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IKA ® Kneading

IKA Kneading 25.07.2002 8:50 Uhr Seite 2 IKA - teknol.eu · IKA® 3 Process control systems The IKA® software team is developing customer specific and tailor-made control systems,

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Page 1: IKA Kneading 25.07.2002 8:50 Uhr Seite 2 IKA - teknol.eu · IKA® 3 Process control systems The IKA® software team is developing customer specific and tailor-made control systems,

IKA®

K n e a d i n g

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Page 2: IKA Kneading 25.07.2002 8:50 Uhr Seite 2 IKA - teknol.eu · IKA® 3 Process control systems The IKA® software team is developing customer specific and tailor-made control systems,

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Vertical kneading machines

PLANETRON® heavy-duty

vertical kneading machines are

always used when high-viscous

masses have to be kneaded

intensively and absolutely free

of contaminations. During the

kneading process the product

neither touches shaft sealings

nor bearings and thus remains

absolutely free of even the

smallest contaminations.

page 6

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Page 3: IKA Kneading 25.07.2002 8:50 Uhr Seite 2 IKA - teknol.eu · IKA® 3 Process control systems The IKA® software team is developing customer specific and tailor-made control systems,

IKA®

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Process control systems

The IKA® software team is

developing customer specific

and tailor-made control systems,

from a simple PLC-control up to

fully automatic process control

systems, even with voice control.

page 10

Continuous kneading machines

The fully automatic kneading

and extrusion machine

CONTERNA, an economic alter-

native to our batch kneaders.

It is a new procedure acc. to the

functional principle of an “inline

kneader”, which already gained

acceptance for many production

processes and replaced the

batch process with its known

disadvantages.

page 8

IKA® Heavy-Duty Kneading Machines

Horizontal kneading machines

The horizontally arranged kneading blades of

the IKA®-DUPLEX and ZETA heavy-duty

kneading machines are able to process

mixtures of highest viscosities. Due to the

increased shear forces achieved by the

DUPLEX blade geometry, the kneading time

can be reduced by up to 30% – at improved

product quality.

Already in the basic execution all IKA® knead-

ing machines are equipped with useful

options and interfaces. Thus IKA® is setting a

standard for kneading machines.

page 4

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A very large viscosity range

from – for a kneading machine –

rather low-viscous glues (hot-

melts) up to extremely high-

viscous rubber mixtures can be

processed with the IKA® hori-

zontal kneading machines with

DUPLEX or ZETA blades.

The use of these kneading

blades patented by IKA® results

in a substantially improved

product homogeneity and a

saving of up to 30% of kneading

time compared to the classical

Z-kneaders.

Vacuum-tight and double

jacketed kneading bowls, high-

quality stainless steel for all

parts in contact with the product

and high-quality shaft seals with

easy access for service and

maintenance are part of the

IKA® basic equipment.

HKS / HKD

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IKA®

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Due to useful options like e.g.

discharge screw, removable

sidewall or removable kneading

bowl IKA® kneaders became the

standard machines for many

applications.

Applications

Glues (e.g. hotmelts)

Rubber masses

Plastic mixtures

Ceramic masses, porcelain

Colour mixtures

(e.g. printing inks)

Carbon pastes

Graphite mixtures

IKA® Horizontal Kneading Machines

Type Useful volume Drive power Dimensions with discharge screw,approx. (L x W x H)

I kW mm

HKD 2,5 1,75 0,75 1175 x 360 x 460HKS / HKD 10 7 1,5 / 2,2 1365 x 500 x 1350HKS / HKD 25 17 2,2 / 4 1450 x 880 x 1280HKS / HKD 50 35 4 / 5,5 1920 x 700 x 1400HKS / HKD 125 85 7,5 / 11 2070 x 1000 x 1770HKS / HKD 250 170 11 / 15 2975 x 1255 x 1890HKS / HKD 500 350 15 / 22 3400 x 1640 x 2750HKS / HKD 1000 700 37 / 37 3830 x 2030 x 3600Further sizes on request

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PLANETRON® HKV

PLANETRON® heavy-duty

kneading machines are working

with kneading blades that are only

one sided running on bearings.

Thus the product to be kneaded

does neither come into contact

with seals nor bearings, resulting

in highest product pureness.

The use of several kneading bowls

enables a semi-automatic process.

Compared to the classical plan-

etary mixer with only one drive

motor, the IKA-PLANETRON®

vertical kneading machine in the

execution with 2 drive motors

enables – additionally to the speed

adjustment – a variable adjustment

of the speed relation of the two

kneading blades. Due to this fact

also very sticky masses like e.g.

hotmelts can now be processed in

a vertical kneading machine. In

standard planetary mixers these

masses climbed up at the knead-

ing blades and were thus no more

effected by the shear forces.

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IKA®

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Frequency controlled drives,

different types of controls, vacuum

emptying system or emptying by

means of a hydraulic pressure

plate, dosing tubes and viewing

glasses represent only an extract

from the rich offer of useful

options.

Applications

Dental masses

Ceramic masses

MIM / CIM

Pharmaceutical and

cosmetic products

Plastics

Food

IKA® Vertical Kneading Machines

Very easy cleaning of the kneading

bowls and – depending on product

viscosity – discharge through a

bottom outlet valve and under

vacuum may save one or several

process steps. The product can

directly be dosed from the

kneading bowl via a transport

system into the packing unit.

