Mixing- Brochure

1» Engineering your success «Top performance for challenging tasksHenschel Mixing Technology32Zeppelin – our name stands for willpower, innovation, proven technology and the quest for new challenges. As Count Ferdinand von Zeppelin conquered the sky more than 100 years ago with his legendary airships, the enterprise displayed above all one thing: the conviction that excellence can only be achieved by allowing visions and uniting all forces.Innovation Tradition To master processes, develop systems and know exactly what the needs of the customers are: these are the requirements for an optimal design and manufacturing of plants. Our objective is to lead in every field of business we deal with by always exhibiting top performance. We are determined to meet your needs and expectations by developing tech-nologically advanced and efficient systems.This is why a product, a plant or a complex system designed by Zeppelin will always be one thing – engineered for your success. Engineering your success Zeppelin plant engineering – business fieldsPolymer Plants Plants for plastics producers and forwarders Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry Reimelt Food Technology Plants for the food, confectionery and bakery industryHenschel Mixing Technology Mixers, extruders and compoundersLiquids Processing Plants for the beverages and pharmaceuticals industry Silos & Filters Silo technology and filters Components Diverter valves, rotary feeders, separators … Service Assembly, maintenance and spare parts54Knowledge of only single elements of a chain can mean danger of not understanding interfaces and their effects. Zeppelin Reimelt offers the complete material handling and material processing from A to Z.The center of engineering excellenceIn order to achieve considerable improvements to our customers’ products, it is not enough to only adjust technical details to the production parameters. Together with our customers, we develop completely new methods of processing and manufacturing of sensitive raw materials. Our Technology Center – Center of Engineering Excellence – holds all essential processes of mechanical process engineering – particularly those used in mixing technology – for the plastics processing and chemical industries.Preliminary results can be verified directly at our state of the art laboratory.Without our Technology Center, many innovations would not even have seen the light of day. Several standard mixing and preparation processes still in use today were invented here. Without the expertise of the Technology Center, processing resin and soft PVC in today’s quality would be unimaginable. Our consistent research efforts ensure our customers a competitive edge in the field of products such as metallic powder coa-tings, Masterbatches, battery production and ceramic powders.Our Technology Center doors are open – come in and talk to our experienced engineers. » Storage silos for bulk materials » Emptying stations for bags and big bags » Pneumatic suction and pressure conveying, secondary air conveying » Mechanical conveyers » Weighing and suction weighing systems, LIW feeders » Liquid dosing and weighing systems » Mixers and compounders » Feeding of downstream equipment » Filling stationsZeppelin Reimelt has control over the whole process of raw material handling. This is why we can integrate our mixing and compounding systems into an existing plant or even provide you with a complete plant from one single source. All essential key components have been developed and manufactured by us:» Engineering your success « Storing Conveying Weighing Mixing Dosing Automating CleaningSolutions by knowing the process76 7Before a plant goes into operation, many Zeppelin Reimelt experts were involved in the realization. All of them reliable specialists in their field of work. During process automation, for example, our IT professionals are responsible for a perfect and individual configuration, customized to your operational processes. From establishing requirement specifications and software programming to training your staff.Great minds build great plantsThe complete range of Henschel expertiseTo achieve efficient production lines with high availability and consistent product quality one should apply an appropriate system technology and a process tailored to the specific needs of the particular product. Our plants and mixers meet these requirements in system solutions for continuous and batchwise processing. Please refer to the chart for a quick overview of our main core competencies.Do you need to rent a mixer, are you looking for second-hand machines or do you need to expand your capacity due to increased demands? We can help you here as well. Whatever your needs, we’ve got the solution. So don’t hesitate to contact usThe mixers need to be installed, integrated into the process, operated, maintained and occasionally repaired. In any case, our qualified staff will provide you with outstanding services.If desired, we can also carry out the assembly work and the start of operation – and that world-wide We train your staff during installation and commissioning with competent instructions of processing and maintenance as well as safe operation procedures of the control technology. We are also there for developing the safety standards. Maintenance work, carrying out inspections and repairs as well as a 24-hour spare parts delivery are also naturally part of our procedures or services.Plastics Colors, paints, pigments ChemicalsPVC-U, PVC-PNatural fiber compositesDuroplasticsPTFEABSTechnical plasticsPolyolefinsEPSPigmentsPowder coatings and bondingsColor concentratesTonerMasterbatchInterior and ex- terior wall paintsOrganic and inor-ganic chemicalsAdditive compoundsMineralsHandlingStoring, discharging ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?Conveying ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?» mechanical ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?» pneumatic ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?» container ? ? ? ? ? ? ? ? ? ? ? ? ? ?Dosing ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?» volumetric ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?» gravimetric ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?Weighing ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?Feeding, filling ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?ProcessMixing ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?Dispersing ? ? ? ? ? ? ? ? ? ? ? ? ? ?Coating ? ? ? ? ? ? ? ? ? ? ? ? ? ?Agglomeration ? ? ? ? ? ? ? ? ?Compounding ? ? ? ? ? ? ? ? ?Granulation ? ? ? ? ? ? ? ? ? ?Conditioning ? ? ? ? ? ? ? ? ? ? ? ?Degassing ? ? ? ? ? ? ?Heating / cooling ? ? ? ? ? ? ?Sifting ? ? ? ? ? ? ? ? ?Do not hesitate to ask our qualified perso-nnel for information on our other products and processes. Our well-equipped Technology Center is also available for tests and trials.98Solutions for manufacturing and processing technical Compounds (ABS, PC, PBT, etc)Features you can rely on: » Suitable for various formulas, i.e. polymer type, fiber type and level of humidity, mixing ratio of the raw materials » Drying and compounding in one process step ensures cost-effective operation » Fully automatic operation ensures a high-ly efficient material handling processWe supply specifically designed complete systems according to the desired throughput and the type of mixer feeding. From semi-automatic feeding of components to fully automatic systems.Features you can rely on: » Direct further processing without intermediate storage » Highly precise dosing – even with the smallest concentration of powder or liquid additives » Constant and uniform wetting of the polymers up to 99.97% » Constant feeding of the Turbo Mixer – up to throughput rates of 7 t/h » Guaranteed polymer coating up to 99.97%Solutions for EPS coatingSolutions for PVC-U window profiles, pipes, sheetsIntelligent solutions for complex tasksA few exemplary solutionsSolutions for PVC-P films, cablesFeatures you can rely on: » Exact consistency of end product characteristics » Elimination of defects (fish-eyes) by adding the exact quantity of ingredients and with high dispersing capacity » Intelligent system layout for a large variety of formulasWe know the optimal raw material handling and mixing process, even for the most demanding formulas and tasks.Features you can rely on: » Minimal extrusion scrap rate due to consistent characteristics of the dryblend » Compact, space-saving construction with high specific throughput of up to 10 batches per hour » Long service life of conveying lines despite abrasive characteristics of raw materials and dryblend » Safe operation in compliance with the ATEX directive for handling additivesConsistent good dryblend characteristics with constant bulk density, color and particle size distribution are the decisive factors for manufacturing high-quality window profiles. Our turn-key concepts, from raw materials intake up to extruder feeding by including the mixing technology and its control system lead to a successful production.Solutions for wood plastic compoundsWe have been setting standards for more than 50 years and have proven expertise in processing of colors, paints and pigments, toners, chemicals, plastic compounds and minerals. We know what’s important and we have the skills to process and handle sensitive materials. No wonder our solutions are in such high demand.Features you can rely on: » Suitable for all types of formulas » Variable processes for dosing / weighing, and the quantity and number of additives » Individual addition of ingredients at defined sequences or temperatures » Processing of recycled materials1110Features you can rely on: » Production free from cross-contamination » Intelligent plant layout for large variety of formulas » Container system prevents demixing during transport » Batch tracing to ensure highest product control » Special explosion protection for maximum safety in day-to-day operationsZeppelin Reimelt has set standards in the industry by perfecting the bonding process for the production of metallic powder coatings. With high efforts on tests and trials, we have developed a process technology adapted to the specific requirements of these temperature- sensitive products. This innovation guarantees brilliant, consistent color powder coatings without demixing and ensures our customers a competitive edge on the international markets.Solutions for powder coatings » Bio-Polymers » Epoxy resin » EPDM » Pencil and color pencil compounds » Flame retardants » Fertilizers » Glass fibers » Rubber flours » Filled polymer compounds » Stearic acid and aluminum hydroxide » Magnetic compounds » Masterbatch » Melamine resins » MIM/CIM compounds » Minerals » Nitrile rubber » Phenol resins » Polyamides » Polycarbonate » Polyethylenes » Polypropylenes » PTFE » Rubber powders » TPE » Toner » Stabilizing compounds » Detergents » Cosmetic products » Battery compounds » WPC / natural fiber composites (PO and PVC based)Other applicationsSolutions for the glass industryFeatures you can rely on: » Consistent melt quality obtained through perfect mixtures » Efficient operation at a high specific throughput » High process safety with the Pneuma MixerReliably fulfilling the specific processing requirements of special and quality glass would not be possible without our Pneuma Mixer. In addition to its ex-cellent mixing quality, and because of its design, the Pneuma Mixer can also be used as a pressure vessel for con-veying the product to the downstream hoppers of the dosing units without demixing.Features you can rely on: » High efficiency even with difficult product characteristics » Safe operation due to explosion protection » Compliance with hygiene guidelines » Consistent product quality » Flexible systems engineering for a large variety of processesDosing and weighing accuracy of 0.1 – 0.05% ensures an optimal product quality when processing powdery or granulated