Rubber Compounding Process

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Release time:

Sep 24,2025

Mixing is a critical process in rubber product manufacturing, aimed at uniformly blending raw rubber with various compounding agents—such as fillers, vulcanizing agents, accelerators, and antioxidants—through mechanical shearing. This process produces a compounded rubber that meets specific performance requirements. The quality of the mixing process directly influences both the processing characteristics of the rubber compound and the final physical and mechanical properties of the finished product. This article provides a detailed introduction to the working principles and procedures of both internal mixers and open mills.

I. Mixing Equipment and General Processes:
1. Internal Mixer:
A Banbury mixer is a high-intensity, high-efficiency, closed-type mixing device whose core components include the mixing chamber, as well as an upper and lower ram positioned on a pair of intermeshing rotors that rotate at different speeds.
Process:

● Preheating: Heat the internal mixer to the set process temperature in advance.
● Feeding: Press the top plunger and add raw rubber, additives, fillers/oil materials, etc., following the established feeding sequence.
● Mixing: The upper plunger is pressed down, applying pressure to the material. The rotors disperse the compounding agents into the raw rubber through actions such as shearing, stirring, squeezing, and folding.
● Degassing: After reaching the set time, temperature, or energy consumption value, press the top plunger to discharge the rubber material into the downstream open mill or extrusion calender.

● Advantages: High efficiency, excellent mixing quality, minimal dust generation, and a high degree of automation.
● Drawbacks: High equipment investment, inconvenient cleaning, and stringent cooling requirements.

2. Open Mill (Two-Roll Mill):
The open mill consists of two rollers rotating in opposite directions at different linear speeds, achieving mixing through the shear and friction forces applied across the nip.
Process:

● Preheating: Heat the rollers to the desired temperature and adjust the roll gap.
● Calendering: Forming a uniform calendered sheet of raw rubber on slow-rotating rollers.

● Adding the powder: Gradually incorporate the compounding agents in sequence, cutting and kneading the rubber mixture from side to side to ensure thorough blending of the powder.
● Refining: Further promote uniform dispersion through techniques such as beating triangular packages, rolling, and thinning.

● Second stage: Adjust the roll gap to press the uniformly mixed rubber compound into a sheet of the desired thickness and width.

● Advantages: Simple equipment, low investment, easy observation of compound status, and convenient for small-batch/experimental production.
● Drawbacks: Low efficiency, high labor intensity, poor safety, and significant dust generation.

II. Detailed Explanation of Mixing Processes for Each Rubber Type:
The core of the mixing process is the material addition sequence, and its basic principle is:

● Raw rubber refining to enhance plasticity.
● Adding "small ingredients" such as activators, antioxidants, and stabilizers plays a protective role.
● Add high-dose fillers (such as carbon black, white carbon black) and plasticizers (oil) during the main dispersion stage.
● After the filler is evenly dispersed, finally add "sensitive minor ingredients" such as vulcanizing agents and accelerators to prevent scorching (premature vulcanization) caused by localized overheating.

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Causes and Prevention of Rubber Product Blooming

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Causes and Prevention of Rubber Product Blooming

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