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Construction and Operation: 

It consists of a square/rectangle trough curved at the bottom to form two half cylinders and a saddle section. Housed in the trough are two mixing elements contrarotating towards each other.The mixing action is a combination of bulk movement,smearing,strecthing, folding, dividing and recombining as the material is pulled and squeezed against mixing elements, saddle and side walls. The mixing elements are pitched to achieve end to end circulation. Based on experience, a variety of blade configurations has evolved for different application.

Choice of Material: 

The standard material of cinstruction for contact parts is eithre Mild steel or Stainless steel to AISI-304. However if necessary, contact parts of stainless steel to AISI-316, Aluminiu,, Monel, Hastelloy, etc. can be offered.

Engineering Design: 

It is needless to emphasize that FABDECON equipment are highly engineered. Every single component is spcially designed as per good engineering practices.In case the equipment is expected to operate under pressure or vacuum, the pressure parts are designed to ASME-Sec.VIII,Div-1 Code for Pressure Vessels.

Standard Salient Features: 

  1. Container:
    This is horizontal,'w' shaped having heavy duty side plates bolted to each end.The side plates carry mounting pads for bearing housings and bear the load of the container with its content. The container is provided with a dust free cover. The cover is pivoted at the rear. When necessary an observation window complete with safety grill can be provided. The cover is electrically interlocked. withy main drive motor to prevent accidental starting when cover is open.
  2. Mixing Elements:
    Unless specified otherwise, they will be of Sigma type-tangential and two in number. The twin elements contrarotate inwards. The profile of the elements is designed to give thorough mixing and kneading action. The elements having intricate profile, are generally cast. The clearance between the container and mixing elements are maintained at 3mm, unless specified otherwise.
  3. Bearings:
    The mixing element shafts are held outside the mixing area in outrigger, by self aligning sperical-roller/angular contact ball bearings generously selected to withstand radial as well as thrust loads. The bearing are mounted seperately from shaft sealing device in rigid housings which in turn are provided with grease nipples for lubricating thye bearings.
  4. Shaft Seal:
    The passage of the rotating shafts through the stationary side plates of the container are sealed by easily replacable gland type stuffing box. These seals are designed to give tight, dust-free performance.
  5. Main Drive:
    This consists of the following elements of reputed make:
    • Motor, of type TEFC Squirrel Cage induction having specified H.P., 1440 RPM, class 'B' insulation, IP 44 protection and rated for 40°C ambient.
    • Gear Reducer, of oil immersed worm and wheel type having suitable size and ratio.
    • Connecting Element, of flexible nature as necessary, between output shaft and front mixing element.
    • Spur Gears, of adequate size and having machine cut teeth, between the front and rear blade complete with gaurd suitable for grease lubrication.
  6. Electricals:
    A control panel incorporating all electrical controls required for safe operation of mixer,shall be mounted on the machine.This shall consist of specified type starter, start-stop push buttons with indicating lamps, lable plates, control fuses, thermal motor protection relay, fitting for limit switches, reversing switch and single phase ammeter for indicating load current.
  7. Stand:
    the container complete with mixing elements, bearings, seals and drive elements are mounted on common base frame generously designed to give a vibration and noise-free composite Mixer.
    This mixer as a whole has to be mounted on a civil foundation of suitable height prepared by client to meet his discharge requirements.
  8. Discharge:
    The mixed product can be discharged by tilting the container around axis of the front mixing elements by:
    • Hand lever, manually operated or,
    • System of gears, manually operated or,
    • System of gears, motorised. In this case, the motor shall be interlocked with a pair of limit switches to control tilt angle of container and thus prevent accidents.
    • Hydraulic cylinders actuated by hydrualic power power-pack
  9. Finish:
    This being workmanship like, all internal welds are ground smooth to avoid any crevices and all unmachined exposed M.S. parts are painted with two coats of red oxide primer plus one coat of synthetic enamel paint.
  10. General Remarks:
    The equipment is supplied in such a state of readiness that it is only necessary for the client to lay it on foundation and connect the power supply to give smooth and satisfying performance.

Optional Features: 

To enhance the performance scope of the Mixer-Kneader, additional features are listed below can be incorporated at EXTRA cost:

  1. Exquisite Mixing Element, in tangential or over lapping design:
    • Sigma type elements, are best for all-round use.
    • 180°C spiral elements, provide excellent mixing for fibre reinforced products with no fibre breakdown.
    • Double Nobben Elements, produce extra shearing action required on certain material.
    • Serrated elements, to give grip on heavy and dense material.
  2. Exquisite Shafts Seals:
    • Standard type, with air purge, to prevent mixed product from entering the stuffing box.
    • Divided type, for preventing gland lubricants from entering the mixing zone in case of high vacuum operation.
    • sanitary type, for food and pharmaceutical application where completeness and ease of cleaning is a must.
    • Mechanical seal type, for applications where leakage of any sort cannot be tolerated.
  3. Exquisite Discharge Arrangement:
    Discharge of mixed product can be effected through.
    • An inbuilt extruder to discharge product in desired from facilitating easy handling.
    • Flush valves mounted on each half cylinder for easy handling of products which end up in flowable form.
    • False Botom Discharge Device for quick unloading of product and preventing pollution.
  4. Jacket:
    Normally of carbonsteel, designed to ASME code requirements, envelops the container portion other then the side plates and the cover to facilitate heating or cooling of product zone with steam, water or other media.
  5. vacuum Suitability:
    Container along with cover specially designed for vacuum service and provided with necessary connections to accomodate, vacuum pump, vacuum guage and vacuum break valve, will permit mixing or drying under controlled atmosphere specially of heat sensitive material.
  6. Flame-proof Electricals:
    Flame-proof motor as per IS 2147 suitable for gas groups IIA & IIB along with flame-proof push button stations atmosphere. Under such circumstances, the control panel, described in standard features shall be designed for remote operation through above push buttons, and it shall be mounted by the CLIENT at location outside the flame-proofarea. CLIENT shall also carryout the necessary interconnecting wiring.
  7. Abrasion Resistant Lining: The container provided with replacable wear resistant lining of TISCRAL plates and with the mixing elements' tip hardfaced, will prolong life of equipment when mixing abrasuve material like Electrode flux etc.
  8. Shredding Arrangement:
    The container provided with serrations at the bottom combined with serrations at the bottom combined with serrated mixing elements will effectively handle heavy and dense or fibrous material where tearing action is required.

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