stabilizers.Solutions for stabilizers1312High Intensity Mixer FM/MBSafety features » Explosion protection according to ATEX » Nitrogen inerting » Oxygen measurement » Available as pressure or pressure containment vessel » Explosion suppression systems » Safety housing and light barrier systems Cleaning and handling » Wall and lid scraper » CIP Systems » Non-stick coating for mixing tools » Aspiration systems » Mixer lid and discharge cylinder for easy accessProcess optimizing » Drive variations » Modified mixing tools » Application-specific safety features » Vacuum equipment » Moisture measurement » Chopper Wear protection » Mixing tools with wear protection » Tungsten carbide coated mixing bowl » Use of special steels » Ceramic coatings and linings » Air purged shaft seals Control system » Fully automatic mixer controls » Program memory for various processing steps » Formula management, security control, quality control » Batch tracingMany processing techniques would not have been possible without the specific new features in mixing and control systems. The mixers’ technical requirements are constantly redefined and adapted to the individual tasks in order to optimize our customers’ products. By choosing optional features, the Henschel-Mixers® and compounders can be tailored to the customers’ production specifications.The following features are only an excerpt of the options available. Please refer to the individual product descriptions for more details.Mixing completedOur systems have led the mixing technology for more than 50 years. Innovative detail solutions and numerous patents are proof of our competence in machine development.Laboratory Mixer FML » Universal use for mixing, coating, granulating and heating » Development of new applications and scale-up to the production machineHigh Intensity Mixer FM/MB » Universal use for mixing, coating, granulating and heating » Also used for homogenizing and coloring Universal Cooler Mixer KM » For cooling processes and homogenizing of bulk materials Horizontal Mixer HM » Product cooling and mixing processes with high throughput rates in batch operation Masterbatch Mixer MB » Friction mixer with water-cooled mixing tools for temperature-sensitive products Container Mixer CMMixing system for a wide range of applications, with transport containers for optimized handling and minimal cleaning effortsContinuous Turbo Mixer CTM » Continuous mixing and coating process with friction at a high throughputContainer Mixer Inliner CMI » Enhancement of the „Container Mixer“ concept into mixing within an inliner for outstanding mixing qualities and mini-mized maintenanceHorizontal HCE » Enhancement of the HM series » Higher throughput » Small size design » Optimized wear protection » Higher operating safetyHorizontal Mixer Food HMF » Designed to suit the specific requirements of the food industry » Easy cleaning, GMP compliant » Flexible tool kit with plough-shape or throwing paddleContainer Mixer CMUniversal Cooler Mixer KMHorizontal Mixer HMTwin-Screw Compounder1514The secret of significantly reduced power consumption lies in the use of non-contacting running twin-screw side feeders. The new fastening modules also save time when exchanging the screws. The vacuum venting system can be positioned in various places and is another good example of our flexibility in meeting our customers’ individual requirements.To ensure perfectly gentle processing and to prevent damage to the materials, we mostly avoid using kneading elements in the process.By combining our unique technology with innovative mechanical concepts, we can achieve highest product quality and still reduce power consumption considerably.These newly developed and patent pending screw elements are part of the RHC series co-rotating twin screw compounders. This system solution boosts even more innovations.Large capacity screw elements with innovative configuration of heating cartridges ensure ideal process conditions. The machine base modular design and the standard construction of the heating-cooling system facilitate cleaning and reduce maintenance work considerably.Synchronized compounding Simply goodAs an extension to the twin-screw compounders, we offer a single screw used as a discharge extruder, for example when compounding highly filled or very shear sensitive plastics. Using minimal space, its displacement of 8D process length provides continuous pressure build-up before granulation without temperature increase. Similar to the Henschel compounder RHC, effective heating performance through innovative heating cartridge configuration in combination with the efficient multi-stage cooling system keep the temperature level extremely stable during the entire compounding process.Features you can rely on: » Superior product quality even with the most demanding materials and compounding tasks » Consistent process conditions with constant capacity even when reaching wear conditions » Minimum cost of operation and energy savings of up to 30% » High availability due to low wear technology » Safe investment as the system can be adjusted to future requirements » Highest flexibility in compounding with a wide range of formulationsThe requirements for compounding systems keep getting more demanding. We provide the solutions. Our latest developement of screw elements can compound even the most sensitive materials. Specific mixing elements designed to work with minimal shear forces enable a unique processing technique for gentle compounding of all types of thermoplastics and filler materials 16www.lake-of-consens.comGlobal presence© Zeppelin Reimelt GmbH Edition 09/11 | 11-0174 Subject to modifications without notice Presented by: » Belgium » Brazil » China » France » Germany » India » Italy » Korea » Russia » Saudi Arabia » Singapore » United Kingdom » USA Zeppelin Reimelt GmbH Henschel Mixing TechnologyHenschelplatz 1 34127 Kassel GermanyTel.: +49 561 801-5889 Fax: +49 561 801-5360 Email: henschel@zeppelin.com www.zeppelin-systems.com