The working principle of a plasticator is mainly based on shear and rheological theories. Through strong shearing, stirring, and mixing actions on the materials, the molecular chains between material particles are broken and reorganized, changing the molecular structure and thus achieving the effect of plasticizing and mixing. The following is a detailed introduction to the working process and the functions of key components of internal mixers and open mixers:

Internal Mixer

• Workflow ：
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  • Material Loading First, the materials that need to be mixed and plasticized are added to the material inlet of the internal mixer. For example, in the production of rubber products, raw rubber and various compounding agents (such as vulcanizing agents and accelerators) are prepared in a certain proportion and then put into the internal mixer.
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  • Heating The internal mixer is equipped with a heating device. Heating brings the materials to the required temperature, softening or melting them for subsequent mixing operations. For example, when processing some harder plastic raw materials, heating allows them to enter a plastic state faster.
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  • Mixing When the material reaches the predetermined temperature, the mixer (rotor) of the internal mixer starts to rotate. It uses the regular contraction of space generated during its relative motion to generate shear force, performing strong shearing, impact, stirring, and mixing on the material. This allows the material to achieve plasticization and mixing under high temperature and high pressure. Taking the mixing of rubber raw materials in automobile tire production as an example, the raw rubber and various compounding agents are fully mixed in the internal mixer through this process, with various components evenly distributed in the rubber matrix, improving the comprehensive performance of the rubber.
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  • Material Discharge After the mixing process is completed, the discharge door of the internal mixer is opened to discharge the mixed material. The discharged material is usually a viscous mass; for example, common rubber is in this state after mixing, and often requires further processing with an open mixer.
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  • Cooling and Cleaning After discharging, the inside of the internal mixer needs to be cooled and cleaned for the next mixing and plasticizing operation, ensuring the normal use of the equipment and the stability of the quality of the next mixed product.
• Key Components and Functions ：
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  • Mixing Chamber This is the main working part of the internal mixer. It has a mixer (rotor) and a heating device inside, providing a closed space environment for material mixing and plasticizing, ensuring that the mixing process takes place under relatively stable conditions, preventing material spillage and the mixing of external impurities.
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  • Mixer (Rotor) As a key component of the internal mixer, its shape is generally pear-shaped in cross-section and Z-shaped helical along the longitudinal direction, and the speeds of the two rotors are slightly different. There is a fixed speed ratio between the rotors and between the rotors and the inner wall of the mixing chamber. Through its own rotational motion, it produces strong shearing, impact, stirring, and mixing effects on the material, enabling the material to achieve mixing and plasticization.
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  • Heating Device It can heat the material to the required softening or melting temperature. According to the different material properties and process requirements, it accurately controls the temperature range to meet the mixing needs.
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  • Transmission Device Used to drive the mixer (rotor) to rotate, ensuring that it operates at the set speed and rotation mode, providing stable power support for the mixing process.
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  • Discharge Device After mixing, it can smoothly discharge the mixed material from the internal mixer, ensuring that the discharge process is fast, smooth, and can completely discharge the material.