EMKAY ENGINEERING WORKS was established in 1975 and designs, develops and manufactures industrial process equipments, chemical process equipments catering to the need of process industry.
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Emkay Neoplast Fluidizing Mixers

HIGH SPEED COMPOUND MIXERS are high speed mixers use to mix solid to liquid and pasty components. It is simple physical mixers where the heat generated due to friction is utilised for mixing & hence known as "HOT MIXING". The material may be sintered, agglomerated, dired, degassed or hot coloured.

Flow Deflector
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Optimum Setting of charge path and mixing process.
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rapid homogenisation.
Temperature probe
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measures temperature of material precisely
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self clicking & Sealed housing design to avoid material infilteration to bearings
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Most efficient V belt drive with motor sliding device to give highest performance and easy installation of belts.
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low slipage
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ensures full energy transfer
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low maintenance


 
     
 

HIGH SPEED COOLING MIXER which is placed in line with HEATER MIXER receive the hot mixer there from HEATER MIXER which cools it down at maximum temperature where it can be stored safely.

The cooling cycle is always shorter then the heating cycle. The special designed tool throws the material on the large contact surface of vessel including conical hollow ring of S.S. to decrease the cooling cycle.

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increase in cooling surface
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reduction in cooling time through forced circulation of mixing charge
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easy fitting to remove mixing tool
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water connection fixed out side to have moisture free mix.
Jacket for cooling with circulation of cooling water.
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Optimum dimensions of cooling surface
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intensive cooling of the mixed material
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cooling in line with heater mixer.
     

A matching cooler mixer for every heater mixer.

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Versatile in use.
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adopted to the process technology requirements. Various type of mixing charge, batch size and number of batches.
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matually balanced heating and cooling capacity.

Summation of the individual features and corresponding advantages of heater mixers and cooler mixers.

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prourable, dry, cooled mixes.
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no deposits or pocket of colour.
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rapid and perfect cleaning.
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complete discharge of the mixed material.
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optimum dispersion and distrubution of the components of the mixer.
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increase in bulk density of compound the results in higher production.
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low compound cost.
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higher production rate with clean environment.
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easy material handling.

Mixer combination can be supplied as individual machines.

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transportation and fitting are simple.
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adoptability to the customer's process technology and available space.
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customer can budget their project in staggered purchase.
 
     
 

It is a combination to obtain a high quality, homogenous mass production with economical cost. Hot mixer will attain the required temperature in short period with homogeneous mixing and cooler mixer receive the discharge. Due to efficient and latest technique, the compound is cooled to a temperature in shorter time then the hot cycle. Discharge of cooler becomes ready to deliver to a feeding line.

Dual speed Motors which is for
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quicker and higher batch production.
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higher tool speed.
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on load start.
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lower power consumption.
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compact size of machine.
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optimum setting of cycle time, temperature and mixing process.
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easy on load during loading of raw material, lequid additives.
    Light Lid & discharge valve
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opening by pneumatics.
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easy cleaning and discharge of raw material.
Roating parts dynamically balanced for
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longer life, vibration free operations.

Optional chopper arrangements
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agglomerate size can be chosen.
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avoids lump formation.
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high digree of dispersion.
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homogenisation of the mixing charge.
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optimisation and shortending of the mixing process.
Compact reduction gear drive
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slow speed tool drive.
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noiseless working.  
Shovel shaped stainless steel mixing tool
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maximum cooling efficiency.
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uniform cooling of mixer.
Light lid swivel type construction.
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easy cleaning.
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short bach change time.
     

TECHNICAL - SPECIFICATION
High Speed Compound Heater / Cooling Mixers

Heater/Cooling Mixer    
Sr.No.
Moden No.
Container Capacity in ltrs.
Container batch capacity (PVC Resin plus Additives in Kgs)
Production capacity of Dry Blend/hr. in kg. Based on 5 batches per hr.
Drive in KW
Motor speed in R.P.M
Tool speed in R.P.M
Suitable Suggested Cooler mixer
Weight in kgs.
1
2
3
4
5
6
7
8
9
10
1.
HSM-10
10
2.5
12.5
2.2/3.7
15/3000
750/1500
CM-40
120
2.
HSM-10 V
10
2.5
12.5
3.7
variable
50-1500
CM-40
160
3.
HSM-130 A
130
28
140
12/15
1500/3000
500/1000
CM-400
650
4.
HSM-130 B
130
35
175
15/18.5
1500/3000
500/1000
CM-400
750
5.
HSM-130MB
130
40
200
15/18.5
1500/3000
500/1000
CM-400
750
6.
HSM-200R
200
60
300
26/31
1500/3000
500/1000
CM-400
750
7.
HSM-200
200
65
325
32/38
1500/3000
500/1000
CM-600
1100
8.
HSM-250
250
85
425
38/46
1500/3000
500/1000
CM-600
1800
9.
HSM-350
350
120
600
49/67
750/1500
430/860
CM-600 or 1000
2100
10.
HSM-500
500
160
850
72/100
750/1500
430/860
CM-1200 or 1500
3000
11.
HSM-750
500
190
950
83/115
750/1500
430/860
CM-1500 or 2000
4000
12.
HSM-1000
1000
390
1950
75/150
750/1500
335/670
CM-2000 or 3000
6500
13.
HSM-1200
1200
500
2500
140/190
750/1500
300/600
CM-3000
7000
     

