Equipment
High-speed compounding mixer (turbomixer / heating mixer) with high-shear aerodynamic fluidizing impeller for PVC dry-blending, masterbatch pre-mixing, and mineral filler coating.
Overview
Delivers high-intensity aerodynamic vortex fluidization, frictional self-heating, and precision dispersion for PVC dry-blends, masterbatch pre-mixing, and mineral filler surface modification.
The Compounding Mixer (also widely designated as a High-Speed Mixer, Turbomixer, or Heating Mixer) is a high-intensity, aerodynamic vortex mixing system engineered for the rigorous demands of plastic compounding, masterbatch manufacturing, and PVC dry-blend preparation. Unlike conventional low-shear horizontal ribbon blenders or vertical paddle mixers that merely homogenize bulk materials, the high-speed compounding mixer rotates precision multi-tier impeller blades at peripheral tip speeds exceeding 25 to 35 m/s. This generates an intense, three-dimensional fluidizing vortex that rapidly fluidizes powders, micro-pellets, and liquid additives in complete suspension.
Through severe particle-to-particle attrition and high-shear mechanical impact against the vessel wall and deflector baffle, the machine converts mechanical rotational energy directly into internal frictional heat. In typical processing cycles (such as PVC formulation dry-blending or mineral filler coating), the batch temperature rapidly climbs from ambient up to 110°C–130°C within 6 to 12 minutes without requiring external heating elements. This controlled frictional self-heating expands polymer pores, drives off residual surface moisture, and facilitates complete, streak-free absorption of liquid plasticizers, stabilizers, and functional coupling agents.
Depending on production formulations and downstream processing requirements, the compounding mixer is deployed in two principal industrial configurations:
Widely utilized for color masterbatch pre-mixing, filler surface modification, and engineering plastic compounding. Ultrafine mineral powders (such as calcium carbonate, talc, or titanium dioxide) are charged together with carrier polymer powders, lubricants, and silane/stearic acid coupling agents. High-speed vortex shear breaks down agglomerates and uniformly encapsulates mineral surfaces with the functional coupling agent, ensuring superior dispersion and melt homogeneity in downstream twin-screw compounding extruders.
The industry benchmark for PVC pipe, profile, cable, and vinyl sheet extrusion plants. The system couples an upper vertical high-speed heating mixer with a lower high-efficiency horizontal or vertical cooling mixer. Once the hot batch reaches its preset plasticizer absorption temperature (typically 115°C–125°C), the pneumatic flush-radius discharge valve opens instantly, transferring the hot blend into the cooling mixer. Utilizing chilled water jackets and low-speed ribbon/paddle agitators, the cooling mixer rapidly reduces blend temperature down to 40°C–45°C. This critical cooling phase prevents thermal degradation, stops plasticizer sweating, and eliminates electrostatic agglomeration, producing a perfectly free-flowing dry blend ready for pneumatic conveying, storage silos, or direct extruder feeding.
Key features
Each picture names one part of the machine and what it does for the material and the batch.
Multi-tier aerodynamic impeller blades cast from high-tensile wear-resistant alloy steel and dynamically balanced. The lower propeller sweeps the vessel floor, the intermediate fluidizing blade creates intense cross-shear, and the upper deflectors induce a high-velocity fluidizing vortex, maximizing particle collisions and rapid frictional self-heating.
Double-walled vessel construction fabricated with mirror-polished SUS304 stainless steel interior (Ra ≤ 0.4 µm). Incorporates internal baffles (deflectors) with embedded PT100 temperature sensors that project directly into the circulating powder stream for real-time thermal monitoring.
Precision multi-stage shaft seal combining mechanical labyrinth rings, PTFE braided packing, and compressed air purge. Positively prevents micro-fine mineral powders and liquid plasticizers from migrating downward into the heavy-duty thrust bearing pedestal.
Double-acting pneumatic cylinder actuates a curved discharge plug that fits perfectly flush with the vessel's internal wall, completely eliminating stagnant unmixed dead pockets and ensuring clean, instantaneous batch emptying in 10 to 20 seconds.
Dual-channel lid sealing ring prevents dust weepage during high-speed fluidization. Pneumatically assisted lid lifting and 90° horizontal swiveling mechanism with dual electrical safety limit switches cuts motor power immediately if the vessel cover is opened.
Siemens PLC coupled with an industrial color touchscreen HMI. Stores multiple mixing recipes, monitors motor amperage and real-time batch temperature, and automatically controls two-speed switching, liquid injection, and pneumatic discharge sequencing.
Material and process
Read the conditions together: a machine is selected for the material and the output, not from its name alone.
Engineered for high-intensity, high-shear dry blending, surface modification, and thermal conditioning across plastics compounding, masterbatch production, and polymer processing industries.
Specifically optimized for challenging powder, granule, and liquid dispersion tasks across multiple industrial processes:
High-shear thermo-mechanical pre-mixer; operational boundaries include:
Accepts dry polymer powders, micro-pellets, regrinds, mineral fillers, and liquid processing aids, including:
Ingredients can be charged manually via bag-dump hoppers or automatically via vacuum pneumatic loaders. Raw materials must be free of ferrous tramp contaminants, agglomerated rock-hard caked lumps, and unyielding foreign debris.
