Process :
Calandering is an efficient process for producing flat rubber sheets & for lamination, frictioning, coating & embossing operation. This process is done by calander machine. Calander machine is similar to a rubber mill, where rubber & other components pass between two or more metal rolls. However, in order to produce product of controlled thickness, significantly higher pressure is needed, hence calander rolls, journals & frame are more carefully designed & constructed.

Types of Calander M/C :

• Two Rolls
• Three Rolls
• Four Rolls

Construction Details :
Bed Plate : The basic bed plate is steel fabricated perfectly machined single piece on which whole machine with gear box & motor are fitted.

Stand & Caps : Precision designed for load bearing under extreme working conditions.

Rolls : Chilled alloy cast iron rolls, hollowed for efficient cooling / heating are provided. The hardness is 450 to 550 BHN.

Journal Boxes & Bushes : Made out of cast iron with adequate wall thickness & machined to close tolerance. Bushes are of phosphorous bronze of laboratory tested composition.

Gear Box : Radicon / Elecon make reduction gear box.

'Santec' Dispersion Kneaders are ruggedly designed for the mixing of different kind of materials ranging from low viscosity adhesive to high viscosity polymers.

Applications :

• Rubber Compounds & End Products
  Natural Rubber, Synthetic Rubber Mastication of NR, IIR, SBR, CR, EPDM, Fluorine Rubber, Silicone Rubber. Rubber Tires, Packing Gaskets, Hose, Belts, Shoe Sole, Sponge, Electric Wire Covering, Casters, Golf Balls, Oil Seal, Weather Strips, Water Proof Sheet, EVA, Thread Compound Battery Containers etc.
• Plastic Compounds & End Products
  HDPE, LDPE, PP, PVC, ABS, PS, EVA Thermoset plastics compounds & profiles wire covering, BMC etc.

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Salient Features :

• Maximum Dispersion & High Production
  Double blades, proper clearance and high cooling effect gives excellent dispersion which can not be obtained form a open roll mill. Its production is 4-5 times more than an ordinary mixing-mill thus saving on labour and electricity.
• No Foundation Required
  The kneader has a common bed-plate for all parts and required no foundation.
• Easy Cleaning & Colour Change
  Mixing chamber can be tilted which enables easy cleaning, because of this, different coloured compounds can be made without trouble.
• Easy Operation
  Easy operation with push-buttons and handlever valves from the operating board.
• Short Mixing Time
  Mixing time ranging from 6 to 12 minutes depending on compound's specific gravity.
• Accident Proof
  No chance of an accident as on open roll-mill.

Comparison Chart:
Comparison chart for Mixing Mill, Dispersion Kneader and Banburry :

	Mixing Mill	Dispersion Kneader	Banburry
Initial Cost	Low	High	Very Expensive
Mixing Quality	Good	Better	Best
Degree of Dispersion	Good	Better	Best
Construction	Open Type	Enclosed Type	Fully Enclosed
Safety	Risky	Completely Safe	Completely Safe
Operator's Experience	3 to 4 Years Experienced Operator	Semi Skilled Operator	Fully Skilled Operator
Mixing Time	15 - 50 minutes	7 - 15 minutes	3 - 5 minutes
Dispersion Effect	Good for High Viscosity Material, but not for Low	Good for both High & Low Viscosity Material	Good for High Viscosity Material, but not for some low viscosity materials
Production Output	Small	Very Good Production	Highly Productive
Heat Conductivity	Good for low temperature mixing, but high temperature mixing is impossible	Good for both high & low temperature mixing	Good for high temperature mixing, but low temperature mixing is impossible
Batch Capacity	Can be increased	Constant	Constant
Colour Charge	Easy	Easy	Difficult

Applications:
' SANTEC ' Dispersion Kneader is suitable for compounds for following products :

Hoses Shoe - Soles Footwears EVA Rubber & TPR Belts Sponges Sports Balls Vibration Insulators Elastic Cord Automobile & Electric Rubber Parts

Chemical Industry Compounds Master Batches Phenol, polythene and other thermoplastic resins Tyres & tubes Micro Sheets Tread Compounds E.P.D.M. Silicone Rubber Plastic Compounds Battery containers and many more applications

PICT2095

PICT2109

Construction
Mixing Chamber : The mixing chamber is made from alloy steel & is a 'W' shape through which the rotors are assembled. The contact surface of the chamber is stelite welded & wear resistant hard chrome plated. Special steel jacket is provided for cooling & steam for heating. The rotors are coupled with special quality rotary joints to take water or steam.

Pressure Lid : This is made from alloy steel & is fitted with special pneumatic cylinder to press the material to be mixed. Wider surface area is provided which allow the ingredients being mixed to turn & move in the chamber freely. An arrangement for water or steam circulation is provided & the surface is hard chrome plated.

Dust Collector : Dust collector is provided to collect spurt powder during mixing & this collected powder can further be used in mixing, hence saving of waste material.

Electrical Control Board : A powder coated, dust proof electrical panel box is provided fitted with voltmeter, ampere meter, temp. indicators cum controller, contactors, timer, buzzer, emergency button, interlocking provision, on/off switches for motors, hand operated valves, overload relay etc.

Bed Plate : The machine has common bed on which all components are arranged in proper manner by which there is no need of foundation.