Sigma
Mixer
A heavy-duty horizontal kneader for viscous, sticky and non-flowing products. Two Z-shaped sigma blades rotate toward each other at differential speeds, working at close clearances to stretch, tear, compress, fold and repeatedly return material to the active kneading zone.
HOW THE MIXER WORKS
CHARGE
Load major and minor ingredients through the top inlet.
SECURE
Prove the t cover or quarding and all safety interlocks.
KNEAD
Twin Z blades counter-rotate at validated differential speeds.
FOLD
Material is stretched, sheared, compressed and returned to the centre.
VERIFY
Confirm the validated endpoint by time or sampling.
DISCHARGE
Stop, isolate and tilt the trough into downstream handling.
APPLICATION FIT & PROCESS VALUE
RIGHT APPLICATION
Viscous pastes and putties
Suitable for cohesive, sticky and non-flowing formulations requiring positive kneading action.
Polymer and rubber compounds
Close-clearance Z blades work dense masses and support solids incorporation after trials.
Adhesives, inks and food masses
High-torque batch kneading supports demanding formulations with controlled temperature.
DESIGN VALUE
Differential blade speed
Two Z blades rotate toward each other at different speeds for cross-kneading action.
Close-clearance working
Blade-to-wall and blade-to-blade clearances create controlled shear and tearing.
Heavy-duty torque
Robust shafts, bearings, gearbox and frame are selected for peak starting and kneading load.
CONSTRUCTION & CONFIGURATION OPTIONS
PRODUCT CONTACT
SS304 or SS316L with application-specific internal finish and weld treatment
MIXER BODY
Heavy-duty horizontal kneading trough with two parallel shafts and sigma-shaped Z blades
DISCHARGE
Manual or hydraulic trough tilting selected for batch mass and product consistency
DRIVE
High-torque geared differential drive with VFD, load monitoring and protected transmission
THERMAL DUTY
Optional jacket for controlled heating or cooling with product temperature monitoring
SAFETY
Interlocked cover or guarding, zero-speed proof, tilt interlocks and lockout provisions
DIFFERENTIAL-SPEED KNEADING CONCEPT
Two Z-shaped blades counter-rotate toward each other at differential speeds. Close blade-to-wall and blade-to-blade clearances pull viscous material into the intermeshing zone, then stretch, tear, compress, fold and return it continuously for repeatable kneading.
CONTROLLED BATCH SEQUENCE
CHARGE
Confirm outlet closed and add ingredients.
SECURE
Prove cover or guarding and tit safety interlocks.
KNEAD
Run both Z blades at validated differential speeds.
FOLD
Maintain repeated shearing, compressione and folding.
VERIFY
Confirm torque, temperature and established endpoint.
DISCHARGE
Stop, isolate and tit the trough for transfer.
CONTROL, SAFETY & MAINTENANCE
Start permissive
Mixer starts only with trough located, cover or guards proven and tilt circuit secured.
Drive protection
Current, torque, speed, bearing and temperature monitoring detect abnormal load.
Speed control
VFD control maintains validated fast/slow blade speeds, ratio and acceleration.
Safe access
Zero-speed proof and isolation are required before blade access or trough tilting.
Recipe control
Blade speeds, kneading time, jacket setpoint and discharge sequence are stored.
Cleaning access
Open trough access and controlled tilt support manual or validated wet cleaning.
STANDARD RANGE & PRELIMINARY SIZING
Screening guide for viscous pastes, putties, dough-like masses and dense compounds. Working volume is shown as a planning range; final fill level, Z-blade geometry, differential speed, peak torque, clearance, thermal duty and discharge must be validated for the formulation.
|
MODEL
|
WORKING VOLUME
|
GROSS VESSEL VOLUME
|
BATCH MASS AT 1.0kg/L
|
WORKING FILL RANGE
|
DISCHARGE OPTION
|
TYPICAL DUTY
|
|---|---|---|---|---|---|---|
|
SM-25
|
12-18 L
|
25 L
|
12-18 kg
|
50-70%
|
Manual tilt
|
Lab / pilot
|
|
SM-100
|
50-70 L
|
100 L
|
50-70 kg
|
50-70%
|
Tilt
|
Pilot/small batch
|
|
SM-250
|
125-175 L
|
250 L
|
125-175 kg
|
50-70%
|
Hydraulic tlt
|
Production
|
|
SM-500
|
250-350 L
|
500 L
|
250-350 kg
|
50-70%
|
Hydraulic tilt
|
Production
|
|
SM-1000
|
500-700 L
|
1,000 L
|
500-700 kg
|
50-70%
|
Hydraulic tilt
|
Heavy duty
|
|
SM-2000
|
1,000-1,400 L
|
2,000 L
|
1,000-1,400 kg
|
50-70%
|
Engineered
|
Heavy duty
|
PRELIMINARY SIZING BASIS
BATCH MASS
Mass = working volume x product density
Example: 500 L x 1.0 kg/L = 500 kg
Use actual density at charging condition
CYCLE CAPACITY
Batches/h = 60/total cycle minutes
Include charge + knead + verify + discharge
Do not size from kneading time alone
WHAT CONTROLS THE FINAL SELECTION
Rheology
Initial and final viscosity, yield stress, tack, elasticity and temperature response.
Kneading objective
Ingredient incorporation, dispersion target, endpoint test and permitted shear.
Mechanical duty
Gross batch mass, peak torque, shaft deflection, bearings and transmission load.
Blade selection
Sigma geometry, differential speed ratio, close clearances and product release.
Thermal duty
Heat generation, jacket medium, heating, cooling, vacuum and inerting requirements.
Hygienic duty
MOC, surface finish, shaft seals, access, cleaning method and validation standard.
FINAL ENGINEERING CHECK
Confirm rheology and batch data
Define endpoint and test
Complete representative trial
erify peak torque and tilt duty
Agree FAT acceptance criteria
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