Bainite Machines are CE & ATEX compliant
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ce
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  •   Turnkey Mixing Room
  •   Tangential Mixer
  •   Intermeshing Mixer
  •   Twin Screw Sheeter
  •   Hot And Cold Feed Extruders
  •   Mixing Mills
  •   Calenders
  •   Peripherals and Spares
  •   Renewals and Upgradation
  •   Lab Mixer and Mill
  •   B-Turbo Rotors

BAINITE MIXING ROOM

Turnkey Mixer

Bainite Machines, leading manufacturer of customized machinery, offers single-stop shop turnkey mixing room for the global tyre and rubber industry.


Our technical team interacts with you right from your project conceptualization stage to design a customized mixing room that fits within your project budget. We help you draw up a complete investment plan as well as feasibility studies including flow diagrams that depict the overall system.


Our experienced top-notch design engineers work on 3D-SolidWorks modelling with simulation to ensure you get a well-researched solution for your compounding requirements while our computer-aided project management system keeps deadlines under tight control throughout the term of the project. Jointly working with us through your planning stage, you get a clear view of the scope of our services till commissioning of your project.


We manufacture the finalized design of your mixing room systems using the latest technology and take care to select wear-protective material of individual mechanical components for durability and reliability.


We guarantee you when we supply our complete mixing room that all the subsystems and components - from raw material feeding to stacking of the finished sheet in the pallets are perfectly matched and all interfaces through to the instrumentation and control equipment render you trouble-free performance. A Bainite Make Mixing Room system complies with CE & ATEX norms and designed for safe user-friendly operations.


And that’s not all. Our experienced engineers are on hand both while you are commissioning your new mixing room systems and when you plan staff training or undertake scheduled maintenance.


We ensure prompt after-market support for our customers both directly and through our partners globally. Our trained engineers and optimized inventory stocking plans assures that your mixing room systems receive the best after-market service and continues to render you continuous service for longest period.


Our control and automation systems improve performance, quality and cost efficiency. Few key features of our mixing room systems that benefits you effortlessly are

INVENTORY MANAGEMENT SYSTEM:-

  • Inventory of raw material storage management through RFID/Bar code technology.
  • Dynamic space allocation for report and storage.
  • FIFO based Issue control.
  • Material acceptance through QA/QC - Lab integration.

CHEMICAL WEIGHING SYSTEM:-

  • Flexible Recipe creations with multilevel authorized system control.
  • Security and protection of your formulations.
  • User friendly /system guided semi auto weighing to ensure error proofing.
  • Real time consumption and inventory reporting.
  • Multilingual display for operator convenience and increased operator efficiency.
  • Reduction of batch to batch variation and compound scorch.
  • Mistake proof loading and weighing ensuring standard operating procedures/sequence with maximum accuracy.

AUTO CARBON SYSTEM:-

  • Auto weighing and charging of carbon.
  • Clean environment of carbon area with minimized spillage and fly-loss.

MIXER SEQUENCE CONTROL:-

  • Tangential/Intermeshing Mixer controls.
  • Foolproof sequential charging of materials.
  • Time / Temp / RPM / Energy / Ram-based mixing.
  • Safety protection for open mills.
  • Auto controlled Final Batch mixing / Direct final batch mixing.
  • Variable frequency drives for Mixer /Open mill/TSS.

A state-of-the-art technology automated Bainite mixing room with internal mixers having hydraulic ram for energy conservation, optimized rotor geometry with intensive cooling for the highest dispersion of compound in a controlled manner, prompt monitoring of different mixing parameters and complete line-integration through latest controls, labour saving TSS (Twin Screw Sheeter) as the downstream equipment and Batch-Off cooling lines with Wigwag and Automatic cutting, Auto-Pick Up, Packer-Stacker, Auto-Palletizer, Auto-Sampling - all of which helps you increase compounding quality, productivity and provides the highest returns on your investment.

Our 30 years of manufacturing experience, material technology expertise, know-how of rubber compounding, stringent quality standards and the core understanding of our customer’s needs has earned us the confidence of the industry leaders from products like rubber bale cutter, weighing and feeding conveyors, internal mixers, TSS, open mixing mills, dump extruders, and batch-off cooling lines to ancillaries like sheet feeder with rotary cutter and Temperature Controller Units.

