Since last twenty five years, the Kneaders have become the most commonly used type of 'mixer' in the rubber industry. Dispersion Kneader is energy efficient, maintenance-friendly, labor and time saving machinery that offers consistent quality of rubber mix compound at higher output as compared to an open mixing mill – thus making it truly Your Friend in 'Knead' for your rubber processing plant.

1. DISPERSION
KNEADER
Your Friend In ‘Knead’
Machinery
World
Rubber & Tyre Knowledge On-The-Go Special Supplement
http://rubbermachineryworld.com

3. For many years, open mill mixing has been the
preferred form of mixing rubber. But then
technology has been evolving.
Thus came mixers and the major considerations had
always been cost. Since last twenty five years, the
Kneaders have become the most commonly used type
of 'mixer' in the rubber industry.
This popularity, prompted us to showcase Kneaders
specifically in this Knowledge On-The-Go Special
Supplement.
Though developed initially for mixing thermoplastics,
Dispersion Kneaders have a unique place in the
elastomer mixing industry. Users love the ease of
cleanliness on this machine especially when they have
to change the colour of their compounds frequently.
Dispersion Kneader is energy efficient, maintenance
friendly, labour and time saving machinery that offers
consistent quality of rubber mix compound at higher
output as compared to an open mixing mill – thus
making it truly for your rubberYour Friend in 'Knead'
processing plant...
I hope you agree and find this special supplement
informative.
As always, I welcome your feedback on
rubbermachineryworld@gmail.com.
BestRegards
Prasanth Warrier
| Editor’s Note |
Your Friend In ‘Knead’ Is A True
Friend Indeed
Since last twenty
five years, the
Dispersion Kneaders
have become the
most commonly used
type of 'mixer' in the
rubber industry.
3
rubbermachineri
rubbermachineryworld
+Rubbermachineryworld1
grp/home?gid=8252803
rubbermachineri
Special Supplement - Rubber Machinery World NOV 2015|

4. 4
| DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
Image: Hevea Engineering Works (HEW) Make Rubber Dispersion Kneader

5. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
5
DISPERSION
KNEADER
For many years, open mill mixing has been the
preferred form of mixing rubber. But then
technology has been evolving, your customers
expectations growing - sustaining quality without
compromising on cost, reducing wastage,
extracting more out of available time has all been
additional challenges that you come across in day-
to-day operations.
Thus came mixers and the major considerations
had always been cost.
In the world of rubber mixing, when 'purists' refer
to 'mixer', they either mean a Tangential Rotor
Type (Banbury®) Mixer or a Intermeshing Rotor
Type (Intermix®) Mixer.
While 'practitioners' have a third category viz.
Rubber Dispersion Kneader.
When discussing with the practitioners (mostly in
Asia) you will hear the terms 'Kneader Banbury',
'Kneader Mixer', 'Kneader Intermix', 'Intensive
Mixer Kneader', 'Internal Mixer Kneader',
'Dispersion Mixer', 'Tilt Mixer' etc.
So, what is this dispersion kneader?
Prasanth Warrier
Your Friend In ‘Knead’

6. 6
| DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
To start with, a kneader
means a machine that
specializes in kneading
substances, something
to a dough form.
I suspect it originates
from Germany when
Heinz List, a pioneer of
modern industrial
processing technology,
first developed a
kneader reactor to
process high viscosity
materials.
Nilesh Parikh, Director
of Microquick
Engineers, says “In
Kneader, the production
of compound increases by
40 to 50 per cent than that
of mixing mill. The batch
preparation time could be
between 10 to 15 minutes.
The compounding takes
place normally with a
mastication time of 3 to 5
minutes and filler
compounding time of 7 to
10 minutes.”
Applications of Kneader
Though developed initially
for mixing thermoplastics,
Dispersion Kneaders have
a unique place in the
elastomer mixing industry.
Image: Bharaj Make 110 Liters Kneader For Export to USA.
Users love the ease of
cleanliness on this machine
especially when they have
to change the colour of their
compounds frequently.
Informs Kulwant Singh
Manpotra, Director of
Modern Machines,
manufacturers and
exporters of Rubber
Machinery “Kneaders are
easy to operate, ensure
uniform dispersion of
compounds and can be
employed in a wide
assortment of material
mixing ranging from low
viscosity adhesives to high
viscosity rubber.”
Dispersion Kneaders have
efficient cooling mechanism
through jacketed
construction. This, in turn,
improves the mixing
dispersion and prevents
your rubber compound
from scorching by
facilitating low
temperature mixing.

