Phase-optimised mixing II

Optimised plasticiser addition in rubber compounding

In order to be able to provide recommendations for the optimisation of the economic efficiency of the mixing process, a methodology for generating mixing instructions is being developed. For this purpose, the mixing processes are to be analysed with regard to possible switching criteria during plasticiser addition such as torque or compound temperature.

In rubber compounding, the addition sequence of the compound components influences the dispersion of fillers such as carbon black. The project “Development of a methodology for the design of optimised compound production with regard to plasticiser addition in the intermeshing rubber internal mixer” (phase-optimised mixing) was launched in November 2024. II) investigates the effects of the addition of the plasticiser on the different mixing phases. It thus extends the experimental investigations of the IGF research project “Development of a methodology for the design of phase-optimised compound production in the intermeshing rubber internal mixer” (Phase-optimised mixing I).

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In order to improve the cost-effectiveness of mixture production through recommendations for action, a methodology for creating mixing instructions is being developed. To this end, the mixing processes are to be analyzed with regard to possible switching criteria for the addition of plasticiser, such as torque or compound temperature. First, the influence of various process parameters on the process flow as well as the compound and molded part quality is investigated. Carbon black incorporation, dispersion and distribution are analyzed as a function of plasticiser addition. The data is then used to optimise the mixing phase.

The resulting general methods can be used to further develop existing mixing rules and optimisation approaches. In the previous project, the mixing time was reduced by up to 88 % by optimizing process parameters while maintaining almost identical compound quality. Following the research project, the strategies developed can be integrated into process control without significant investment.

Project data and funding

We would like to thank the BMWE for funding the IGF project (funding code 23485 N) and the project partners for their cooperation.

Project duration: 01.11.2024 – 31.10.2026

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