Schill & Seilacher Schill & Seilacher

Correcting Batch
Correcting Batch
Weight
Weight
CORRECT BATCH WEIGHT
CORRECT BATCH WEIGHT
CORRECT BATCH WEGHT S CRTCAL FOR
GOOD MXES
NCORRECT BATCH WEGHT WLL LEAD TO
POOR PROPERTES & POOR PROCESSNG
WHAT S BATCH WEGHT ? : TOTAL AMOUNT
OF MATERALS NSDE AN NTERNAL MXER
- 10 % +10 %
Unvulcanised Properties
Mooney viscosity 69 76 68
Mooney scorch 12.1 13.8 11.1
Rheometer Properties
ML 6.4 6.9 6.1
MH 35.0 36.8 34.0
T2 2.4 2.6 2.2

Tc 50 3.6 3.8 3.3
Tc 90 6.4 6.6 6.0

Vulcanised Properties
Hardness (Shore A) 63 65 62
Modulus 300 % 15.0 15.9 13.9
Tensile strength 18.0 19.2 16.1
Elongation 370 385 360
Tear strength 48 53 51
DlN abrasion 141 136 138
Specific gravity 1.18 1.20 1.17
Data from Lim Yew Swee - Polysar
VARlABLE PHYSlCAL PROPERTlES


CORRECT BATCH
WEIGHT
----------------------------
Let the Correct Batch Weight = W
W = V x B x P
V = Volume of mixing chamber
B = Batch weight factor
P = Polymer loading factor
To determine
Batch Weight Factor
Let B = Batch Weight factor
Then, B = S + A - F
S = S.G. of compound
A = Factor from ADDITIVES
F = Factor from FILLERS

Calculation
of
Factor From ADDTVES
"A"
Add together
OiIs & Waxes; Resins
Stearic acid; Antiox/Antioz
DENTFY TOTAL AS
ADDTVES
f % of ADDTVES
more than 10%
Then, A = [(% -10) x 0.003] + 0.1
f % of ADDTVES
less than 10%
Then, A = % x 0.01
To determine
Batch Weight Factor
Let B = Batch Weight factor
Then, B = S + A - F
S = S.G. of compound
A = Factor from ADDITIVES
F = Factor from FILLERS


To determine
Batch Weight Factor
Let B = Batch Weight factor
Then, B = S + A - F
S = S.G. of compound
A = Factor from ADDITIVES
F = Factor from FILLERS
Calculation of
Factor from FILLERS
f % of Fillers
more than 28 %
Then, F = (% - 28) x 0.01
f % of Fillers
less than 28 %
No Correction Needed


CORRECT BATCH
WEIGHT
----------------------------
Let the Correct Batch Weight = W
W = V x B x P
V = Volume of mixing chamber
B = Batch weight factor
P = Polymer loading factor
PoIymer Loading Factor
For most common polymers
e.g. NR, SBR, NBR & CR
P = 1
In the case of HIIR, IIR & EPDM
If HIIR / IIR more than 75 phr, P = 1.10
between 75 & 25 phr, P = 1.08
between 25 & 18 phr, P = 1.05
If EPDM more than 75 phr, P = 1.11
between 75 & 50 phr, P = 1.09
between 50 & 20 phr, P = 1.07


CORRECT BATCH
WEIGHT
----------------------------
Let the Correct Batch Weight = W
W = V x B x P
V = Volume of mixing chamber
B = Batch weight factor
P = Polymer loading factor
PoIymer Loading Factor
(Continued)
Polybutadiene is very common to be
used in blend with NR and/or SBR
For Polybutadiene
phr of BR x 0.08
P =
total phr of polmers
Note :-
If BR is used in the formulation,
add "P" of BR to "B" (Batch Weight Factor)
before calculating "W"


ExampIe of BATCH WEIGHT CaIcuIation
MateriaI phr S.G. VoI. Wt.%
SMR 20 55.00 0.92 59.783 30.522
SBR 1502 30.00 0.94 31.915 16.648
BR 1203 15.00 0.91 16.484 8.324
Stearic acid 1.50 0.85 1.765 0.832
Resin SP 1068 2.00 1.03 1.942 1.110
Wax 3.00 0.91 3.297 1.665
6PPD 2.50 0.99 2.525 1.387
TMQ 1.80 1.06 0.943 0.555
Aromatic oil 8.00 1.00 8.000 4.440
N660 black 40.00 1.82 21.978 22.198
Hi-Sil 15.00 2.00 7.500 8.324
CBS 1.20 1.37 0.876 0.666
DPG 0.50 1.20 0.417 0.277
Zinc oxide 3.50 5.57 0.628 1.942
Sulphur 2.00 2.00 1.000 1.110
Total 180.20 1.133 159.052 100.000


ExampIe of BATCH WEIGHT CaIcuIation (Cont.)
Total % of Fillers = 30.5216 (more than 28%)
Then, Factor From Fillers, F = (% - 28) x 0.01
= (30.5216 - 28) x 0.01
= 0.0252
Total % of Additives = 9.9889 (less than 10)
Factor from Additives, A = % x 0.01
= 0.099889
Loading Factor for BR, P = (phr BR) x 0.08 / 100
= (15 x 0.08) / 100
= 0.012
Batch Weight Factor, B = S + A - F
= 1.1330 + 0.099889 - 0.0252
= 1.207689
lf Volume of lnternal Mixer , V = 75 litre
Then, BATCH WElGHT W = V x B x P
= 75 x (1.207689 + 0.012) x
1
= 91.476675
= 91.47.


BANBURY
VOLUME
AII banburies wear at different rates
- so voIume must be measured every 6
months
Best way is to use "Masterbatch" technique

BANBURY VOLUME
MEASUREMENT
by "MASTERBATCH" method
Take a "normal" masterbatch -- NR,SBR etc
Watch ram just before "drop" time
1) f ram seated - no movement - UNDERLOADED
2) f steady pumping action - OK
3) f not seated - OVERLOADED
When underIoaded
- weigh 3 x 2kg , 3 x 1kg , 3 x 1/2kg pieces
- load "normal" batch weight, run for 1 minute
- add till steady pumping action observed
When overIoaded
- reduce "normal" batchweight 10kg
- add as above till steady pumping action

BANBURY VOLUME
CALCULATION
FROM AVERAGE S.G. & BATCH WEGHT
FINAL B.W.
= VOLUME
S.G.
Measure actual S.G. - 5 x (3 decimal
places)
SHOULD BE DONE FOR EVERY
BANBURY EVERY 6 MONTHS


CORRECT RAM PRESSURE
Depends on body and rotor configurations
Specified by manufacturer - check manuals
(Fracis Shaw 2-wing 5 Kg./cm

etc.)
f Manuals are not available check time to reach
drop temperature at 3.0, 3.5, 4.0 etc. Kg./cm

effective stock pressure until time saving

becomes
minimal OR dispersion becomes bad.

CORRECT RAM PRESSURE
Shaft diameter =
d
Ram face area =
A
Shaft pressure =
p
Effective stock pressure =
P
P = p.22/7.(d/2)

/ A

CORRECT RAM PRESSURE
No.11 FarreI 40rpm
1.4
2.11
2.81
3.51
4.22
4.92
5.62
Effective Stock Pressure (Kg./cm2)
60
70
80
90
100
110
Mixing Time Rating
Waste of
Power