SRL500/1000 High-Speed Mixer Unit

Key Features of the SRL500/1000 High-Speed Mixer Unit

Innovative Mixing Technology

• High-speed hot mixer (SRL500) paired with efficient cooling mixer (SRL1000) for rapid thermal exchange, enabling short batch cycles and stable bulk density.
• Precision rotor geometry with multi-level blades creates strong vortex flow, intensive shear, and micro-dispersion for consistent color and additive distribution.
• Optimized hot/cold ratio ensures fast gelation and deagglomeration while preventing thermal degradation and yellowing.

Materials and Build Quality

• Contact parts in SS304/SS316L optional; heavy-duty bowl with mirror-polished interior reduces residue and cross-contamination.
• Wear-resistant blade tips and reinforced bearing seats extend service life for abrasive fillers like CaCO3, TiO2, and glass beads.
• Double-lip mechanical seal and PTFE labyrinth for dust-tight, maintenance-friendly operation.

Process Engineering and Controls

• PID temperature control with high-accuracy RTD probes for stable setpoints during heating and cooling phases.
• PLC + HMI touch panel (Ethernet/IP, Modbus-TCP) with recipe management, batch traceability, alarms, and interlocks.
• Automatic feeding options: screw feeder, vacuum loader, and loss-in-weight dosing for resin, stabilizers, and pigments.
• Integrated dust extraction ports and optional inline filter keep work environment clean and compliant.

Applications and Industries

Building Materials and Construction

• PVC pipe and fitting compounds, cable conduit, window profiles, SPC/WPC flooring base, and CaCO3-filled masterbatch.

Furniture and Interior

• PVC edge banding, decorative film, rigid foam board formulations, and wood–plastic composites.

Automotive and Electrical

• Cable insulation and sheath compounds, automotive interior trims, sealing profiles, and under-hood accessory components.

Packaging and Consumer Goods

• Rigid packaging sheets, thermoforming grades, appliance parts, and color masterbatch for injection and extrusion.

Technical Specifications of SRL500/1000

Performance and Capacity

• Nominal hot mixer volume: 500 L; working volume: 60–70% depending on formulation.
• Cooling mixer volume: 1000 L with high-efficiency jacketed design.
• Typical batch size: 120–180 kg (PVC compound, formula-dependent).
• Cycle time: 6–12 minutes per batch (heating + cooling), enabling 800–1500 kg/h line throughput.

Mechanical Configuration

• Hot mixer drive: high-torque motor with frequency inverter, rotor speed up to 1200–1500 rpm (configurable).
• Cooling mixer drive: robust motor with optimized paddle design for fast heat extraction.
• Discharge: pneumatic or manual quick-release valve; optional inline sieve and magnet drawer.
• Sealing and bearings: heavy-duty bearing group with forced lubrication and dust barrier.

Controls and Connectivity

• PLC/HMI with recipe storage, batch counters, and quality events logging.
• Safety: lid interlock, over-temperature shutdown, motor overload protection, emergency stop.
• Connectivity: Ethernet/IP or Modbus-TCP for plant SCADA/MES; remote diagnostics ready.

Energy and Utilities

• Installed power (typical): 75–110 kW for hot mixer, 7.5–15 kW for cooling mixer (varies by configuration).
• Specific energy: optimized kWh per ton via VFD and intelligent temperature ramping.
• Air and dust extraction: DN150–DN200 ports for central dust collector; 0.5–0.7 MPa compressed air for actuators.

Note: Exact parameters may vary by recipe, options, and regional standards. Custom engineering available.

Customer Case

User Recognition and Market Validation

Customer Feedback

• Consistent batch-to-batch homogeneity reported by converters in PVC profile and pipe plants, reducing on-line adjustment and scrap.
• Noted 10–20% cycle time reduction versus legacy mixers due to improved blade geometry and heat exchange.
• Maintenance teams highlight easy access for cleaning, fewer seal changes, and reliable bearings under high-load, high-temperature duty.

Representative Case Studies

• Building profiles producer: boosted line throughput from 1.0 t/h to 1.3 t/h with stable gelation index and color consistency.
• Cable compounder: improved dispersion of stabilizers and flame retardants, lowering speck defects by 35%.
• WPC board manufacturer: achieved uniform filler distribution at higher filler ratios, maintaining surface quality and screw feeding stability.

Market Competitiveness

• Balanced CAPEX with premium process control, delivering lower total cost of ownership through energy savings and uptime.
• Flexible options (materials, drives, feeders) fit diverse formulas and regulatory needs in global markets.