Heater/Cooling Mixer

   
Sr. No.
Model No.
Container Capacity in ltrs.
Charge batch capacity in kgs.
Production capacity
Drive in KW
Tool Speel in R.P.M.
Quantity of Cooling water/reqd. m3/hr
Cooling Surface M2
Weight machine kgs
1
2
3
4
5
6
7
8
9
10
1.
CM-40
40
4
20
0.75
150
1.0
0.6
175
2.
CM-400
400
55
275
3.7
72
2.5
3.0
850
3.
CM-600
600
160
800
5.0
72
3.0
5.5
1250
4.
CM-1000
1000
200
1000
7.5
60
3.5
6.5
1750
5.
CM-1200
1200
300
1500
11.0
60
3.75
8.5
2500
6.
CM-1500
1500
350
1750
11.0
55
4.0
12.0
2800
7.
CM-2000
2000
500
2500
25.0
50
5.0
14.0
3000
8.
CM-3000
3000
750
3750
37.5
45
5.0
18.0
4000
 

The data given are approximate and for general calculations. Various tool designs can be provided for various application.

  1. Charge batch capacity is based on rigid formulation of PVC.
  2. Production capacity is based on 5 batches/hr. and final temperature of 115°C for hot mixer and batch time of 8 minutes. For cooler mixer batch time of 8 minutes and depends on cooling water temperature and pressure. Pressure should not be more then 1.5 kg/cm2 maximum. Final drop temperature of mix 45°C to 50°C
 
Robust, easily serviceable and maintained construction. - long life
- low noise level
- maintenance and repair takes little time.
Freely programmable controls. - optimum adoptability to process technology requirements.
- constant high quality of the mixed material.
Bottom curvatured vassels. Jacketed stainless steel container - corrosion, chemical and abrasion resistance.
- mirror polished
- high efficiency and homogeneous mixing.
- heating & cooling facality.
- adoptability to different type of mixing charge.
Vessel discharge palte high gloss-polished. Inside discharge Plate matches bottom dish. - no deposit, crusts or pockets of colour.
- rapid and complete discharge of the mixed material.
- easy and perfect cleaning.
For different process requirements the right type of mixing tool. - special tools for special application on request.
- mixing tool self cleaning, adjustable in height.
- simpale design and abrassive resistive coating on edge.
- easy, rapid removal and refitting.
- high digree of filling achievable up to 90%.
- 6-8- batches per hour for hot mixing.
- higher tool life.
- optimum dispersion of the components of the mixture.
- optimum adoptibility to each type of mixing charge and size of charge.
 

RANGE OF PRODUCTS :

HIGH SPEED HEATER FLUIDIZING MIXERS SUTABLE EXTRUSION DIES FOR PLASTIC INDUSTRIES
COOLER MIXERS MATERIAL CONVEYING SYSTEM
COMBINTION OF HIGH SPEED HEATER COOLER MIXERS AUTOMATIC WEIGHING & FEEDING SYSTEM
RIGID PVC PIPE PLANTS AUTOMATIC BAGGING MACHINE
PVC BLOWN FILM PLANTS DIEFACE CUTTER
SINGLE SCREW EXTRUDERS PNEUMATIC CONVEYING DOSING EQUIPMENTS
CONICAL TWIN SCREWS EXTRUDERS COMPUONDING EXTRUDERS
PVC REINGORECED FLEXIBLE BRAIDED PIPE PLANTS CUSTOM MADE MACHINES FOR SPECIAL PLASTIC PRODUSTS.
PVC PROFILE PLANTS
 
ACCESSORIES
 
 

EXTERNAL HEATING ARRANGEMENT WITH THERMIC FLUID POWER PACK OR ELECTRIC HEATER FOR MIXER VESSEL/CONTAINERS, CLOSED CIRCUIT OIL HEATERS.