So, when you plan for a new mixing room why not speak to us for a single-stop turnkey solution. Our technical experts will be delighted to provide you with more details when you reach out to us.



BAINITE MAKE TANGENTIAL TYPE INTERNAL MIXER

Tangential Mixer

Bainite Internal Mixers are widely recommended for mastication, master batch and final batch production. Specially designed contours rotors, designed & developed in house, ensures proper mixing and dispersion of carbon. Improve compound quality and rapid mixing is possible with new generation rotors. On the metallurgy side today we offer special coating for tougher applications like silica.

Salient Features:-

  • Capacities ranges from1.6L lab mixer to 440L production mixer
  • Rotor Types – 2W, 4W, 6W, 4W - Turbo RotorTM
  • Pneumatic or Hydraulic Ram operation with Ram Position Indicator
  • Swing type drop door and toggle latch design for locking.
  • Large hopper throat for easy feeding.
  • Direct drive or uni-drive gear box.
  • PLC/SCADA and Recipe Management Software.
  • Optimal utilization of space – Flexi Layout
Tangential Mixer

Superior Metallurgy:

All the parts, comes in contact with compound, are surface treated for wear protection. For accuracy all the parts are machined on CNC and ultrasonically/hydraulically tested. Stress relieving is done after welding. We have developed range of options for hard surface treatment for application like Silica.

Cooling:

Effective water cooling passage is drilled in Rotors, Chambers, Floating Weights, Rotor End Plates and Drop Doors. This ensures uniform batch temperature without localised heat build up situation. Provision for thermocouple is provided in door top and chamber for measuring compound temperature. We also offer Temperature Control Unit (TCU) for heating/cooling as per your requirement

Feed Hopper:

Large steep charging area for rapid feeding. Radius bottom floating weight to present maximum cooling and mixing surfaces to the compounds. Dust extraction hood fitted as standard. Charging door pneumatically/hydraulically operated.

Dust Seal:

Self sealing designing ensures any leakage of material from rotor ends. Working faces are stellited and ground to smooth finish. Hydraulic pressure is used for sealing in larger mixer 270 and above.

Discharge Door:

Bainite offers hinged type “swing away” design operated by double rack and pinion arrangement. 135 Deg opening ensures quick drop of batch. Door top is postiviely locked by toggle type hardened steel latch on a hardened steel contact plate. Latch is actuated by a hydraulic cylinder.

Tangential Mixer

Rotor:

Computer designed rotor geometry is accurate machined to get better shear and movement of material from one end axially. This ensures uniform mixing batch to batch and higher productivity. We offer even speed TurboRotorsTM for higher range of 270 Ltrs, 330 Ltrs, 440 Ltrs, Mixers. Please contact for further details.

Drilled Side:

Chambers are dovelled close to lip area and have higher included angle of lip to avoid inward banding or shearing of lips due to hydraulic closing and locking pressure of door.

Hydraulic Ram:

Bainite offers hydraulically operated hopper assembly as an option to pneumatically operated. The advantage Hydraulic Hopper Design are:

  • Eliminate compressed air requirement, lower operating costs and energy saving
  • Provide constant working pressure to the ram. Ram operation is not affected by variation in the plant compressed air. This results in increase product uniformity and repeatability
  • Motion of ram is smooth and its speed can be controlled and regulated. This allows efficient mixing of different compounds. Pressure control and ram down speed control is possible.

Safety Arrangement:

  • Bearing & Dust Seal Protection – Temperature Sensor & Hooter provided
  • Feeding Door – Manual Locking
  • Drop Door – During Maintenance can be locked at 180 Deg opening
  • Floating Weight – Locking pin provided during maintenance.