Delivers a perfectly homogeneous, highly dispersed, free-flowing dry blend or surface-coated powder compound:
Throughput
Read a figure together with the basis below it: the same machine reaches different numbers on different materials.
Figures denote the effective batch working volume (typically 65% to 75% of total vessel volume) required to establish a full fluidizing vortex without material overflowing or suffocating the impeller. Usable batch mass (kg/batch) is governed by formula bulk density, filler loading percentage, and resin type:
Models
The figures are the reference values entered for each model. The model for your line is confirmed against your material and output before it is quoted.
Scroll the table sideways to read every column →
| Model | Total volume (hot/cold) | Effective volume (hot/cold) | Speed (hot/cold) | Mixing time | Motor power (hot/cold) |
|---|---|---|---|---|---|
| NC-G200 | 200/500 L | 150/320 L | 950/130 r/min | 8-12 min | 45/11 kW |
| NC-G300 | 300/600 L | 220/420 L | 950/100 r/min | 8-12 min | 55/11 kW |
| NC-G500 | 500/1000 L | 375/650 L | 860/70 r/min | 8-12 min | 75/15 kW |
| NC-G800 | 800/2500 L | 560/1600 L | 740/50 r/min | 8-12 min | 110/22 kW |
| NC-G1000 | 1000/3000 L | 750/2250 L | 680/60 r/min | 8-12 min | 160/37 kW |
Scope of supply
The quotation states the scope for the confirmed configuration; the groups below describe how a supply is normally split.
Installation planning
These are the connections the machine and the line around it have to agree on before the layout is fixed.
Mechanical: Rigid steel base frame anchored to level concrete floor or elevated mezzanine platform; top charging ports (DN150–DN250) compatible with vacuum loader receivers and manual dumping hoods; pneumatic discharge gate flange (DN150–DN250) connecting to cooling mixer chute, screw conveyor, or mobile transition hopper.
Electrical & Automation: Three-phase industrial power supply terminated at the free-standing control console; auxiliary terminal interface for interlocking signals with upstream auto-batching systems and downstream cooling mixers/extruders.
Pneumatic & Water: Dry, clean compressed air supply (0.5–0.7 MPa) for lid lifting, cylinder discharge, and shaft air purge; cooling water connection (BSP/NPT flanges, 12–18°C) for the cooling mixer jacket or hot mixer jacket cooling.
The buyer provides a reinforced level concrete industrial floor or mezzanine steel platform capable of handling dynamic rotational loads and vibration, main electrical supply cabling routed to the primary breaker in the control console, continuous cooling water supply (12–18°C, 0.2–0.3 MPa) piped to the cooling mixer jacket inlet/outlet manifolds, compressed dry air line (0.5–0.7 MPa) for pneumatic lid and discharge valve actuation, and downstream storage bins or pneumatic conveying receivers.
Spare parts
The parts that wear in normal service, and the spares worth keeping on site. How often a part is replaced depends on the material and the duty the machine runs, so the basis is confirmed for each machine.
Inspect blade leading edge weekly; replace or re-hardface when blade tip erosion exceeds 5–8 mm or when batch heating time increases by > 25%.
Set of dynamic rotating blades (bottom scraper, intermediate shear blade, top deflector). Primary high-wear component. Keep one spare dynamic-balanced set in stock.
Inspect air purge pressure daily; replace PTFE packing rings and labyrinth wear sleeves every 1,500–3,000 operating hours or immediately if dust leakage appears below the drive deck.
Shaft seal assembly preventing powder/liquid ingress into bearing housing. Critical for preventing bearing seizure and contamination.
Inspect during monthly maintenance; replace if cut, hardened, or leaking fine powder.
High-temperature elastic profile seal fitted around the flush-radius discharge plug. Prevents fine powder and liquid additive leakage during high-speed fluidization.
Replace every 6 to 12 months or if dust weeping occurs around the vessel rim during high-speed mixing.
Perimeter sealing gasket for the main vessel lid. Ensures dust-tight sealing under high internal aerodynamic pressure.
Grease periodically with high-temperature synthetic grease; replace upon vibration, temperature anomaly, or every 12,000–16,000 operating hours.
Precision heavy-duty cylindrical roller and angular contact ball bearings supporting the vertical impeller drive spindle under extreme dynamic loads.
Inspect quarterly; service piston seals or replace solenoid valves if actuation delay occurs.
Pneumatic cylinders for vessel lid lifting/swiveling and discharge gate opening/closing.
Blades, screens and other normal consumables are outside the standard warranty. How a spare part is identified and ordered is set out under Warranty & Spare Parts.
Selection
Work through what you already know. The rest is settled in the conversation, not before the first message.
Selecting the optimal compounding high-speed mixer requires evaluating recipe rheology, thermal goals, hourly output, and downstream cooling requirements:
Request a Quote A model name, a material or a drawing is enough to start.
Tell us the material, the process and what you need to achieve. Technical details can be completed later together with our sales team.
