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Kneader

Your Professional Kneader Supplier

KUNYA Machinery has been continuously expanding its expertise in the mechanical design and manufacturing of dispersion kneaders, extrusion units, and pelletizing systems. Our machinery and production lines are widely utilized in various industries, including high-filler masterbatches, black and white masterbatches, color masterbatches, cable and wire compounds, general plastics, plastic modification, rubber granules, engineering plastics, and elastomers.

Professional Team
Our core team members possess over 15 years of technical experience in the aforementioned fields. They ensure optimal machinery performance through targeted design and assembly tailored to meet specific customer requirements.

Professional Solutions
With extensive industry experience and personalized one-on-one services, we assist clients in selecting suitable products and addressing technical inquiries effectively.

Efficient Transportation
We collaborate with reputable sea freight, air freight, and logistics companies to provide efficient and reliable transportation solutions for our customers.

Global Sales Market
Our market presence spans across Africa, the Americas, East Asia, Eastern Europe, the Middle East, Southeast Asia, and beyond.

Parameter

Model	KYM-75	KYM-110
Volume	75L	110L
Capacity	60-85kg/unit	100-140kg/unit
Mixing Time	5-7unit/hr	5-7unit/hr
Compress Air	0.6-0.8Mpa (6-8kg/cm²)	0.6-0.8Mpa (6-8kg/cm²)
Main Motor	AC110kw	AC160kw
Tipping Motor	AC3.75kw	AC5.5kw
Air Cylinder	φ350mm	φ420mm
Tipping Angle	125°	125°
Rotors Speed	42/33rpm	42/33rpm
Machine Weight	9200kg	1400kg
Feeding Port	Front or back	Front or back
Temp. Control Accuracy	±5℃	±5℃
Machine Dimension (mm)	3770x2140x3180	4400x2750x3770

Types of Kneader

The kneaders produced by our company mainly include the following types

Dispersion Kneader

A dispersion kneader is a type of mixer specifically designed for uniformly dispersing solid particles within a liquid or viscous medium. It's commonly used in industries like rubber, plastic, and chemical processing to ensure materials are thoroughly mixed and distributed, creating a homogenous compound.

Dispersion Kneader

Internal Kneader

An internal kneader, also known as an internal mixer or Banbury mixer, is a type of mixing machine used to knead and plasticize polymer materials like rubber and plastic. It utilizes two counter-rotating rotors within a closed chamber to evenly mix and blend materials with additives.

Internal Kneader

Advantages of Kneader

Improved Mixing Efficiency
Rubber kneaders are designed to ensure materials are thoroughly and evenly dispersed during the mixing process. Whether mixing natural or synthetic rubber with additives like fillers, plasticizers, or vulcanizing agents, rubber kneaders excel at efficient mixing. The rotor design is critical, utilizing powerful shearing and kneading actions to fully integrate materials, reducing processing time and enhancing the consistency of the mixture.

Increased Productivity
Rubber kneaders are equipped with advanced automation control systems that minimize the need for manual intervention. These systems precisely control the kneading cycle’s time, temperature, and pressure, allowing faster completion of each batch, thus significantly boosting productivity. Automation also reduces errors from manual operations, ensuring consistent and stable production processes.

Energy Savings and Cost Efficiency
With rising energy costs, companies increasingly prioritize energy-efficient equipment. Rubber kneaders use energy-saving motors and optimized rotor designs, ensuring efficient mixing while minimizing energy consumption. Precise temperature and pressure control prevent unnecessary energy waste, leading to lower production costs.

Versatility and Broad Applicability
Rubber kneaders are versatile, handling various types of rubber and additives, making them suitable for a wide range of industrial applications. They are essential not only in tire manufacturing and seal production but also in aerospace, construction, medical, and other fields. For example, in medical device manufacturing, rubber kneaders process high-purity rubber materials, ensuring products meet stringent hygiene standards.

Consistency in Product Quality
Consistency in product quality is a key measure of production success. Rubber kneaders, with their precise temperature and pressure control, ensure each batch meets expected quality standards. This capability is especially important for producing high-performance rubber products like industrial seals and highly wear-resistant tires.

Applications of Kneader

01/

Mixing and Compounding
One of the primary applications of kneader mixers in the silicone rubber industry is mixing and compounding. These mixers are used to process large amounts of silicone rubber, fillers, and other additives, resulting in a homogeneous mixture. The kneading action of the mixer provides excellent dispersion of fillers and additives, leading to a product with improved physical properties.

02/

Devolatilization
Devolatilization is another significant application of kneader mixers in the silicone rubber industry. During the production process, volatile components like solvents, moisture, and other impurities can become trapped in the rubber, leading to defects in the final product. Devolatilization is the process of removing these volatile components from the rubber.

03/

High-Filled Compounds
Kneader mixers are also used to manufacture high-filled silicone rubber compounds. These are compounds composed of a high percentage of fillers and reinforcing agents, leading to improved physical properties. The process involves mixing silicone rubber with a large amount of filler material, which requires a high mixing capacity.

04/

Pigment and Color Dispersion
The silicone rubber industry also uses kneader mixers for pigment and color dispersion. Pigments are added to silicone rubber to give it color and improve its appearance. The dispersion of pigments in silicone rubber can be challenging due to the high viscosity of the material.