BAINITE MAKE INTERMESHING TYPE INTERNAL MIXER

intermeshing mixer

Bainite Intermeshing type Internal Mixers are widely preferred by non tyre industries. Data shows with increase silica mixing intermeshing mixers are gaining popularity in tyre segments also. Higher surface to volume ratio (in comparison to Tangential Mixer) and spiral water cooling design makes it right choice for those mixing where temperature rise is sudden. Interlocking design of Intermeshing rotors allows the compound to flow over and around the nogs into the high shear zones maximizing the dispersion of the ingredients and fillers within the batch.

Salient Features:-

  • Capacities ranges from1.6L lab mixer to 330L production mixer
  • Rotor Types – HR5
  • Pneumatic or Hydraulic Ram operation with Ram Position Indicator.
  • Swing type drop door and toggle latch design for locking.
  • Large hopper throat for easy feeding.
  • Direct drive or uni-drive gear box.
  • Constant or Variable Speed Drive.
  • PLC/SCADA and Recipe Management Software.
  • Optimal utilization of space – Flexi Layout
intermeshing mixer

Superior Metallurgy:

All the parts, comes in contact with compound, are surface treated for wear protection. For accuracy all the parts are machined on CNC and ultrasonically/hydraulically tested. Stress relieving is done after welding. We have developed range of options for hard surface treatment for application like Silica.

Cooling:

Effective water cooling passage is drilled in Rotors, Chambers, Floating Weights, Rotor End Plates and Drop Doors. This ensures uniform batch temperature without localised heat build up situation. Provision for thermocouple is provided in door top and chamber for measuring compound temperature. We also offer Temperature Control Unit (TCU) for heating/cooling as per your requirement

Feed Hopper:

Large steep charging area for rapid feeding. Radius bottom floating weight to present maximum cooling and mixing surfaces to the compounds. Dust extraction hood fitted as standard. Charging door pneumatically/hydraulically operated

Dust Seal:

Self sealing designing ensures any leakage of material from rotor ends. Working faces are stellited and ground to smooth finish. Hydraulic pressure is used for sealing in larger mixer 270 and above.

Discharge Door:

Bainite offers hinged type “swing away” design operated by double rack and pinion arrangement. 135 Deg opening ensures quick drop of batch. Door top is postiviely locked by toggle type hardened steel latch on a hardened steel contact plate. Latch is actuated by a hydraulic cylinder.

Rotor:

Each HR5 rotor has one long wing and two small nogs for mixing. Long wing has wider tip which greatly inhance dispersion effect. Most of the mixing happens between the rotors. Rotor is made in two piece design and drilled for water passage close to material surface.

Drilled Side:

Chambers are dovelled close to lip area and have higher included angle of lip to avoid inward banding or shearing of lips due to hydraulic closing and locking pressure of door.

Hydraulic Ram:

Bainite offers hydraulically operated hopper assembly as an option to pneumatically operated. The advantage Hydraulic Hopper Design are:

  • Eliminate compressed air requirement, lower operating costs and energy saving.
  • Provide constant working pressure to the ram. Ram operation is not affected by variation in the plant compressed air. This results in increase product uniformity and repeatability.
  • Motion of ram is smooth and its speed can be controlled and regulated. This allows efficient mixing of different compounds.
  • Pressure control and ram down speed control is possible.

Safety Arrangement:

  • Bearing & Dust Seal Protection – Temperature Sensor & Hooter provided
  • Feeding Door – Manual Locking
  • Drop Door – During Maintenance can be locked at 180 Deg opening
  • Floating Weight – Locking pin provided during maintenance.

BAINITE MAKE TWIN SCREW SHEETER

tss

Bainite offers TSS completely designed, customised and manufactured inhouse with latest technology. In an automated mixing line “TSS”, placed underneath the Internal mixer is today accepted for batch mixing replacing dump mill concept. Apart from the savings in power and labor, the material self-fed in TSS gives high quality of mix consistently, keeps the environment clean and is also a very safe operation.

