XK-550 Type Rubber Mixing Mill with 100kg Batch Capacity and 1500mm Roll Working

Product Specification

The XK-550 Type Rubber Mixing Mill With A Production Capacity Of 100kg Per Batch, 

Here's a detailed breakdown of what this system is, how it works, and its role in a rubber manufacturing plant.

Overview: The "One-Two Punch" of Rubber Mixing

This setup is a two-stage mixing process:

1. Stage 1: The 110L Kneader (Intermixer) - For intensive mixing, blending, and plastication.

2. Stage 2: The XK-550 Open Mixing Mill - For final mixing, homogenization, and sheet-down.

This is a more modern and efficient alternative to using only a large open mill for the entire mixing process, which is more labor-intensive, time-consuming, and less consistent.

1. The 110L Rubber Kneader (The Workhorse)

• Function: This is a batch-type internal mixer. It performs the initial, high-intensity work of incorporating various ingredients (polymers, fillers, oils, chemicals) into a uniform mass.

• How it Works: It consists of a sealed, jacketed chamber with two counter-rotating, intermeshing rotors. The shearing and kneading action inside the closed chamber ensures thorough dispersion of carbon black, silica, oils, and other additives.

• Key Features:

  • Capacity: 110 Liters. This volume refers to the total chamber volume. The typical "fill factor" is 0.6 to 0.75, meaning the actual batch weight of rubber compound is usually between ~65 kg and 80 kg.

  • Efficiency: It mixes much faster than an open mill for the initial stage, saving time and energy.

  • Quality: Provides superior dispersion of powders, leading to a more consistent compound.

  • Environment: Enclosed design contains dust and fumes, improving the working environment.

2. The XK-550 Open Mixing Mill (The Finisher)

• Function: This machine receives the masterbatch from the kneader for final mixing, homogenization, cooling, and forming into sheets.

• How it Works: It consists of two parallel, counter-rotating rolls. The friction between the rolls (different speeds and temperatures) generates high shear stress, which further blends the compound and adjusts its viscosity.

• Key Features:

  • Size: The "550" typically refers to the roll diameter in millimeters (550mm or ~22 inches). The roll length (e.g., 1500mm) determines the batch size capacity.

  • Capacity: Rated for 100 kg per batch, which is well-matched to the output of the 110L kneader (after accounting for the kneader's fill factor, multiple kneader batches might be combined on the mill for a single final batch).

  • Versatility: It is used for:

    • Dumping: Receiving the hot mass from the kneader.

    • Blending: Mixing different masterbatches or adding sensitive curatives (like sulfur) that cannot withstand the high heat of the kneader.

    • Sheeting: Forming the mixed compound into a continuous, uniform sheet of specific thickness for easy handling and feeding to the next process (e.g., calendering or extrusion).

    • Cooling: The large surface area of the water-cooled rolls helps bring down the compound temperature.

The Typical Workflow in a Plant

1. Weighing: All raw materials (natural/synthetic rubber, carbon black, zinc oxide, stearic acid, process oils, antioxidants, etc.) are precisely weighed according to the recipe.

2. Loading & Mastication: Rubber is loaded into the kneader first to soften it (mastication).

3. Intensive Mixing: Powders and liquids are added in a specific sequence to the kneader. The machine runs for a set time or until a target energy/temperature is reached.

4. Dumping: The mixed "masterbatch" is dumped from the kneader, often directly onto a conveyor that feeds the XK-550 mill.

5. Final Mixing on the Mill: The operator works the compound on the mill, repeatedly cutting and folding the sheet to ensure final homogenization. At this stage, curatives (sulfur, accelerators) are added.

6. Sheeting & Cooling: The final compound is passed through the mill rolls to form a smooth sheet. This sheet is then run through a cooling system (e.g., a cooling water bath or festoon cooler) to prevent premature vulcanization.

7. Storage/Feeding: The cooled sheets are stacked or cut for storage or directly fed to downstream processes like extrusion, calendering, or molding.

Advantages of This Combination

• High Productivity: The kneader handles the slow, intensive part quickly, while the mill handles the finalizing and sheeting.

• Excellent Compound Quality: Achieves good dispersion and consistency, which is critical for product performance.

• Labor Optimization: Reduces the heavy manual labor required if the entire mix were done on an open mill.

• Process Control: Allows for precise control over mixing temperature, time, and energy input.

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• Technical parameters

• model	XK-450	XK-550	XK-560
  roller diameter	450mm	550mm	560/510mm
  roller working length	1200mm	1500	1500
  front roll linear speed	24.5	27.94	27.87
  frictio ratio of roller	1:1.27	1:1.22	1:1.2
  motor	55	110	90
  Batch capacity	25-50	50-60	50-60
  machine size	5200*2380*1770	5900*2680*2080	6500*2300*2000
  machine weight	about 12000 kg	27000 kg	19500 kg

Industries and Applications

This specific setup is commonly found in plants manufacturing:

• Tire Components (tread, sidewall, inner liner)

• Automotive Rubber Parts (hoses, belts, gaskets, seals)

• Industrial Rubber Products (conveyor belt covers, rubber linings, rollers)

• Footwear (soles)

• Dense, technical rubber products requiring high-quality mixing.

In summary, the 110L Kneader + XK-550 Open Mill is a robust, industry-standard combination that provides an excellent balance of productivity, quality, and versatility for a serious rubber product manufacturing facility.