A PVC High-Speed Heater Cooler Mixer Machine (often called a Hot & Cold Mixer) is a specialized two-stage compounding machine used primarily in the plastics industry. It blends raw PVC resin with necessary additives—such as heat stabilizers, plasticizers, lubricants, fillers (like calcium carbonate), pigments, and processing aids—into a homogeneous, moisture-free, extruder-ready dry blend. 1. Primary Function & Working PrinciplePVC resin cannot be extruded or molded in its raw state; it requires uniform dispersion of additives and pre-heating to drive off absorbed ambient moisture. [Raw Materials: PVC, Stabilizers, Fillers, Pigments]
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│ STAGE 1: HOT MIXER │
│ • High Speed: 500 – 1500 RPM │
│ • Heating: High friction raises temp to 110-120°C│
│ • Functions: Moisture removal & additive fusion │
└────────────────────────┬────────────────────────┘
│ Automatic Pneumatic Discharge
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┌─────────────────────────────────────────────────┐
│ STAGE 2: COOLER MIXER │
│ • Low Speed: 30 – 100 RPM │
│ • Cooling: Water jacket drops temp to 40-50°C │
│ • Functions: Prevents agglomeration & thermal │
│ degradation before storage │
└────────────────────────┬────────────────────────┘
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[Ready-to-Use Dry Blend for Extrusion / Injection Molding]
2. Main Components & Structural DetailsA. High-Speed Heating Mixer (Hot Chamber)Mixing Vessel / Bowl: Constructed from high-grade Stainless Steel (SS304 / SS316) to resist abrasion and chemical corrosion. Highly polished inner surfaces prevent material sticking. High-Shear Blades: Specially angled 2-blade or 3-blade assemblies rotated by a heavy-duty electric motor.Heating Mechanism: Primarily powered by frictional heat generated by intense mechanical shear at high RPMs (500–1500 RPM). Supplementary electrical jacket heaters are used for initial pre-heating. Deflector Plate: Directs the vortex flow of material downward to ensure thorough circulation throughout the vessel.Pneumatic Discharge Valve: A bottom-discharge pneumatic door opens automatically upon reaching set temperature parameters to transfer the hot blend into the cooling unit. B. Cooling Mixer (Cold Chamber)Cooling Vessel: Features a significantly larger volume than the heating chamber (often 2x to 2.5x capacity) to allow rapid thermal expansion and surface-area contact.Water Cooling Jacket: Double-walled vessel construction circulating chilled or cold water to draw heat away efficiently.Low-Speed Agitator: Large, sweep-type paddle blades operating at slow speeds (30–100 RPM) continuously move material against the cold jacketed walls without generating friction heat.Exhaust & Ventilation: Integrated with dust extraction ports to discharge residual water vapor released from the hot compound.C. Control & Electrical SystemAutomation (PLC & HMI): Microprocessor or PLC-based control panels with touchscreen interface for recipe management, temperature setpoints, timed cycles, and batch tracking. Safety Interlocks: Emergency stop switches, lid limit switches (preventing blade rotation while open), motor overload protections, and temperature cut-offs.3. Key Specifications (Standard Range)Technical ParameterHeating MixerCooling MixerMaterial ConstructionStainless Steel (SS304/SS316)Stainless Steel (SS304)Operational Speed500 – 1500 RPM30 – 100 RPMTarget Temperature RangeAmbient to 110°C – 120°C120°C down to 40°C – 50°CHeating/Cooling MethodFrictional Shear + ElectricalWater Jacket CoolingCommon Capacity Ratios100 L, 200 L, 300 L, 500 L200 L, 400 L, 600 L, 1000 LBatch Capacity Range25 kg to 1000+ kg per batchMatches heating mixer volume4. Primary Industrial ApplicationsPVC Pipe & Fitting Manufacturing: UPVC, CPVC, and Flexible PVC pipe extrusion lines.PVC Profiles & Doors: Window/door profiles, wall paneling, and trunking.Cable & Wire Compounding: Insulation sheath material mixing (plasticized PVC compounds).WPC / SPC Flooring & Sheets: Wood-Plastic Composite and Stone-Plastic Composite board manufacturing.Masterbatch & Granule Compounding: Color masterbatch and resin compounding lines.5. Main Advantages Eliminates Moisture & Bubbling: Drying out moisture prevents voids, structural defects, and surface marks during final extrusion. Homogeneous Dispersion: Ensures uniform distribution of additives and liquid plasticizers into the porous PVC resin matrix. Prevents Agglomeration: Rapid controlled cooling stops hot resin particles from fusing into large lumps. High Output & Efficiency: Short cycle times (typically 8–15 minutes total per complete batch) support continuous production plant operations.