Salient Features & Benefits:-

  • Suitable for 50L to 440L mixer
  • Conversion of Batch to Continuous Sheet
  • Replace traditional single or double dump mill setup
  • Prevents atmospheric contamination(Dust and vapour) due to inclosed operation.
  • Save labour, save space.
  • Less maintenance and lower downtime
  • Can be used for master as well as final batches.
  • Automatic synchronized with line speed for maximum productivity.
  • Modular design and movable roller head for ease of maintenance.
tss

Large Hopper Chute:

Fixed with bolts over feed Barrel opening and customised to be connected at the bottom of the Mixer platform. Level sensors are provided to adjust the screw and roll speed according to batch weight from mixer. For visual inspection additional window are provided.

Feed Barrel:

Downward Inclined design barrel, duly hard chrome plated, allows faster movement and complete unloading of dump towards rolls. Barrels are drilled for effective cooling or heating.

Twin Screws:

Counter Rotating, Intermeshing, Conical & non contact screws are supported by antifircation bearing in the gear housing. They are mounted inclined and hard chrome plated for self cleaning. Shafts are drilled for cooling/heating to match dump temperature.

tss

Roller Die Assembly:

Complete assembly with bearing housings can be removed horizontally through frame windows for maintenance purpose. Two hydraulic cylinders each side can be actuated electrically or manually(during power failure) for movement. Load cell at discharge end of extruder is mounted for synchronization of screw speed with roll speed. Sensing excess load, through interconnected with control panel, will speed up Calender and maintain balance of material flow with speeds of extruder/Calender. Optionally a dancer roll can be mounted on discharge side of calender to synchronize cooling line with the sheet output.

Drive and Control Systems:

Both screws and rolls are independently driven by variable speed motors and reducing gear arrangement. System start up, line synchronization and optimum performance are achieved by PLC based control systems. Operating variable are automatically adjusted to provide continuous sheet.

Safety Arrangement:

  • All movable parts covered with guards
  • Safety rope for emergency stop
  • Replaceable shear pad for roll protection
  • Mechanical locking for roller die assembly
  • Scrapper plate for preventing sheet accumulation.

Hot And Cold Feed Extruders

cold feed extruder

Bainite make screw type rubber extruders are popular in rubber processing industries for highest output, continuous mixing and consistent extrudate quality. We have hot feed extruder or cold feed extruder with suitable die head (like cross head, tube head, single or multiple tread heads upto 1250 mm width, strainer head, or roller head) for your choice of application. Bainite offers duplex or triplex extruder for tire tread and side wall extrusion.

Salient Features & Benefits

  • Designed for 24 x 7 operation and automatized – minimize your labor.
  • Screws, made in alloy steel for better strength, are designed with biting features at the feed zone for homogenous mixing, accurate throughput and porosity free compounds.
  • Screws completely heat-treated or stellited on the working surface for wear protection ensuring long-life, trouble -free and smooth running.
  • Liners are either nitrided, case carburised or bimetallic in construction and is of wet design for efficient heat transfer.
  • Solid barrels with spiral cuts at inner diameter also ensures efficient heat transfer.
  • Design and material technology of the die head is adopted to withstand 700 bar max. pressure – eliminates any porosity, free of blisters or bubbles.
  • Specially designed feed-roll assembly reinforces positive strip feed- giving you a leakage- free clean machine operation.
  • Quick and effortless installation/ shifting/ relocation possible due to single base.
  • Special Cold Feed Extruders designs available for feeding the calender.
cold feed extruder

Hot Feed

Bainite make Hot Feed Extruders (L/D of 4:1 to 6:1) are economical choice for applications like treads and sidewall, pelletizing, strainers etc. Pre-heated rubber using cracker and warmer mill is fed into these extruders. A variant of this type is used as dump extruder below internal mixer in which screws are larger in diameter and a ram pusher is used for feeding dump.

cold feed extruder

Plain type Cold Feed

Bainite make plain type Cold Feed Extruders finds applications in tubes, hoses, cable coating, bicycle tyre tubes, etc. The barrel is constructed in tow or three sections depending upon L/D ratio. These are fitted with replaceable, hardened and wear protected liner for durability. The screws are critically designed to have gradually reducing pitch and flight depth in the central zone. Mixing of 2/3 different layers of compound flowing on different screw flight paths, facilitates high shear uniform mixing that gives you consistency in the homogeneity of the mixed rubber compounds.