8. 8
| DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
Their varied applications
include
- Oil seal, Body seal, Belt,
Gasket, Hose, Tube for
Automobiles
- Rubber for Electric
wires
- Conveyor Belts & Power
transmission belts
- Rubberized Rolls
- Rubber based products
like Plug, Cap, Glove,
Dental for Medical line
- Sporting goods like
rubber ball, etc
Construction of Kneader
The construction comprises
of a hopper with ram,
mixing chamber with dust
seals, pressure lid, rotors
(blades), tilting mechanism
to facilitate discharge,
gearbox, motor-controls.
Operating Principle of a
Dispersion Kneader
The concept of mixing
inside Kneader is
essentially a carry forward
of what happens in Two-
Roll mills. This means that
there is friction between
two rotors (similar to rolls
in mills) to aid mixing.
However, here it happens in
a closed environment.
Introduction of ram pressure
forces the material into the
chamber and hence the
rotors. The Kneader with its
uniquely designed rotors,
rotor blades, mixing chamber
and pressure lid allows for
thorough material flow and
controlled shear mixing
within the mixing chamber.
Nilesh Parikh says, “The
differential rotation of
rotors; Helical, Wide width
of rotor wings and clearance
of rotors gives excellent
pressing/shear/tear/folding/
stretching/smear of
ingredients of compound.
This leads to the best
kneading effect and
promotes the uniform
dispersion of fillers”.
The production of compound increases
by 40 to 50 per cent than that of mixing
mill.
Nilesh Parikh
Director, Microquick Engineers
Image From Web

10. 10
| DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
Highest quality mixing with minimum
time has been a major push force for
regular technology developments.
Kneaders have come a long way. They
have evolved from shabby mixing rooms.
Amardeep Singh Bharaj
Director (Sales)
Bharaj Machineries Pvt. Ltd.
Evolution and Technology
Developments in Kneader
Since last twenty five years,
the Kneaders have become
the most commonly used
type of 'mixer' in the rubber
industry.
“Highest quality mixing with
minimum time has been a
major push force for regular
technology developments.
Kneaders have come a long
way. They have evolved from
shabby mixing rooms and
are respectfully placed in
air-conditioned areas” says
Amardeep Singh Bharaj,
Director (Sales) of leading
rubber machinery
manufacturer, Bharaj
Machineries Pvt Ltd.
He further adds, “Efficient
dust proof systems and
technology has made the
compounding room a
matter of pride. Hydraulic
rams and lid designs for
controlled dispersion effect,
automatic stage mixing
features for consistent
compound, PLC controlling
systems with energy-
efficient variable frequency
drives.”.
Image: Bharaj Make 75 Liters Kneader For Japanese Co.

12. 12
| DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
Rotors
Traditional Kneaders have
two counter rotating rotors
with each rotor having two
wings affixed on it.
The two wing rotors rotate
at different speeds
facilitated through
connecting gears. The wings
move your rubber material
from one portion of the
chamber to the other while
also providing material
movement along the rotor
axis.
Conventional Kneaders
have a one piece rotor
design which includes a
rotor shaft with two long,
high and narrow wings
welded on the shaft.
Water cooling is provided
through a passage in the
rotor shaft and small
jackets in each wing in
traditional kneaders. This
cooling method is not
sufficient for single pass
mixing.
Explains Amardeep Singh,
“In terms of mixing
technology and usage, there
is major development
happening in the Kneader
rotor. Rotor designs have
changed with cooling
channels for better and
quick mastication. For
example, Bharaj has
specially developed
tri-blade rotors where
mixing with highest
quality dispersion effect
is achieved with a 15%
reduction in the mixing
time.”
Opines Tom C. Abraham,
Director of the leading TSR
processing machinery
manufacturer Hevea
Engineering Works Pvt.
Ltd. “Introducing
peripheral cooling to the
rotor improves the mix
quality”.
Hevea Engineering Works
has recently launched their
Image: Microquick Engineers.
Image of Rotors
For example, Bharaj Machineries has
specially developed tri-blade rotors
where mixing with highest quality
dispersion effect is achieved with a 15%
reduction in the mixing time.
Amardeep Singh Bharaj
Director (Sales)
Bharaj Machineries Pvt. Ltd.

