1. Too High Temperature
If the temperature is too high during the kneading process, the raw materials (such as rubber or plastic) may undergo thermal decomposition and produce black carbonized products.
2. Incompatible Materials
If the mixed raw materials are incompatible, it may cause local overheating or uneven reaction, resulting in coker materials.
3. Mechanical Shear
The high shear force of the sigma mixer may demange some materials during the mixing process, resulting in black particles or slag.
4. Impurity Contamination
The raw materials may contain impurities or contaminants, which will turn black during processing and form black slag.
5. Improper Operating Parameters
If the mixing time is too long and the speed is too high, the materials will be over-mixed, generating unnecessary heat and black slag.
1. Reduced Product Quality
Black slag affects the appearance, color and uniformity of the final product, making the product non-compliant with quality standards, which may lead to customer complaints or returns.
2. Reduced Performance
The presence of black slag may affect the physical and chemical properties of the material, such as strength, elasticity and chemical resistance, thereby reducing the overall performance of the product.
3. Reduced Processing efficiency
Black slag may cause increased wear of equipment, increase maintenance frequency, and increase production downtime, thereby reducing production efficiency.
4. Environmental and Safety Issues
Black slag may contain harmful substances, and improper handling may cause environmental pollution. In addition, some black slag may be flammable, increasing safety risks.
5. Increased Costs
In order to solve the black slag problem, additional cleaning, screening or reprocessing may be required, which will increase production costs and labor costs.
1. Optimize Blade Design: Use specially designed mixing blades to improve the fluidity and dispersion of materials and reduce local overheating.
2. Add Cooling System and Vacuum Box: Cooling system can reduce the temperature during mixing in real time to prevent the material from coking. Vacuum box can absorb the black slag produced.
3. Improve Sealing Structure: Optimize the sealing design to prevent material leakage adn reduce oxidation and deterioration caused by contact between materials and air.
4. Small Gap Between Blade Shaft and Cylinder: The gap between the blade shaft and cylinder of JCT Machinery's sigma mixer is between 2-3mm, and the black slag will not get stuck in the gap.