Fully Automatic Control on Banbury Lines

In the rubber and tire industry, certain challenges exist in the manufacturing process of products such as car tires, hoses, sealing gaskets, and vibration dampers. It is necessary for a wide range of materials — from filler materials such as carbon black and silica, fed into high-energy mixers such as the Banbury Mixer or Kneader, to chemical additives such as accelerators and antioxidants that must be weighed with gram-level precision — to be added at the right time, in the right quantity, and in the right order

| Automatic Dosing of Main Raw Materials

Complex, dusty, manual processes bring with them high labor costs, inconsistent mixture quality due to human error, and worker health risks. VOLDE offers fully automatic raw material feeding and dosing systems on a turnkey basis to help your facility achieve its efficiency and quality goals.

_ Filler Materials

• Carbon black
• Silica
• Calcium carbonate
• Talc and kaolin

main filler materials such as these are transferred to the mixer in a dust-free environment via special pneumatic conveying or high-capacity screw conveyors, using Silo and Big Bag Discharge Stations.

_ Polymers (Solid Rubber Mass)

• Neoprene (CR)
• Styrene-butadiene rubber (SBR)
• Ethylene propylene diene monomer (EPDM)
• Natural rubber

bales such as these are automatically cut, precisely weighed, and fed into the mixer via a belt conveyor.

| Micro-Dosing and Chemical Additive Automation

The small-quantity additives that require high precision and determine the chemical and physical properties of the rubber compound are also fed automatically from the system.

• ZnO
• Stearic acid
• Antioxidants
• Accelerators
• Corrosion inhibitors

For more than 20 additive materials such as these, specially designed, semi-automatically pre-weighed packages or material taken directly from small-volume silos is fed into the mixer on time and in full.

| Liquid Additive Dosing and Injection

Fully controlled injection of liquid raw materials that improve mixture properties and enable processability.

• Paraffinic, naphthenic, and aromatic process oils
• Resins
• DOTP, DINP, plasticizers

chemical additives such as these are drawn from heated, agitated tanks and automatically injected into the Banbury Mixer at the correct temperature and quantity via precision pumps and mass flow meters.

| Advantages

• Thanks to the precision of the micro-additives, fluctuations in viscosity and vulcanization curves are reduced.
• Sequential feeding guarantees that polymer, carbon black, and liquid additives enter the Banbury cycle exactly on time.
• By shortening the Banbury cycle time, productivity becomes more efficient
• Unnecessary waiting times are eliminated thanks to the [automatic, replacing the] manual weighing system.
• Thanks to enclosed pneumatic conveying systems, carbon black and chemical dust emissions drop to zero. Worker exposure to hazardous substances is completely prevented.
• A digital record of the raw materials consumed for each batch is kept, providing full traceability and ease of auditing.
• Precise dosing prevents the loss of valuable raw materials caused by manual errors.