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14. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
range of Kneaders, expand-
ing their engineering
competence from TSR
processing machinery.
Validates Tom C. Abraham
on their unique advantage
to benefit customers “We
have our own rubber
processing unit where we
test our machinery. We
continuously innovate and
improve our machinery
based on our experience
and customer feedback.”
Intermeshing type of rotors
in Kneader imparts
superior dispersion during
the kneading process. This
advancement is similar to
those observed in
Intermix® Rotors that have
a rotor shaft with two nogs
(small blades) for mixing.
The materials are subjected to
a larger smearing action of
the batch against the rotor tip
to chamber wall as well as the
rotor tip to rotor shaft.
Informs Nilesh Parikh, “The
new kneader has much wider
land width and stubby in
shape. The wide rotor tips
enhance the dispersion effect.”
Intermeshing rotors have a
much larger outside diameter
than conventional kneader
rotors. This allows for more
cooling surface as well as
larger mixing surfaces.
The cooling circuit is
designed inside wing of
rotors and all around mixing
chamber. The result is
quality compounding at less
temperature even at high
rate of production.
Hopper and Feed Area
Conventional Kneaders use
pneumatic pressure to push
the batch down into the
rotors and mixing chamber
with a floating weight (ram).
This pneumatic system is
unreliable and inconsistent.
The pneumatic ram moves
completely uncontrolled and
the ram position is
controlled by the rotor
dragging force as well as the
size of rubber pieces it is
trying to force into the
rotors. The hydraulic ram
exerts positive pressure on
the batch and can be
accurately controlled in the
desirable position which
leads to better batch to batch
consistency.
Introducing peripheral cooling to the
rotor improves the mix quality. We have
our own rubber processing unit where
we test our machinery. We continuously
innovate and improve our machinery
based on our experience and customer
feedback.
Tom C. Abraham
Director
Hevea Engineering Works Pvt. Ltd.
14

15. Manufacturing, Supply, Erection
and Commissioning of New
- Dispersion Kneaders
- Mixing Mills
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- Extruders
- Hydraulic Presses
Repair Services of Old Machinery.
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16. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
is required for mixers
with drop door.
Customization & Automation
A standard Kneader
construction can be usually
considered for all applications.
However, it is the
accompanying automation
that makes this machinery
customized to its users.
Confirms Amardeep Singh,
“As per customer products
and demands, Kneaders are
offered with various
options. For example, in
case of hard to process
rubber compounds heavy
transmissions gearboxes
and motors are used. For
high friction rubbers
temperature controlling
systems are provided to have a
grip on quality by providing
efficient cooling and
maintaining consistent
temperature. Automatic
sequence stage wise mixing
through PLC is also highly
effective.”
A standard Kneader construction can be
generally considered for all applications.
Emphasizes Amardeep
Bharaj, “A Hydraulic system
ensures zero maintenance
compared to geared designs;
enhancing the life of the
equipment with better
mixing and minimum
downtime.”
Adds Tom C. Abraham,
“Earlier the feeding and
discharge were done from
the front side. Now, feeding
is done from the rear side,
and discharge to the front
side, which allows for better
automation and efficiency.”
Discharge Mechanism
Observes Tom C. Abraham,
“In kneaders, hydraulic
tilting mechanism has
largely replaced the worm
gear type mechanism.
Instead of the tilting
mechanism, a drop door
mechanism can be
introduced, which would
allow for better automation
and accessory equipments
such as the skip conveyor
may be eliminated.”
This is particularly
interesting as the kneader
tilts 125-140 degrees to
discharge the batch unlike
a batch mixer that
discharges the batch
through a bottom drop-
door.
However, this drop door
mechanism could dilute
the widely broadcasted
advantage i.e. Kneaders
can be positioned on the
ground level.
While a mezzanine floor
Image: Tilt Discharge Mechanism
(Moriyama Make Kneader)
16

18. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
He further recommends the
standard Kneaders for
customers starting new
and/or shifting from
primitive mixing on two-roll
mills, so that they can learn
the art of mixing the
compounds on the Kneaders.
And then improvise with
better upgrades in future.
Explains Ashutosh
Chincholikar, Business
Head of Smart Controls
India Ltd, “Mixing
Automation today has
changed significantly.
Earlier, recipe-based
weighing and mixing was
considered ultimate. But
now we talk of a Mixing
Room Automation. We today
have Advanced Process
Control giving higher
efficiency and better batch-
Mixing Automation has changed
significantly. We today have Advanced
Process Control giving higher efficiency
and better batch-to-batch uniformity in
spite of the varying properties of your
raw material.
Ashutosh Chincholikar
Business Head
Smart Controls India Ltd.
to-batch uniformity in spite
of the varying properties of
your raw material.”
This has helped the users
in terms of a more efficient
and integrated system that
can be completely managed
from one room.
Smart Controls India Ltd is
pure integrators and their
solutions are based on state
of the art products from
Siemens. They have an
ability to integrate almost
any kind of control system
with their Mixing Line
Controls based on Siemens
18

