Sigma Kneader Mixer
Sigma Mixer for Bauxite
Standard Design（Customizable）:
Material: SUS 304, 316 or mild steel
Discharging: Tilting discharging/Screw extruding discharging/Bottom plate
Heating: Electric heating/Water heating/Oil heating/Steam heating
Cooling: Water cooling/Jacket cooling
Vacuum: Water-ring vacuum pump/ buffer tank.
Motor: Explosion proof motor
Independent Control Panel: Variable speed/ Temperature/Discharging
Working Volume: 5 to10,000 Cubic Feet (from experiment to production)
Product Overview
Addressing the Pain Point: Wear
Tungsten Carbide: The End of Costly Downtime for Alumina & Bauxite
Tungsten carbide-coated sigma kneader mixers are the ultimate solution for mixing bauxite. They act like armor protecting the mixing blades and screw, ensuring continuous production line operation and eliminating impurity contamination caused by wear.
Tungsten carbide (WC), a compound composed of tungsten and carbon atoms, is the primary component of cemented carbide.
Extreme Hardness: WC's hardness is second only to diamond and significantly higher than traditional SS304 or SS316L stainless steel. On the Mohs hardness scale, WC's hardness is approximately 9 to 9.5, while stainless steel typically ranks around 5.5.
High Heat Resistance: WC has an extremely high melting point, maintaining structural stability and high hardness even under frictional heat.
Excellent Compressive Strength: WC can withstand high shear and compressive stresses without plastic deformation.
Technical Parameters
| Type | NH-5 | NH-10 | NH-100 | NH-300 | NH-500 | NH-1000 | NH-1500 | NH-2000 | NH-3000 | NH-4000 | NH-5000 | |
| Total Volume (L) | 5 | 10 | 100 | 300 | 500 | 1000 | 1500 | 2000 | 3000 | 4000 | 5000 | |
| Mixed amount/batch (L) | 1.5-3.5 | 3.0-7 | 30-70 | 90-210 | 150-350 | 300-700 | 450-1050 | 600-1400 | 900-2100 | 1200-2800 | 1500-3500 | |
| Rotation Speed (rpm) | 42/34 | 42/34 | 37/21 | 37/22 | 37/23 | 37/26 | 37/22 | 30/21 | 30/21 | 30/20 | 28/18 | |
| Main Motor Power (Kw) | 0.75-1.5 | 1.1-3 | 5.5-11 | 7.5-30 | 15-37 | 22-90 | 22-90 | 30-110 | 30-110 | 45-110 | 55-132 | |
| Heating Methods | Steam Pressure (MPa) | Jacket for steam ≤0.3MPa | ||||||||||
| Electric Power (Kw) | 2.4 | 2.4 | 6 | 12 | 18 | 30 | 45 | 54 | 72 | 72 | 90 | |
| Vacuum (MPa) | 0~ -0.096Mpa (Vacuum Kneader) | |||||||||||
| Discharging Method | Tilting cylinder | |||||||||||
| Screw extrusion | ||||||||||||
Our Services
LABORATORY TEST In order to be able to demonstrate the advantages and modes of action of our industrial mixing machine with your products, our fully equipped modern laboratory/technical center is at your disposal. |
PROFESSIONAL ENGINEER The experienced team of engineers is specialized in the R&D and design of mixers, grinding equipment, and plastic recycling machine. Karvil explores new technical points constantly to create perfect solutions for customers. |
DIRECT FACTORY Karvil factory has a series of strict standard system to control the procurement of raw materials, manufacturing process, in-process inspection, and product inspection, so as to ensure the quality of our products. |
Applications
F.A.Q.
Q1. Which specific components are covered by the Tungsten Carbide (WC) coating, and why is this necessary?
The high-performance WC coating is applied to all key high-wear areas that contact the material. This is crucial for mixing abrasive materials like Alumina and Bauxite. The WC coating's extreme hardness minimizes abrasive wear and erosion, extending the life of the blades and screw by several times, and preventing material contamination from metal debris.
Q2. What is the effective working capacity for a 50L kneader, and what is the minimum batch size?
For optimal performance and shear efficiency in a Sigma mixer, the effective working capacity is generally between 60% and 80% of the total volume. For the 50L model, we recommend a minimum batch size of around 30 liters to ensure proper material turnover and high-intensity kneading action.
Q3. What is the maximum vacuum level, and what is the benefit for materials like Alumina paste?
The integrated water-ring vacuum pump system can achieve a maximum vacuum level of -0.09 Mpa (10 kPa absolute pressure). For Alumina and Bauxite slurries, this is vital for deaeration and solvent removal, resulting in a final product with higher density, better homogeneity, and superior physical properties.
Q4. Is the 7.5kW Siemens motor sufficiently powered for high-viscosity ceramic pastes?
Yes. We use a powerful 7.5kW Siemens brand motor coupled with a heavy-duty, custom-engineered gearbox. This configuration is specifically rated to provide the necessary high torque required to handle the extremely high shear resistance of ceramic and high-viscosity polymer pastes.
Q5. How is temperature consistency maintained during the mixing cycle?
The mixing chamber is equipped with a double-layer cooling jacket. This jacket is designed for circulating chilled water or cooling fluid, which effectively and precisely removes the heat generated by the high-shear friction. The temperature is constantly monitored and displayed on the PLC control panel.
Q6. Does the PLC system comply with modern industrial control standards?
Absolutely. The machine utilizes a PLC (Programmable Logic Controller) system with a HMI (Human-Machine Interface) touch screen for full automation. Key features include: Variable Frequency Drive (VFD) control for precise speed adjustment (0-42 RPM), automatic cycle timing, and advanced safety interlocks.
Q7. Is the screw discharge mechanism designed for easy cleanup between batches?
Yes. Screw extrusion is inherently cleaner and more efficient than traditional tilting discharge. Since the screw and barrel liner are WC-coated, the highly smooth, abrasion-resistant surface minimizes material adhesion and residue, simplifying manual cleaning procedures for fast batch turnaround.
Q8. Is this Sigma Kneader compliant with European safety regulations?
Yes, this machine is manufactured and certified with the CE Mark, ensuring it fully complies with the essential health, safety, and environmental protection standards required for sale and operation within the European Economic Area (EEA).
Q9. What is the typical lead time from order confirmation to delivery?
Due to the specialized Tungsten Carbide coating process and custom fabrication, the standard production lead time is approximately 30 working days. A precise schedule will be provided upon order.
Q10. What warranty and post-sale technical support do you offer?
We provide a standard free 12-month warranty on all major machine components. Our post-sale support includes:
Remote Video Support: Troubleshooting and operational guidance for installation and daily use.
Spare Parts Supply: Fast availability for critical wear parts (e.g., shaft seals).
On-Site Engineer Service: Upon request, our qualified engineers are available for commissioning, installation, and operator training at your facility.
CERTIFICATION