Banbury & Kneader Automatic Feeding

Accuracy Before the Mix, Performance in Every Batch

Rubber compounding brings together raw materials with very different handling and dosing characteristics — from elastomer bales and high-volume carbon black or mineral fillers to process oils and low-dose chemical additives. The performance of a Banbury mixing line depends on preparing these ingredients accurately and delivering them to the mixer in the correct quantity, sequence and timing. VOLDE develops complete raw material preparation, weighing, mixer charging and automation systems for rubber mixing rooms. Each system is engineered around the compound recipe, mixer batch size, mixing cycle and plant layout, integrating bulk powders, elastomers, liquids and chemical additives into one coordinated feeding infrastructure. The same approach can also be applied to kneader and other internal-mixer-based rubber processes

| Carbon Black, Silica & Filler Preparation

Carbon black, silica and mineral fillers represent some of the highest-volume powder ingredients in rubber compounding, yet their handling characteristics can differ significantly. Low bulk density, dust generation, compaction and poor flow behavior must be considered from storage through to weighing and mixer charging.

VOLDE integrates silos, big bag unloading systems, silo discharge equipment, pneumatic or mechanical transfer and dedicated powder weighing systems according to the characteristics of each filler.

For carbon black in particular, conveying velocity and handling method are important. Excessive conveying velocity can increase pellet degradation and fines generation, so the complete transfer route is engineered to provide stable material flow with lower unnecessary mechanical impact.

• Carbon black and silica storage
• Big bag and bulk material intake
• Pneumatic conveying to the mixing room
• Dedicated filler weighing hoppers
• Flow assistance for poor-flowing powders
• Enclosed transfer and dust extraction

| Ingredient Weighing for Banbury Recipes

A rubber compound recipe can contain materials ranging from high-volume fillers to relatively small quantities of zinc oxide, sulfur, accelerators, antioxidants and other chemical additives. Since these ingredient groups differ greatly in quantity and physical behavior, weighing and dosing technology must be selected accordingly.

Major powders can be automatically weighed in dedicated hopper scales, while chemical additives can be prepared through automatic or operator-guided weighing stations. Elastomer weighing can be incorporated into the batch preparation sequence, while process oils and other liquids can be dosed through dedicated weighing or metering systems.

The objective is to have every ingredient prepared and ready before the corresponding Banbury charging step begins.

| Banbury Charging & Mixing Sequence

Mixing-room productivity depends not only on mixing time, but also on how consistently the next batch is prepared and delivered to the mixer.

VOLDE coordinates elastomer feeding, powder weigh-hopper discharge, chemical additive preparation and liquid dosing with the actual Banbury cycle. Ingredients are released according to the active formulation and required mixing sequence rather than being introduced as independent material streams.

Depending on the plant layout, weighed materials can be transferred by gravity, belt or screw conveyors, pneumatic conveying or dedicated mixer-top charging equipment.

Mixer-ready signals, charge doors, weighing systems and transfer equipment are interlocked so that each addition takes place only when the required process conditions are confirmed.

For plants operating multiple mixers, common storage and weighing infrastructure can also be configured to serve different Banbury lines according to production demand.

| Mixing Room Automation & Batch Traceability

The complete mixing room can be managed around the active compound recipe rather than as a collection of independent machines. Raw material selection, weighing, chemical preparation, liquid dosing, mixer charging and confirmation of each addition are coordinated through the VOLDE PLC/SCADA platform.

Actual weights and dosing values can be compared with recipe targets before charging is authorized. Batch records can include ingredient quantities, material lots, recipe revisions, charging events, alarms and operator actions.

• Central recipe and batch management
• Target / actual weighing records
• Automatic charging-sequence control
• Mixer and feeding-system interlocks
• Raw material and lot traceability
• Batch and consumption reporting
• User authorization and alarm history
• ERP / MES integration where required

Where combustible powders or classified hazardous areas are present, dust collection, grounding, explosion protection and Ex equipment can be incorporated according to the material properties, area classification and project-specific risk assessment.

VOLDE brings raw material preparation, weighing and Banbury charging together in one coordinated mixing-room infrastructure — developed around repeatable rubber compound production and the actual requirements of each mixer cycle.