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20. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
platform. He further adds
“We understand the Mixing
Machinery very well, be it
Mixing Machinery,
Upstream or Batch off. We
possess good skills on IT
integration as well. So the
Mixing solution can be
connected to the business
If the kneader is structurally sound,
reconditioning is okay. Provided the
major components like rotor, chamber,
and bearings etc supports within the
price expectations of reconditioning.
Kulwant Singh Manpotra
Director
Modern Machines
platforms like SAP or Oracle.”
Is Kneader Reconditioning
Recommended?
Reconditioning, timely
maintenance and service is
the most important factor for
longevity of any rubber
machinery's life. And I
suppose, it is the same with
Dispersion Kneaders too.
However, the varying
opinion amongst
manufacturers is interesting.
Nilesh Parikh of Microquick
Engineers does not
recommend reconditioning
because it is expensive to
replace the major
components and he feels
there would be drop in
kneader performance.
While Kulwant Singh
Manpotra of Modern
Machines calls for a cautious
approach. “If the kneader is
structurally sound,
reconditioning is okay.
Provided the major
components like rotor,
chamber, and bearings etc.
Image: A Rebuild Kneader (From Web)
20

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22. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
supports within the price
expectations of
reconditioning.”
Tom C. Abraham of Hevea
Engineering Works feels
“It is easy to replace/
refurbish the worn out
parts, such as rotor,
chamber etc. So if the
kneader is structurally
sound, reconditioning is OK.
However, it will not be
possible to change the
feeding side, or change
the tilt mechanism with a
simple reconditioning.”
Amardeep Singh of
Bharaj Machineries says
“there are times when due
to continuous running and
fatigue factor of machines,
some parts wear-out
effecting the productivity
of the machine and thus
causing various energy
losses, product quality
issues, increased cycle
times and sometimes
contamination of rubber
with worn out parts.
Upgrading the electrical
features and
reconditioning with
available technology will
ensure that the equipment
runs trouble free with
optimum results.”
When it comes to reconditioning, you
need an expert diagnosis of the condition
of your machinery to evaluate the pros
and cons of refurbishing or upgrading.
The bottom line is that when
it comes to Kneader
reconditioning, you need a
expert diagnosis of the
condition of your machinery
to evaluate the pros and cons
of refurbishing or upgrading.
And then make an informed
trade-off between your costs
versus performance
expectation.
Differences between Kneader
and Mixer
The respective rotor, throat,
chamber and floating weight
designs are different in a
dispersion kneader and batch
mixer (or internal mixer).
Kneaders are available in more
customized capacities than
batch mixer and can be
Image: Modern Machines Make Kneader Working At A Plant.
22

23. KELACHANDRA MACHINES
(MFRS. OF RUBBER INDUSTRIAL MACHINERY)
Chingavanam - 686 531, Kottayam, Kerala. India.
Phone Off: +91- 481-2430325. Fax: +91- 481-2430596
e-mail: km1912@gmail.com

24. | DISPERSION KNEADER |
Special Supplement - Rubber Machinery World NOV 2015|
positioned on the ground
level.
For similar capacities,
Dispersion Kneaders use
lower power than mixer.
The mixing time is higher
than an internal mixer and
hence production volumes
are lower in kneader.
Over a period of time,
kneader manufacturers
have developed designs,
features and automation
for high quality and
optimum mixing
performance to position
them closer to the internal
mixer. Yet, a kneader is
different from an 'internal
mixer' and should be
viewed contextually
during your discussions to
avoid the confusing
terminologies corelating
them to mixer (that I
outlined in the start).
Summarizing, Dispersion
Kneader is energy efficient,
maintenance friendly,
labour and time saving
machinery that offers
consistent quality of
rubber mix compound at
higher output as
compared to an open mixing
mill – making it truly your
Friend in 'Knead' for your
rubber processing plant.
RMW
Image: Internal or Batch Mixer (Left) and Dispersion Kneader (Right).
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