Pin Type Cold Feed

Bainite make pin type Cold Feed Extruders have rows of pins radially inserted in barrel that divides the flow of rubber. Pins extend to the screw core and flights paths are discontinuous. This design causes high shearing zone (Central zone) and creates different layers of rubber. These layers then mix with one another and results in well mixed uniform layer of compound.

The screw's special design involves a 6 or 8 flight start (with axial and radial tapering) at the feed section to impart a cutting action on the rubber strip. This reinforces positive feed towards central zone. The screw is of forged alloy steel and nitrided after machining on a special thread milling machine. The entire screw is ground smooth finish in working area and is centrally bored for water circulation (temp Control). They carry threads at rear end to prevent the material flow in backward direction.

Our CFEs are fast replacing 2 or 3 warming mill setup together with Hot feed extruder. Please contact us for a economical solution. Output of CFE is also higher compare to HFE for same size screw.

Feed Roll Assembly

Feed roll assembly is of box type design that can be effortlessly removed/ reinstalled without disturbing feed hopper. It help in positive feeding of rubber strips. The feed roll is positively driven from screw by inter connecting gears. The roll section can be opened manually or hydraulically for cleaning and maintenance. Both ends of feed roll surface is grooved to prevent rubber reaching the bearing and thus avoids any premature failure. An adjustable scraper blade is provided for continuous roll cleaning.

Head profile

Bainite adopts latest flow simulation software to ensure that all die-heads are designed to have smooth flow of compound- spread in all directions under proper pressure and speed to eliminate any porosity. This in turn ensures that the final extrudate product are free of blisters or bubbles.

Screw Concentricity

Bainite recognizes that with screw having a cantilever design, there is possibility of screw tip area scoring against the barrel inner surface. Hence particular attention is given so that the thrust bearing housing in the gear reducer output assembly is designed to ensure concentric alignment with respect to barrel inner bore across the length of the screw.

Screw Removal

Effortless screw removal is possible manually without any hammering through a special tooling attachment that is supplied along with the extruder.

Mixing Mills

QUALITY, PERFORMANCE, RELIABILITY

Mixing Mill

Bainite Mixing Mills (plain barrel or cracker) are used

  • as dump mills below the internal mixer for compounding and sheeting out
  • as warm up and feed mills for calender and extruders
  • for re-mixing
  • for plain compounding and mixing

The compounds may be of rubber, plastic / polymer or tile compound. Bainite Mixing Mills are sturdy enough to mix newer and tough compounds in a silent, trouble-free, smooth manner and are very durable and reliable in operation. All our mills are manufactured with rigidity in selection of materials, machining and strict inspections at various manufacturing stages as per rigid international standards to ensure customer delight. The mills come with attractive salient features and optional fittings.

Mixing Mill

Key Features & Benefits

Rigid and reliable construction :- To mix newer and tougher compounds

  • Special design at necks to withstand high-impact loads
  • Frames & Caps are fabricated

Long Service Life :- From minimum wear

  • Bearing bushes are centrifugally cast from wear-resistant copper alloy
  • Connecting gears are of special alloy steel and are flame hardened leading high durability
Mixing Mill

Trouble free maintenance

Precise Heat Transfer :- Rolls (of alloy chilled Cast Iron & uniform wall-thickness) with large cooling pockets restricts heat build-up in compound during mixing. Cored or Peripherically drilled Rolls are offered

Silent & Vibration Free :- Single beam base structure makes mill silent and vibration free.

Effortless Operation :- Manually or Motorized or Hydraulically Operated Nip adjustments with numerical controls available

Quick Installation :- Mills with Vibromount needs no foundation or time consuming installation procedures

Low Power Consumption :- Mills with anti-friction roller bearings save power.

Range :- 16" x 42", 22" x 60", 26" x 84" and 30" x 100"

Safety Features

  • Air operated brake mechanism between motor and gear box. Easily activated either by pulling an overhead wire or pressing a safety bar with chest
  • Bearings fitted with an alarm system to caution you when temperature shoots up

Calender

Flexibility, Accuracy, Quality, Reliabilty

calenders

Bainite Calenders are specially designed for frictioning of fabrics, single or double coating of fabrics, and sheeting applications. They are custom designed precision machines available with two, three or four roll configurations in different diameters and lengths, for rubber and plastic polymer industries.