IKA-PLANETRON® vertical

kneading machines are available

in many different sizes. They can

thus be used from research (e.g.

development of recipes) with mini-

mum useful volumes starting from

100 ml up to mass production with

useful volumes up to 1600 l.

Type Useful volume Drive power Dimensions, approx. (L x W x H)I kW mm

HKV 1 0,5 0,37 400 x 600 x 880HKV 5 2,5 1,1 600 x 660 x 860HKV 25 12,5 2,2 960 x 800 x 1800HKV 50 25 4 1140 x 935 x 2150HKV 100 50 5,5 1370 x 1045 x 2295HKV 200 100 7,5 1660 x 1280 x 2635HKV 400 200 11 2040 x 1570 x 3300HKV 800 400 18,5 2600 x 2320 x 4300HKV 1600 800 45 3400 x 2700 x 4550HKV 3200 1600 75 4200 x 3600 x 6000Further sizes on request

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CONTERNA HKC

An HKC 6/2,5 with 6 chambers of each 2,5 l

useful volume. This size is especially suited

for development of recipes, parameter

optimization or as a pilot plant. A machine

of this size is available for trials in the pilot

plant of the IKA® process equipment

division.

An HKC 12/10 with 12 chambers

of each 10 l volume for the

production of different silicone

rubber masses. Due to the

increased number of chambers

the optimum viscosity can be

adjusted at the end of the

kneading process.

HKC 6/50 with 6 chambers of each 50 l

useful volume. Up to 1 t/h of rubber-

masterbatch is processed in this

CONTERNA. All renowned European

masterbatch producers changed over to

this continuous production process.

Type Throughput Drive power per chamber Dimensions, approx. (L x W x H)I/h kW mm

HKC 6/2,5 10 – 80 1,5 1600 x 1480 x 1600HKC 6/5 20 – 200 3 1600 x 1550 x 2000HKC 6/10 70 – 400 5,5 1750 x 1600 x 2600HKC 6/25 120 – 1000 9,2 2600 x 1900 x 3600HKC 6/50 200 – 2000 22 3200 x 2200 x 4490HKC 6/125 500 – 4000 37 4300 x 2950 x 6100Further sizes on request Dimensions with hydraulic opening of chamber block and extruder

Since already several years the CONTERNA,

IKA®´s continuous kneading and extrusion machine,

is doing an excellent job in numerous production

processes, which in former times could only be

managed batchwise at high cost and with a great

number of personnel.

There are different industrial branches where this

so-called “inline-kneader” gained acceptance as

the standard machine within a few years. Great

profitability by reduction of kneading times and

higher product quality.

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Page 9: IKA Kneading 25.07.2002 8:50 Uhr Seite 2 IKA - teknol.eu · IKA® 3 Process control systems The IKA® software team is developing customer specific and tailor-made control systems,

Applications

Rubber masterbatches

Plastics masterbatches

Glues

Sealing masses

Food, animal food

Silicone rubber

IKA®

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IKA® Continuous Kneading

The constructional principle of the

CONTERNA allows to arrange as

many kneading chambers “in line”

as necessary for the respective

task.

There is the same variability

regarding the geometry of the

kneading blades, the execution

of the drives of each chamber, the

cooling resp. heating possibilities

and many other machine para-

meters.

The CONTERNA can replace several former

process steps, at reasonably shorter kneading

time and improved product quality. The

homogeneous repartition of the raw materials in

a finished rubber masterbatch has e.g.

been much improved compared to the

batchwise processing in piston kneaders.

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The process control system

developed by IKA® does not

only control the kneading

machine or the mixing

process itself, but also all

other process steps like

dosing and the downstream

equipment of the kneading

machine.

Together with our customers

the IKA® software team

elaborates individual

solutions.

Process control systems

10

IKA® Process Control

Schema

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Spare parts and repairs

For securing a quick and smooth

supply of spare parts, also in

case of repairs, IKA®-WERKE

is keeping a modern parts

stockroom with continuous

stock supervision.

Research and development

A well equipped pilot plant with

all necessary trial machines as

well as measuring and docu-

mentation possibilities is at our

customers’ disposal. Existing

processes can be optimized by

trials and new procedures can

be developed.

This pilot plant is of course

also intensively used by our

own design department for

optimization of existing and

development of new machines

and processes.

Quality assurance

Every single IKA® product

is submitted to a final quality

assurance control before it

leaves our workshop, in order

to test its complete function-

ality and to ensure a smooth

integration into the customer’s

production line.

11

IKA® Service

IKA®

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IKA®-WERKE GMBH & CO. KGJanke & Kunkel Str. 10 D - 79219 Staufen

Phone 49 (0) 76 33 / 8 31-0 Fax 49 (0) 76 33 / 70 87E-Mail: [email protected] Internet: www.ikaprocess.com

IKA®

subsidiaries world-wide

IKA®-WERKE

Staufen, Germany

IKA®

WORKS ASIA

Kuala Lumpur, Malaysia

IKA®

WORKS Japan

Osaka/Nara

IKA®

WORKS

Guangzhou, China

IKA®

WORKS USA

Wilmington, North Carolina

DIN EN ISO 9001Reg. Nr. 20602-01

IKA®

WORKS do BRASIL

Rio de Janeiro

IKA®-WERKE

Liaison Office India

Cochin, Kerala

KN

/06/

02-G

B

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