│
▼
┌─────────────────────────────────────────────────┐
│ STAGE 1: HOT MIXER │
│ • High Speed: 500 – 1500 RPM │
│ • Heating: High friction raises temp to 110-120°C│
│ • Functions: Moisture removal & additive fusion │
└────────────────────────┬────────────────────────┘
│ Automatic Pneumatic Discharge
▼
┌─────────────────────────────────────────────────┐
│ STAGE 2: COOLER MIXER │
│ • Low Speed: 30 – 100 RPM │
│ • Cooling: Water jacket drops temp to 40-50°C │
│ • Functions: Prevents agglomeration & thermal │
│ degradation before storage │
└────────────────────────┬────────────────────────┘
│
▼
[Ready-to-Use Dry Blend for Extrusion / Injection Molding]
2. Main Components & Structural DetailsA. High-Speed Heating Mixer (Hot Chamber)Mixing Vessel / Bowl: Constructed from high-grade Stainless Steel (SS304 / SS316) to resist abrasion and chemical corrosion. Highly polished inner surfaces prevent material sticking. High-Shear Blades: Specially angled 2-blade or 3-blade assemblies rotated by a heavy-duty electric motor.Heating Mechanism: Primarily powered by frictional heat generated by intense mechanical shear at high RPMs (500–1500 RPM). Supplementary electrical jacket heaters are used for initial pre-heating. Deflector Plate: Directs the vortex flow of material downward to ensure thorough circulation throughout the vessel.Pneumatic Discharge Valve: A bottom-discharge pneumatic door opens automatically upon reaching set temperature parameters to transfer the hot blend into the cooling unit. B. Cooling Mixer (Cold Chamber)Cooling Vessel: Features a significantly larger volume than the heating chamber (often 2x to 2.5x capacity) to allow rapid thermal expansion and surface-area contact.Water Cooling Jacket: Double-walled vessel construction circulating chilled or cold water to draw heat away efficiently.Low-Speed Agitator: Large, sweep-type paddle blades operating at slow speeds (30–100 RPM) continuously move material against the cold jacketed walls without generating friction heat.Exhaust & Ventilation: Integrated with dust extraction ports to discharge residual water vapor released from the hot compound.C. Control & Electrical SystemAutomation (PLC & HMI): Microprocessor or PLC-based control panels with touchscreen interface for recipe management, temperature setpoints, timed cycles, and batch tracking. Safety Interlocks: Emergency stop switches, lid limit switches (preventing blade rotation while open), motor overload protections, and temperature cut-offs.3. Key Specifications (Standard Range)Technical ParameterHeating MixerCooling MixerMaterial ConstructionStainless Steel (SS304/SS316)Stainless Steel (SS304)Operational Speed500 – 1500 RPM30 – 100 RPMTarget Temperature RangeAmbient to 110°C – 120°C120°C down to 40°C – 50°CHeating/Cooling MethodFrictional Shear + ElectricalWater Jacket CoolingCommon Capacity Ratios100 L, 200 L, 300 L, 500 L200 L, 400 L, 600 L, 1000 LBatch Capacity Range25 kg to 1000+ kg per batchMatches heating mixer volume4. Primary Industrial ApplicationsPVC Pipe & Fitting Manufacturing: UPVC, CPVC, and Flexible PVC pipe extrusion lines.PVC Profiles & Doors: Window/door profiles, wall paneling, and trunking.Cable & Wire Compounding: Insulation sheath material mixing (plasticized PVC compounds).WPC / SPC Flooring & Sheets: Wood-Plastic Composite and Stone-Plastic Composite board manufacturing.Masterbatch & Granule Compounding: Color masterbatch and resin compounding lines.5. Main Advantages Eliminates Moisture & Bubbling: Drying out moisture prevents voids, structural defects, and surface marks during final extrusion. Homogeneous Dispersion: Ensures uniform distribution of additives and liquid plasticizers into the porous PVC resin matrix. Prevents Agglomeration: Rapid controlled cooling stops hot resin particles from fusing into large lumps. High Output & Efficiency: Short cycle times (typically 8–15 minutes total per complete batch) support continuous production plant operations.
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