1、 Background of the establishment of the rubber mixing center

1. Existing production capacity is limited

The existing small tipping bucket internal mixer has small specifications, low configuration, and low rubber mixing efficiency. It takes 20 minutes or even longer to apply one hand of rubber, while using a falling type to apply one hand of rubber
Usually it only takes 3-5 minutes. The existing equipment production capacity is no longer able to meet the company's production needs.

2. The automation level of existing equipment is low

All small ingredients are manually mixed, which is inefficient and prone to errors. There is no information linkage between the refining and mixing equipment, and the production process relies on employee operation
This leads to high labor intensity for employees and difficulty in quality control. Under the trend of vigorously promoting intelligent manufacturing in the country, the company's existing equipment is no longer able to keep up with the situation.

3. Improvement of production environment

The ingredients, feeding, and refining are completely completed manually. Although dust removal measures have been taken on site, it is still impossible to completely avoid potential health hazards to employees.

4. Enterprise strategic upgrade

Enterprise development is like sailing against the current. If you don't advance, you will fall behind. The market is cruel, and standing still will only gradually marginalize or even eliminate the company. There are already 18 companies established
At the age of 18, it is time for young people to overcome difficulties and break through bottlenecks, standing on new steps.

Industry manufacturers consider cost and risk issues, and generally adopt the form of outsourcing processing or purchasing glue, compounded by the epidemic, trade war, raw material price increase, and overall environmental situation
Despite the severity, we have decided to invest 20 million yuan to build our own rubber mixing center.

2、 Characteristics of rubber mixing center

   1Upper auxiliary/material conveying

I. The large powder material is transported to the rooftop daily storage warehouse using positive pressure and high-pressure dense phase transportation, with high conveying efficiency and mature technology;

II. The unpacking and feeding port is placed on the second floor, eliminating the need for a four story factory building and saving construction costs;

III. Independently enclose the unpacking room to avoid dust damage to workers' health and also to avoid any impact on quality.

2Upper auxiliary/large powder weighing (oil scale)

I. Adopting a dual scale structure, one hand of material is weighed in advance in the middle bucket for backup, effectively improving production efficiency;

II. Intermediate review scale to ensure accurate match between material weight and formula, improving product quality;

III. Error prevention function, which prevents abnormal power outages or abnormal weighing from being discharged from the rear material outlet in a timely manner.

3Feeding of auxiliary/adhesive materials and small materials

I. The rubber material scale has a verification function to ensure that the feeding weight matches the formula;

II. The feeding belt is equipped with metal detection to prevent metal foreign objects from entering and damaging the equipment, which may affect the quality.

4internal mixer

I. The core equipment adopts the top domestic internal mixer brand and adopts the latest PES5 meshing rotor structure, with high mixing efficiency;

II. The mixing chamber, upper and lower top plugs, and rotor are all equipped with internal circulating water channels, which, when combined with independent temperature control devices, can accurately control the material temperature within a range of ± 5 ℃.
Rubber mixing is a temperature sensitive process, and precise temperature control will make the quality more stable;

III. Adopting hydraulic top bolt, precise control, high and stable downforce without floating;

IV. Adopting 10kV high-voltage variable frequency drive, with low energy loss, more energy-saving, and adjustable speed to adapt to various complex processes.

5Lower auxiliary/open mill

I. Adopting dual frequency conversion motors to drive two rollers respectively, the speed/ratio of the front and rear rollers can be adjusted arbitrarily, and the process adaptability is strong;

II. Both the front and rear rollers adopt a drilled structure, and the cooling water channel is close to the working surface, resulting in better cooling effect on the roller surface;

III. Hydraulic distance adjustment is adopted, with high precision and the ability to adjust the distance with the material. In case of abnormal situations, the roller distance can be quickly pulled apart within 5 seconds, making it safer;

IV. Equipped with an automatic turning device, there is no need to manually make triangular bags, reducing the labor intensity of workers.

6Lower auxiliary/film cooling

I. Adopting a hanging rod structure, with a cooling isolation agent tank and air cooling, dual cooling, the film temperature after cooling is ≤ 5 ℃ of room temperature;

II. Automatic cutting of A adhesive with automatic grabbing and stacking by robotic arm, high efficiency, labor-saving, and reduced labor intensity for workers;

III. The B glue strip adopts a mechanical arm to automatically swing the strip into the frame, which is efficient, labor-saving, and reduces the labor intensity of workers.

 7. Fully automatic small material weighing

I. The accuracy reaches ± 10g, ensuring that the weight of trace small materials meets the formula requirements, improving the quality of rubber materials, and saving costs;

II. Programmed weighing control, the equipment automatically weighs according to the input formula to prevent errors caused by human involvement;

III. High weighing efficiency, ingredient capacity of 180-240 bags/shift, able to meet the production needs of at least three lines simultaneously;

IV. Each small material is independently enclosed and weighed, equipped with independent dust removal equipment, and there is no dust on site to avoid physical harm to workers.

  8. Information quality control

Mixing realizes closed-loop control from raw materials to finished products, preparing for the next step of MES system to achieve informationization and intelligence of the entire production base

3、 Looking ahead to the future

  1. No longer troubled by insufficient production capacity

      Capacity accounting of rubber mixing center

       140L×0.65 ×1.2kg/L×10hand/h×10h×300Heaven ≈3300ton/year

     Once the rubber mixing center is built and put into operation, the production capacity will be released, and the production of products will no longer be limited by the rubber mixing capacity. Previously, orders that could be accepted but were not, and customers that could be served but were not, due to production capacity issues, will be completely resolved.

  2. Preliminary achievement of intelligent manufacturing goals

      The rubber mixing center has achieved comprehensive quality closed-loop control from raw material feeding barcode error prevention, automatic weighing and rechecking feeding, automatic flipping of sheets, and finally automatic bar stacking and pasting of traceable barcodes containing production information. The mixing process will fully realize quality closed-loop control from raw materials to finished products. Thanks to the implementation of automation, many manual intervention steps have been reduced, which will further improve product quality.

  3. Benefit employees

      Due to the implementation of automation and the rational layout of production lines, all production processes that previously required manual labor will be automatically completed by equipment, greatly reducing the labor intensity of workers.

  4. Accelerate the development of enterprises

We are well aware that the more difficult the market environment, the more opportunities for enterprise development. When others are afraid, we move forward bravely. Once the market recovers, we seize the opportunity ahead of time and develop faster than others.

All of this is just for implementation

Our Commitment

Excellent quality and accurate delivery time

Reasonable prices and thoughtful services

Article Editor: Matthew Liu