When scaling up production of high-performance PUR hot-melt adhesives, the client encountered the following bottlenecks with their existing conventional mixing equipment:
- Inadequate handling of ultra-high viscosity: As the reaction progresses, material viscosity surges rapidly to the 500,000~3,000,000 cPs range; the old equipment's motors overheat due to overload, frequently causing shutdowns.
- Poor degassing and sealing performance: PUR is extremely sensitive to trace moisture, yet the original equipment struggled to maintain a vacuum level below -0.098 MPa over extended periods, leading to premature curing, bubble formation, and product waste.
- Low temperature control precision and localized overheating: Conventional horizontal kneaders offer limited heat transfer surface area; localized overheating causes the polymer resin to carbonize, resulting in "black speck" defects.
- Difficulties in discharging and cleaning: High-viscosity material adheres heavily to the vessel walls, resulting in high residual rates upon discharge, while cleaning and color-switching operations are time-consuming and labor-intensive.
To meet the client's high-specification requirements, we customized a vacuum kneader for them:
- Powerful Drive and Thorough Kneading: Utilizes a gear reducer paired with Sigma-shaped blades that rotate in opposite directions at differential speeds; this setup effortlessly handles extreme viscosities exceeding 15,000,000 cPs while completely eliminating mixing dead zones.
- High-Sealing Vacuum Degassing System: Equipped with dual mechanical seals and a dedicated vacuum unit, maintaining a stable vacuum level of -0.098MPa to ensure reactions and degassing occur in a moisture- and bubble-free environment.
- Multi-Stage Precision Temperature Control Jacket: Both the vessel body and base feature jackets designed for thermal oil or steam heating; combined with high-precision PID control, the system achieves temperature accuracy of ±1°C, preventing the carbonization or degradation of heat-sensitive resins.
- Screw-Driven Discharge Design: Employs a combination of gravity and screw propulsion to discharge the hot-melt adhesive, achieving a discharge rate of over 95% for high-viscosity materials.
This hot melt glue sigma mixer has completely resolved the challenges we faced regarding degassing and temperature control during the production of ultra-high-viscosity hot-melt adhesives. The equipment operates stably, maintains an excellent vacuum level, and ensures a very clean discharge. This has not only significantly boosted our production line's automation but also enabled our products to successfully break into the high-end adhesive market.
Our technical team can customize kneading and mixing solutions based on the specific characteristics of your materials (viscosity, temperature control requirements, and production output).
Tel: +86-181 3837 3963 (Whatsapp, Wechat)
Email: jctmixing@outlook.com
JCT 
2026-10-14