Close circuit oil heaters are available for additional cooling/Heating arrangement of mixer Jacket in order to get longer/shorter batch time for certain compounds.

This is the sometime required for special application like drying, degassing etc.

Maximum system pressure will be 2 to 3 kg/cm2 write up available.

     

AGGLOMERATE CRUSHER

Suited for batches with high plasticizer contents which are very likely to from lumps. It will have a separate drive, fitted to side wall fo cooler mixer. Brings high dispersions.

Granule size can be chosen exactly to avoid lump formation, Optimisation and shortening of the mixing process useful, in the pharmaceutical food stuffs, animal feeds, paint and chemical industries.

 
     

VARIABLE SPEED DRIVE FOR MAIN HEATER MIXER MOTOR.

Variable speed will bring you advantage like.

  1. Formulation adoptibility.
  2. Liquid additives -Filler additives at slow speed.
  3. load control - Heat Control shearing of material control.
  4. Sweeping actions.
  5. Control of starting on load current.
  6. Short batch time.
  7. High efficiency - lesser electricity bill.
  8. Optimum utilization of installed motor power.
  9. Versatibility of feeding of material at desired speed. Detailed write up available on request.
     
 

COOLING OF MIXING TOOLS

Sapecifically developed for the preparation of master batches to achieve maximum dispersion. Equipped with intensive cooling reching into the tool baldes to avoid deposits fo material. It will also require for Heat sensitive materials.

     

COMPOUND SIEVING VIBRATION SCREEN ARRANGEMENT/ROTATING SCREEN ARRANGEMENT

The screeners are filled directly from a sack or they are mounted below a filling hopper or under the cooler mixer discharge valve. It can be also mounted under the silos. They are used for :
- Control screnning .
- Protection screening.
- Separation fo foreign particles.
- Disintegration of lumps.
- Aeration of products.

 
     

ELECTRONIC SOFT START FOR MOTOR CONTROL


This electronic unit will control full load starting current of the motor to 3 tims Full load current which will help mixers running on low maximum demands and aslo on generators. It will also dampen voltage fluctuation. It will give safety to electronic devices in the factory.
     
 

DIFFERENT DESIGNS OF TOOL FOR VARIOUS APPLICATION THE CORRECT MIXING TOOL FOR ALL FIELD APPLICATION

Various tools are available for :

  1. Extremely high shearing forces.
  2. Exceptionally good vortex with light bulk materials.
  3. Standered tool (two tierd) a fluidizing blade set which can be adjusted in high Frictional heat rises with a higher setting and decreases with a lower setting.
    (Adaptation of the tool to the particular mixing problem)
  4. A special tool for mixing and colouring of polyolefins.
  5. Additional Horn shaped rotor improves in the case of container filled to a high level.
  6. Special tool for preparation of master batches to achieve maximum dispersion and with a minimum of shear wear.
     

ROATING SCRAPER BLADE

Revolving wall and lid scrapper to avoid deposits of the mixing charge and crusts in case of pasty like material and with high dosage liquid additive compound (Highly ionicized compounds).

This will keep the side wall and lid of HEATER MIXER clean by scraping clogged material Scrapper material can be selected as per customer's requirement.

 
     
 

AUTOMISATION OF ELECTRIC CONTROL PANEL WITH VARIOUS INTER LOCKS AND AUTOMATIC PROCESS CONTROL PROGRAM CONTROL/SYSTEM LOGIC PROGRAMMABLE UNITS. (PLC)

Entire Compounding activity can be automised by logic programmable unit which will be useful to the most stringent process technology requirements. Various factors can be considerd like control via temperature or time, if desired also via current taken or power taken, switch over from manual to automatic, more reliability and accuracy in various indication. Waring signal output can be accommodated. Mixer can be programmed freely on site with varuous flexibility and with safety inter locks. System can be designed as per customer's requirements studying individual needs.

     

AUTOMATIC BATCH WEIGHING AND FORMULATION CONTROL ARRANGEMENT.

HIGH SPEED batching system is an Automatic precision control of high speed filling & emptying operation. This control is provided by a combination of weighing systems consisting of loadcells, indicator & and electronic controller. The process operate by comparing the instantaneous batch weight to the preset stored information including offsets for valve closure, transit time & anticipating in-flight material.

 
     
 

DEGASSING ARRANGEMENT/VACUUM EQUIPMENT, VACUUM OR INTER GAS PROVISION IN THE MIXER VESSEL/CONTAINER.

Certain Compound requires to be free from moisture from the materials, Vacuum units and filters are available to do the job. With optional fitting arrangement on the lid of the mixer. HOT AIR UNIT is required in regions with humid or tropical climates for drying of material.

 
 
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