IKA - Siselec

IKA ®Kneading

IKA ® Heavy-Duty Kneading MachinesIKA ®Horizontal kneading machinesThe horizontally arranged kneading blades ofthe IKA ® -DUPLEX and ZETA heavy-dutykneading machines are able to processmixtures of highest viscosities. Due to theincreased shear forces achieved by theDUPLEX blade geometry, the kneading timecan be reduced by up to 30% – at improvedproduct quality.Already in the basic execution all IKA ® kneadingmachines are equipped with usefuloptions and interfaces. Thus IKA ® is setting astandard for kneading machines.page 4Process control systemsThe IKA ® software team isdeveloping customer specificand tailor-made control systems,from a simple PLC-control up tofully automatic process controlsystems, even with voice control.page 10Continuous kneading machinesThe fully automatic kneadingand extrusion machineCONTERNA, an economic alternativeto our batch kneaders.It is a new procedure acc. to thefunctional principle of an “inlinekneader”, which already gainedacceptance for many productionprocesses and replaced thebatch process with its knowndisadvantages.page 83

HKS / HKDA very large viscosity rangefrom – for a kneading machine –rather low-viscous glues (hotmelts)up to extremely highviscousrubber mixtures can beprocessed with the IKA ® horizontalkneading machines withDUPLEX or ZETA blades.The use of these kneadingblades patented by IKA ® resultsin a substantially improvedproduct homogeneity and asaving of up to 30% of kneadingtime compared to the classicalZ-kneaders.Vacuum-tight and doublejacketed kneading bowls, highqualitystainless steel for allparts in contact with the productand high-quality shaft seals witheasy access for service andmaintenance are part of theIKA ® basic equipment.4

IKA ® Horizontal Kneading MachinesApplicationsIKA ®Glues (e.g. hotmelts)Rubber massesPlastic mixturesCeramic masses, porcelainColour mixtures(e.g. printing inks)Carbon pastesGraphite mixturesDue to useful options like e.g.discharge screw, removablesidewall or removable kneadingbowl IKA ® kneaders became thestandard machines for manyapplications.Type Useful volume Drive power Dimensions with discharge screw,approx. (L x W x H)I kW mmHKD 2,5 1,75 0,75 1175 x 360 x 460HKS / HKD 10 7 1,5 / 2,2 1365 x 500 x 1350HKS / HKD 25 17 2,2 / 4 1450 x 880 x 1280HKS / HKD 50 35 4 / 5,5 1920 x 700 x 1400HKS / HKD 125 85 7,5 / 11 2070 x 1000 x 1770HKS / HKD 250 170 11 / 15 2975 x 1255 x 1890HKS / HKD 500 350 15 / 22 3400 x 1640 x 2750HKS / HKD 1000 700 37 / 37 3830 x 2030 x 3600Further sizes on request5

PLANETRON ® HKVCompared to the classical planetarymixer with only one drivemotor, the IKA-PLANETRON ®vertical kneading machine in theexecution with 2 drive motorsenables – additionally to the speedadjustment – a variable adjustmentof the speed relation of the twokneading blades. Due to this factalso very sticky masses like e.g.hotmelts can now be processed ina vertical kneading machine. Instandard planetary mixers thesemasses climbed up at the kneadingblades and were thus no moreeffected by the shear forces.6PLANETRON ® heavy-dutykneading machines are workingwith kneading blades that are onlyone sided running on bearings.Thus the product to be kneadeddoes neither come into contactwith seals nor bearings, resultingin highest product pureness.The use of several kneading bowlsenables a semi-automatic process.

IKA ® Vertical Kneading MachinesApplicationsIKA ®Dental massesCeramic massesMIM / CIMPharmaceutical andcosmetic productsPlasticsFoodFrequency controlled drives,different types of controls, vacuumemptying system or emptying bymeans of a hydraulic pressureplate, dosing tubes and viewingglasses represent only an extractfrom the rich offer of usefuloptions.Very easy cleaning of the kneadingbowls and – depending on productviscosity – discharge through abottom outlet valve and undervacuum may save one or severalprocess steps. The product candirectly be dosed from thekneading bowl via a transportsystem into the packing unit.IKA-PLANETRON ® verticalkneading machines are availablein many different sizes. They canthus be used from research (e.g.development of recipes) with minimumuseful volumes starting from100 ml up to mass production withuseful volumes up to 1600 l.Type Useful volume Drive power Dimensions, approx. (L x W x H)I kW mmHKV 1 0,5 0,37 400 x 600 x 880HKV 5 2,5 1,1 600 x 660 x 860HKV 25 12,5 2,2 960 x 800 x 1800HKV 50 25 4 1140 x 935 x 2150HKV 100 50 5,5 1370 x 1045 x 2295HKV 200 100 7,5 1660 x 1280 x 2635HKV 400 200 11 2040 x 1570 x 3300HKV 800 400 18,5 2600 x 2320 x 4300HKV 1600 800 45 3400 x 2700 x 4550HKV 3200 1600 75 4200 x 3600 x 6000Further sizes on request7

