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Tips for More Effective Blending

15 May, 2017

The constantly increasing price of the majority of the raw materials and rising importance of product consistency have made the process of blending resins a more complex job than ever before. These changes along with cost cutting and amended environmental mandates have made reintroduction of regrinding of the end products an extremely common affair.

This article would educate you about some highly effective blending tips that would reduce both labor and material costs significantly while ensuring that the finished product you get is more consistent. Some things you’ll need to do include:

  • Keeping the distance between the processing machine and blender as low as possible.
  • Prevent static buildup
  • Opt for the suitable receivers 
  • Destroy the bridges 

Keep the Blender Close to Your Processing Machine

The closer would be the blender device to your processing machine, the more homogenously you would be able to mix the raw materials. According to experts, the possibility of separation remains pretty high when the blend needs to cover a big distance before entering the machine’s feed throat. Such situations arise when the materials are in various bulk quantities. The results tend to become even worse when virgin materials are blended with regrind; this happens primarily because the size and bulk density of regrind might vary greatly.

Inconsistencies in the bulk density result in separation of the lighter and smaller pellets from the heavier and larger pellets. This, in turn, causes formation of uneven material layering on the machine’s feed throat. The best way to deal with this issue is by blending over the feed throat after placing it on mezzanine. Blending directly on the feed throat is also a feasible option.

If you don’t have any other option besides placing the blender remotely, put it adjacent to the machine (of course try to keep the distance between the two as small as possible). You can also use a high quality, high torque, low speed granulator. It would be able to assist you in keeping the regrind size and bulk density consistent.

Avoid Static Buildup

This is extremely important as static buildup is possibly the worst enemy a blender had. Avoiding static buildup is an absolute must as it causes materials to cling to the mixing chamber’s walls, which triggers formation of inconsistent batches. Here, it must be mentioned that with the addictive percentage on the lower side, even a small amount of pellets in the mixing bowl might affect the quality of the final product significantly. Efficient grounding of the vacuum blenders and receivers and use or high-end grounded hose can reduce static buildup noticeably.

Picking the Right Receivers is Extremely Important

Your blending hoppers manufacturer would tell you what kind of receiver you should place on the hopper you are using. You must abide by the suggestion as your blender’s accuracy depends largely on the receiver you are placing on it. Gravimetric and volumetric blenders, which depend on time, can be affected adversely only by external factors like pressure changes taking place within the hopper.

Opting for a pressure cyclone or venture style separator receiver would generate positive pressure inside the hopper. Such positive pressures would work by forcing the materials through the hopper valve at a greater speed. This change in speed would trigger an overdose of the materials during the conveying cycle of the receiver.

By placing a specially designed gravity-style discharging valve on the vacuum receiver (possibly a leaking flap), you would be able to generate negative pressure inside the hopper. This obviously would cause an under-dose of materials.

Thwarting the Bridges is an Absolute Must

If you are planning to work with comparatively difficult materials like sticky addictive, flake, or regrind, you must be ready to deal with material bridging within the hopper. In other words, you must be ready to take necessary steps for thwarting those bridges. Bridging materials have been found to hinder the performance of blenders; this happens as formation of bridges prevents smooth material flow. Picking valves of the right size is extremely vital when it comes to maintaining flow of a difficult material. It would also be wise to pick bigger hoppers, particularly in case of blenders boasting hoppers of different sizes. Material flow can also be improved by forcing agitation of the difficult materials.


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