह:

1. PLC HMI मा पूर्व-कार्यक्रमित नुस्खा चयन गर्नुहोस् (वा अनुकूलन प्यारामिटरहरू इनपुट गर्नुहोस्: तापमान, time, गति).
2. तातो मिक्सर हपरमा कच्चा माल लोड गर्नुहोस् (म्यानुअल वा स्वचालित कन्वेयर फिडिंग).
3. Initiate the mixing cycle – heat mixer operates at set speed/temperature (electric or self-friction heating).
4. Upon completion of heat mixing, materials are automatically transferred to the cool mixer for cooling/degassing.
5. Cool mixer operates at set speed until target temperature (typically 40-50°C) is reached.
6. Automated (pneumatic) or manual discharge of mixed materials to storage hopper/extruder feed.
7. Clean the mixing chamber (वैकल्पिक, for material changeovers) using compressed air or food-grade cleaning agents (FDA-compliant).

Zhuoyue provides a detailed SOP manual (English/German/French/Spanish) with photos and step-by-step instructions for all models.

3. Preventive Maintenance Schedule

Regular maintenance ensures long mixer life (10+ वर्ष) and consistent performance:

• Daily Maintenance:
  • Inspect hopper for material bridging/blockages.
  • Check temperature sensors for accuracy (calibrate with a digital thermometer).
  • Clean discharge gate to prevent material buildup.
• Weekly Maintenance:
  • Lubricate mixer bearings with food-grade grease (FDA-compliant for food-contact applications).
  • Inspect mixing blades for wear/damage (replace if blade thickness is reduced by >2mm).
  • Test emergency stop function and safety interlocks.
• Monthly Maintenance:
  • Calibrate PLC temperature control (verify against NIST-traceable thermometer).
  • Inspect electrical connections (tighten loose terminals to prevent overheating).
  • Clean heat exchanger (cool mixer) to maintain cooling efficiency.
• Annual Maintenance:
  • Replace mixing blades (if worn) or recoat with wear-resistant tungsten carbide.
  • Overhaul motor and gearbox (replace oil, inspect gears).
  • Full system inspection by Zhuoyue technical team (includes performance testing and calibration).

Zhuoyue offers a preventive maintenance program with scheduled on-site visits (quarterly/annually) र 24/7 technical support for emergency repairs.

FAQs About SRL Series High/Low Temperature Cold Mixer

Q: Can the SRL series mixer handle recycled plastics with high moisture content?

ए: हो. The heat mixer’s drying function (electric or self-friction heating) effectively removes moisture from recycled plastics (सम्म 5% moisture content) during mixing, while the cool mixer’s degassing port eliminates water vapor. For high-moisture recycled materials (5-10%), we recommend the optional vacuum degassing upgrade to ensure complete drying.

Q: What is the lead time for custom-configured SRL series mixers?

ए: Standard models (SRL-Z 50/100 को 800/1600) have a lead time of 6-8 हप्ताहरू. Custom configurations (जस्तै, FDA-compliant contact parts, vacuum degassing, vertical design) require 10-12 हप्ताहरू. Expedited production (4-week lead time) is available for an additional 20% fee for standard models.

Q: Is training provided for operators and maintenance technicians?

ए: हो. Zhuoyue provides 1-day on-site operator training (basic operation, recipe setup, troubleshooting) and 2-day maintenance technician training (advanced calibration, blade replacement, PLC programming). Training is available in English, जर्मन, French, Spanish, and Mandarin, with hands-on sessions using your actual materials for maximum relevance.

Q: Can the mixer be integrated with a complete extrusion line?

ए: Absolutely. The SRL series mixer is designed to integrate seamlessly with Zhuoyue’s complete extrusion systems (extruders, फिडरहरू, downstream equipment). The PLC control system can be synchronized with extruder PLCs to ensure material feeding is matched to extrusion output, eliminating production bottlenecks and reducing waste.

Q: What warranty is provided for the SRL series mixer?

ए: Zhuoyue offers a 2-year warranty on all mechanical components (mixing blades, frame, discharge system) and a 1-year warranty on electrical/PLC components. विस्तारित वारेन्टी विकल्पहरू (3-5 वर्ष) are available, including annual preventive maintenance visits and priority spare parts delivery.

For nearly two decades, the SRL series high and low temperature cold mixer has been a trusted solution for plastic manufacturers worldwide, delivering precision mixing, cost efficiency, and regulatory compliance. Whether you’re compounding PVC for pipes, drying ABS for automotive components, or mixing phenolic resins for industrial applications, this mixer is engineered to meet the demands of modern plastic processing. Contact our technical team today to request a free mixing process analysis and quote tailored to your production needs.