MIXING TECHNOLOGY | PROCESSING Achieving a better mix
The latest mixing technology developments aim to improve dispersion while minimising energy use in both compounding and blending applications, writes Mikell Knights
Developments in high-speed mixers and hybrid mixing technologies are targeting improvements in dispersion, energy efficiency, monitoring and control, providing compounders with solutions able to handle a widening array of processing types and the challenges that come with them. Continuous mixer specialist Farrel Pomini has
long argued it is the optimal technology for processing temperature sensitive materials because of the controlled levels of shear imparted into the polymer blend. The chamber and rotor cooling features permit increased heat extraction during processing as well as minimal residence time which limits thermal exposure, the company says. It adds that it sees significant feeding challenges in handling recycled materials and biopolymers which, due to their temperature sensitive nature, present difficulties that will require innovations in processing and feeding technology. The irregular shape of recycled material feed stock and the low bulk density of materials such as biopolymers are churning the wheels of developments, the com- pany says. The company’s R&D department is working on developments that improve efficiency and contrib- ute additional value for customers, citing its continuous mixer design as being well suited to applications including recyclate processing, direct mechanical recycling and chemical recycling. In
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such applications, energy efficiency of processing equipment is important not only to maintain profitability, but also to impart less specific energy into the polymer, to minimise heat history and maintain molecular structure. Farrel Pomini marked both the 175th of its formation and the 60th
anniversary of the
introduction of its Farrel Continuous Mixer (FCM) technology earlier this year. This is based on two counter-rotating, non-intermeshing rotors running within a large free volume mixing chamber. This allows for liberal material circulation and good distributive mixing, while the specialised rotor geometry enables efficient levels of shear and excellent dispersive mixing. Other key features include a single large feed
port that allows materials to be fed into the mixer separately or as a pre-blend, while liquids can be injected directly. The system is also energy efficient. “Energy efficiency is often a primary consideration when selecting compounding equipment and can be a competitive advantage for processors,” the company says.
Static improvements Co-rotating twin-screw extruders perform the main mixing task in compounding processes, where different plastic raw materials including additives, colour masterbatches, blowing fluids, or recycled
November 2023 | COMPOUNDING WORLD 51
Main image: The Promix static cooling mixer fits between
anniversary
compounder and pelletiser to improve physical and thermal
homogeneity
IMAGE: PROMIX SOLUTIONS
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