Design parameters are determined by type of product, specific gravity, PLI, widths, thickness, temperatures, accuracy and productivity. Sophisticated Calenders with self-aligning roller bearings cross axis or roll bending mechanism, preloaders, direct drives, with motorized nip adjustment, etc are offered for precision products.


Key Features & Benefits

mixers
  • Rigid Construction :- Calender Housing is heavy-duty sturdy box type from fabricated, stress relieved & fully machined, steel and rolls are of chilled cast iron (or SG iron).
  • Efficient Heat Transfer :- Through Peripherally Drilled Rolls when running at high speed and temperatures.
  • Wrinkle Free Sheets :- From highly precision-ground super finished rolls with accurate degree of concentricity& profile.
  • Long Service Life :- From minimum wear and tear, as rollers of frictionless operation.
  • Consistent Quality - Roll Bending Device, Preloading Mechanism and Cross Axis adjustment of the rolls offset roll bend and achieves uniform thin sheet at high PLI.
  • Safety :- Emergency switches at convenient points as per international standards.
  • Hydraulic cushion (Splice Relief)

    mixers
  • Changing device for profile sleeves
  • Calendar Drives of International Standards - DC or VFD variable speed units.

Accessories

  • Edge Trimming Device
  • Centralized Grease Lubricating System
  • Roll Grinding & Polishing Devices
  • Associated Auxiliary Equipment

Configuration

We offer Calenders in vertical, offset as well as inverted "L", "S", "I" & modified "Z" type configurations.


Wide Range

16” x 36”, 18” x 48”, 18” x 54”, 22” x 60”, 24” x 68”, and 26” x 84”

Peripherals & Spares

Our quality solutions have prompted even overseas companies to turn to BAINITE for their requirements of spares & ancillary parts. Today, the company supplies a range of spares to match existing equipments, in addition to a line up of ancillary units like Cooling Drum Assembly, Heating Drum Assembly, Tension Stands, Stock Blender units for Mills and various special purpose machines.


peripheral and spares

Sheet Feeder

Bainite make sheet feeders come with high performance curved profile cutter made of hardened special alloy.
The sheet feeder, designed for effortless installation onto your exisiting mixing mill (or Batch Mixer) line, replaces manual labor with automatic feed, increase efficiency and improves the mix quality through better dispersion of uniformly cut rubber sheets upto 24mm thickness. Its hugger sheets up to 24mm thickness. Its hugger belt provides continous positive feed for sheets upto 800mm width. The conveyor is driven by 2.2KW, AC motor while a 7.5KW gear motor with VFD drives the cutter.

sheet feeder

Renewals and Upgradation

Renewals

Bainite Machine offers a spectrum of rebuilding / reconditioning services to clients who wish to rebuild their machinery after a fixed period or after the conclusion of the specified number of clearances. While rebuilding and upgrading such machines, the company conducts a close scrutiny of existing design characteristics. With well-equipped drawing and engineering facilities, the company uses latest technology to upgrade machines for higher productivity, mechanical strength & thermal efficiency.

 

 

 



BAINITE MAKE 1.6L LABORATORY MIXER

Lab Mixer

WIDE RANGE :


Capacity :1.6L / 3L / 5L


Types :Tangential and Intermeshing


Lab Mixer

Lab Mill

WIDE RANGE :


Capacity :150mm x 325mm


Types :Independently Driven Rolls / Unidrive / Semi-Unidrive


lab mill

B-TURBOTM ROTOR

B-Turbo

Features

120 0 Helix Angle / Extended Long Wing / Tip Cooling Higher Long Wing-Short Wing Ratio Suitable For both Carbon and Silica


Benefits

Quick Stock Bitings / Improved flow Dynamics of Compound Higher Dispersion / Improved distribution of compound low temperature Mixing-Tip cooled / Higher Contact Area per Kg of Compound


 

 

 



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