CONTERNA HKCSince already several years the CONTERNA,IKA ®´s continuous kneading and extrusion machine,is doing an excellent job in numerous productionprocesses, which in former times could only bemanaged batchwise at high cost and with a greatnumber of personnel.There are different industrial branches where thisso-called “inline-kneader” gained acceptance asthe standard machine within a few years. Greatprofitability by reduction of kneading times andhigher product quality.An HKC 12/10 with 12 chambersof each 10 l volume for theproduction of different siliconerubber masses. Due to theincreased number of chambersthe optimum viscosity can beadjusted at the end of thekneading process.An HKC 6/2,5 with 6 chambers of each 2,5 luseful volume. This size is especially suitedfor development of recipes, parameteroptimization or as a pilot plant. A machineof this size is available for trials in the pilotplant of the IKA ® process equipmentdivision.HKC 6/50 with 6 chambers of each 50 luseful volume. Up to 1 t/h of rubbermasterbatchis processed in thisCONTERNA. All renowned Europeanmasterbatch producers changed over tothis continuous production process.Type Throughput Drive power per chamber Dimensions, approx. (L x W x H)I/h kW mmHKC 6/2,5 10 – 80 1,5 1600 x 1480 x 1600HKC 6/5 20 – 200 3 1600 x 1550 x 2000HKC 6/10 70 – 400 5,5 1750 x 1600 x 2600HKC 6/25 120 – 1000 9,2 2600 x 1900 x 3600HKC 6/50 200 – 2000 22 3200 x 2200 x 4490HKC 6/125 500 – 4000 37 4300 x 2950 x 6100Further sizes on requestDimensions with hydraulic opening of chamber block and extruder8

IKA ® Continuous KneadingApplicationsIKA ®Rubber masterbatchesPlastics masterbatchesGluesSealing massesFood, animal foodSilicone rubberThe constructional principle of theCONTERNA allows to arrange asmany kneading chambers “in line”as necessary for the respectivetask.There is the same variabilityregarding the geometry of thekneading blades, the executionof the drives of each chamber, thecooling resp. heating possibilitiesand many other machine parameters.The CONTERNA can replace several formerprocess steps, at reasonably shorter kneadingtime and improved product quality. Thehomogeneous repartition of the raw materials ina finished rubber masterbatch has e.g.been much improved compared to thebatchwise processing in piston kneaders.9

IKA ® Process ControlProcess control systemsSchemaThe process control systemdeveloped by IKA ® does notonly control the kneadingmachine or the mixingprocess itself, but also allother process steps likedosing and the downstreamequipment of the kneadingmachine.Together with our customersthe IKA ® software teamelaborates individualsolutions.10

IKA ® ServiceIKA ®Spare parts and repairsFor securing a quick and smoothsupply of spare parts, also incase of repairs, IKA ® -WERKEis keeping a modern partsstockroom with continuousstock supervision.Research and developmentA well equipped pilot plant withall necessary trial machines aswell as measuring and documentationpossibilities is at ourcustomers’ disposal. Existingprocesses can be optimized bytrials and new procedures canbe developed.This pilot plant is of coursealso intensively used by ourown design department foroptimization of existing anddevelopment of new machinesand processes.Quality assuranceEvery single IKA ® productis submitted to a final qualityassurance control before itleaves our workshop, in orderto test its complete functionalityand to ensure a smoothintegration into the customer’sproduction line.11

IKA ® subsidiaries world-wideIKA ® WORKS USAWilmington, North CarolinaIKA ® -WERKEStaufen, GermanyIKA ® -WERKELiaison Office IndiaCochin, KeralaIKA ® WORKS JapanOsaka/NaraIKA ® WORKSGuangzhou, ChinaIKA ® WORKS ASIAKuala Lumpur, MalaysiaIKA ® WORKS do BRASILRio de JaneiroIKA ® -WERKE GMBH & CO. KGJanke & Kunkel Str. 10D - 79219 StaufenPhone 49 (0) 76 33 / 8 31-0Fax 49 (0) 76 33 / 70 87E-Mail: process@ika.deInternet: www.ikaprocess.comDIN EN ISO 9001Reg. Nr. 20602-01KN/06/02-GB