Views: 0 Author: Site Editor Publish Time: 2025-05-08 Origin: Site
US Customer, a leading manufacturer of industrial adhesives and sealants based in New York, specializes in formulating high-viscosity colloidal products for applications in automotive assembly, construction sealing, and electronic component bonding. Their products, which include hot adhesives and structural sealants, often reach viscosities ranging from 300,000 to 5,000,000 CPS, requiring robust mixing equipment to ensure homogeneous blends.
In 2023, the company initially purchased a 30L laboratory-scale kneader from Our company, Karvil Machinery,The leader in Chinese mixer manufacturing. To develop new formulations for their high-viscosity product line. The Lab Sigma mixer met their R&D needs, but as production demands grew, Beacon Adhesive sought a larger-scale solution for commercial manufacturing.
By 2024, they needed a production-grade kneader capable of handling 2000L batches while addressing critical technical challenges:
1. Heavy-Duty Agitator Requirement: The client asked if the kneader could be equipped with (heavy-duty blades) to withstand the extreme high viscosity by 5,000,000 CPS.
2. High-Viscosity Mixing Capability: They needed assurance that the equipment could efficiently mix materials at viscosities up to 5,000,000 CPS without motor overload or blending inefficiencies.
3. Temperature Resistance: The process required heating the colloids to 450°F (232°C) to achieve flowability, necessitating a robust heating system and material compatibility with high temperatures.
4. Power Specifications: The client required a 480V, 60Hz, 3-phase electrical system to align with their factory’s power infrastructure.
5. Lead Time: They needed the equipment delivered within 50 days to meet a tight production schedule for a major automotive client.
Karvil Machinery, already familiar with the client’s R&D setup, was prioritized for the project due to their expertise in custom kneader designs for high-viscosity applications.
Karvil’s engineering team analyze their production workflow and Key design modifications included:
• Heavy-Duty Agitator Design: Although the customer suggested heavy-duty Z-blades, the customer ultimately chose standard paddles, believing that they were more cost-effective and could meet basic mixing needs.
• High-Temperature Heating System: Electric heating of the jacket to achieve uniform temperature control, using thermal oil as the medium heating, balanced and stable
• Power supply & Voltage: Customized 480V, 60Hz three-phase power supply, in line with industrial standards, stable operation.
• Sealing method: High-temperature and wear-resistant PTFE packing (woven Teflon) combined with polytetrafluoroethylene (PTFE) seals ensure leak-proof performance under medium and high temperature conditions.?
To meet the 50-day deadline,Karvil accelerated production by:
1. Pre-ordering long-lead components (motor, gearbox) during the design phase.
2. Drawing schematics.
3. Prioritizing expedited shipping for critical components, leveraging a network of local suppliers.
The 2000L custom kneader, constructed from contact material part is SUS304 and the rest is carbon steel , features:
• Capacity: 2000L (Effective working volume 1400L).
• Heating: Electric jacket with the heat transfer oil. Electric heating power reach 72KW. The outer of screw barrel was wrapped the heater sheets to prevent ice during winter
• Agitation: Two Sigma-blades rotating speed:0-37r (fast); 0-27r (slow), (adjustable via VFD).
• Discharge: Bottom screw extrusion discharge
1. Loading: Raw materials are fed through via manhole
2. Heating & Mixing: The cylinder is heated to 450°F, and the blades engage in a counter-rotating motion or clockwise rotating, kneading the colloid for 10-20 minutes until a uniform consistency is achieved.
3. Discharge: The mixture is discharged out by screw
• Viscosity Handling: Successfully processes 5,000,000 CPS colloids with a mixing uniformity of >99.5%, as verified by viscosity testing and visual inspection.
• Temperature Control: Maintains 450°F within ±2°F, eliminating thermal hotspots that could degrade adhesive properties.
• Production Efficiency: Reduced batch time by 20% compared to legacy equipment, enabling Beacon Adhesive to increase monthly output by 300 tons.
• Safety & Compliance: Meets OSHA standards for electrical safety and noise levels, with safety devices that close the motor when the lid is opened.
their production manager, noted:
• Sigma Blades: “The reinforced Z-blades have shown no signs of wear after 1000+ batches, even with our most abrasive fillers.”
• Lead Time & Support: “Karvil Machinery delivered the kneader in 49 days—faster than promised—and their service team helped us troubleshoot a minor power supply connection issue within half an hour.”
• Scalability: The 2000L kneader complements their existing 30L unit, creating a seamless transition from R&D to full-scale production.
Impressed by the custom solution, htey have already discussed plans for a second 2000L kneader to support a new contract with a global construction firm. The success of this project highlights Karvil’s ability to engineer robust, high-temperature kneaders for the most demanding high-viscosity applications, solidifying their role as their preferred mixing equipment partner.
Contact: Karvil Machinery - www.Karvil.com / info@karvil.com