Precautions for Operation of Kneader

Operators must wear work clothes, safety helmets, masks and goggles.

Before starting, make sure there is no debris in the kneader, and the pulley guard has been tightened, and the gear oil level in the reducer is between 1/2 and 2/3 of the oil level gauge. The manual kneader ensures that the rotating parts are free of abnormal noise and friction.

When starting, it should be confirmed again that there is no foreign matter in the kneader, and the kneader can be opened only after rotating the parts and staff. When starting, the kneader must be watched by a special person on site to ensure that the staff first open the circuit breaker in the power distribution room, and then open the on-site switch to close.

After starting, observe whether the current is within the range when the machine is running empty, and observe whether the operation of the mechanical transmission part is normal. If there is vibration or abnormal noise, stop checking and troubleshooting immediately.

Close the inlet and outlet valves of the cooling water pump, turn the cooling water pump flexibly by hand, and then electric the cooling water pump to see if the steering is correct. Make sure the cooling water pump is steered correctly and idling well, then open the water inlet valve of the cooling water pump. When turning on the circulating cooling water, the principle of water first and then water should be followed to ensure that the equipment shell is not squeezed and burst.

The cooling water pump of the water inlet and outlet valve of the kneader is fully opened. According to the pressure gauge on the outlet pipeline of the cooling water pump, gradually open the outlet valve of the cooling water pump to ensure that the cooling water pressure does not exceed 0.3Mpa. If the pressure gauge reacts abnormally during opening the outlet valve of the cooling water pump, the pump should be stopped immediately to replace with a new pressure gauge, and then continue the operation.

Feeding should follow the principle of "even feeding, small amount of rapid feeding", and keep continuous and uniform feeding according to process requirements.

Ordering Process

Contact with our sales to get more information about machines.

Our sales prepare proposal with machine details.

Clients confirm machine details and request sales contract with stamp & signature.

Clients arrange first payment according to contract. Then we start machine manufacturing.

We inform clients when machines ready. Clients are welcomed to visit or assign someone to join machine testing.

We arrange machines loading and delivery after receiving balance payment.

Packaging and Shipping

Packaging	Wooden box
Shipping	We will help you to choose the best shipping way according to your detail requirements. By sea, by air, or by express, etc.

Our Service

Before-Sale

● Introduce products in detail
● Recommend suitable solution

During Manufacturing

● Provide layout and engineering conditions
● Offer machine plan and related documents
● Inform the project processing status
● Insure the product designed in accordance with technical document

After-Sale

● Provide installation, commissioning and training
● Offer spare parts
● Provide necessary technical support and update information

FAQ

Q: What is a rubber kneader?

A: A rubber kneader is a specialized machine designed for the plasticating, mixing, and sometimes vulcanization processes of rubber materials. It's used to blend natural rubber, synthetic rubber, reclaimed rubber, and various additives. By subjecting the rubber compounds to intense mechanical forces, it ensures uniform dispersion of ingredients, which is crucial for achieving the desired properties in the final rubber products.

Q: How does a rubber kneader differ from a regular mixer?

A: While a regular mixer is designed for general - purpose mixing of a wide range of materials with relatively low - viscosity or less complex requirements, a rubber kneader is tailored specifically for rubber. Rubber kneaders have a more robust construction to handle the high - viscosity and elastic nature of rubber. They often feature specialized mixing elements like sigma - shaped blades or specific rotor designs.

Q: What are the main components of a rubber kneader?

A: The main components include the mixing chamber, which is where the rubber and additives are processed. Inside the chamber, there are mixing elements such as sigma - blades or rotors. These can be of different designs, like the common sigma - shaped blades that work together to knead and mix the rubber. The drive mechanism, consisting of motors, reducers, and gears, powers the rotation of the mixing elements.

Q: How does a rubber kneader work?

A: When the rubber kneader is in operation, the mixing elements (such as sigma - blades or rotors) rotate within the mixing chamber. As they turn, they grab, shear, and fold the rubber material. The shearing action breaks down the long rubber polymer chains, reducing the molecular weight and making the rubber more workable.

Q: What factors affect the performance of a rubber kneader?

A: The speed of the mixing elements significantly impacts performance. Higher speeds generally result in more intense mixing, but if too high, it can cause over - heating of the rubber and additives, leading to degradation. The temperature inside the mixing chamber is crucial. Different rubber compounds and additives have optimal temperature ranges for effective mixing.

Q: How do you clean a rubber kneader?

A: After each use, first, allow the machine to cool down if it was operating at high temperatures. Then, turn off the power and disconnect the machine from the electrical source. Remove any remaining rubber or debris from the mixing chamber using appropriate tools. A soft - bristle brush can be used to clean the walls and mixing elements. For stubborn residue, a mild solvent that is compatible with the rubber and the materials of the machine can be used.

As one of the most professional kneader manufacturers and suppliers in China, we're featured by quality products and good price. Please rest assured to buy kneader for sale here from our factory. Contact us for customized service.

high speed kneader, Dispersion Kneader, user friendly kneader

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