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The adjacent figure illustrates which standards and quality requirements MTI places on its mixers. Please click on a label to receive additional information.

Vertical Mixers

--> Please choose: a) Vertical Vessels / Mixing Tools b) Lifting Device / Heating Mixer Lid c) Material Deflector / Lid Clamps &Transport Eyelets d) Vertical Mixer Discharge / Alternatives e) Temperature Measurement / -Monitoring f) Jet-Filter / Aspiration g) Bearings / Shaft Seals / Standstill Control h) Drive Frame with V-Belt Drive / Intermediate Drive i) Machine Base / Platform

Horizontal Mixers

--> Please choose: j) Cooling- / Horizontal Mixing Vessel / Mixing Tools k) Speed- / Standstill Control l) Lid Lifting Device / Two-Hand operation m) Safety Lid / Safety Shoe n) Horizontal Mixer Discharge / Alternatives o) Cooling Water Installation / Double Jacket p) Temperature Measurement q) Jet Filter r) V-Belt Drive / Gear Drive s) Mixer Shaft Bearings / Seals t) Special Accessories

Control Boxes and Motors

--> Please choose: u) Control Boxes on Vertical Mixers v) Vertical Mixer Motor Variants w) Control Boxes on Horizontal Mixers x) Horizontal Mixer Motor Variants

a - Vertical Vessels / Mixing Tools

The special vessel form in combination with the geometry of the mixing tools and mixing tool speed ensure intensive mixing and at the same time short mixing cycles and careful product handling.

Mixing Vessels

• All product-related parts from stainless steel 1.4541.
• Discharge piston, adapted to the contour of the vessel, manufactured from stainless steel 1.4470
• Industry cross section 180 to 1200 grain correlates to roughness depths of " 2.5 µ - < 0.2 µ.
• Wall strengths, depending on mixer sizes, of 8 mm - 12 mm.
• Mixer floors, depending on mixer sizes, of 10 mm - 15 mm.
• Vessel isolation with insulating material and high-grade steel paneling from 1.4301.

Mixing Vessel Options

• Double jacket for heating and cooling.
• Up to 3 discharges possible.

Mixing Vessels

• Number of tools depends on mixer size and field of application.
• Tool blades

  complete with wear protection.

• Variable tool assembly, high flexibility through long mixer shaft (see g) and hull combinations.

b - Lifting Device / Heating Mixer Lid

Lifting device

Pneumatic lifting device with short-stroke pneumatic cylinder for lifting and swiveling of the mixer lid incl. solenoid safety sensor.

Vessel Lids

Variant 1 - Lift-/swivel lid:

• All product-related parts from stainless steel 1.4541.Flexible number of supports and positions - per customer specification.
• Completely rotatable (2 x 180°) for optimal lid and mixing vessel cleaning.

Variant 2 - Lift-/swivel lid:Lid can be opened, swivelled and rotated fully automatically.

c - Material Deflector / Lid Clamps &Transport Eyelets

Material Deflector (vortex support)

• All product-related parts from stainless steel 1.4541.
• Material deflectors mounted laterally in the vessel wall, variable positioning.
• Supports product circulation and input of liquid components.

Lid Clamps / Transport Eyebolts

• Lid clamps for dust-proof attachment of mixing vessel / lid.
• Transport eyebolts for assembly purposes.

d - Vertical Mixer Discharge / Alternatives

Vertical Mixer Discharge

• Generously dimensioned for fast and residue-free product discharging.
• Size depends on vessel size.
• Pneumatically operated with limit switch control.

Alternative 1 - Standard:

• Aluminum casing not swivelling.
• Cleaning lid at the top.

Alternative 3 - swivelling - steel:

• Stainless steel casing with swivelling front plate incl. discharge pistons and pneumatic cylinders.
• Casing made of steel 1.4301.
• Optimal cleaning by easy access.
• incl. Safety interlock via key transfer system.

e - Temperature Measurement / -Monitoring

Temperature Measurement / -Monitoring

• Sensors mounted laterally in the vessel wall with wear coating.
• Embedded in PTFE sleeve for isolation.
• Available as PT 100 or Fe-Cu-Ni.
• Analyser installed in the control cabinet.

Over temperature monitoring

• Hardware over temperature monitoring with automatic emergency functions.
• With integrated control panels by MTI - up to 3 temperature points with emergency management.

f - Jet-Filter / Aspiration

Jet Filter in compact design (optional)

• Available in 4 sizes with 1 - 4.8 sq.m.
• Conical filter cartridges with quick-change function.
• Compressed-air filter cleaning after loading and discharging.
• Size depends on vessel size and field of application.
• Stainless steel filter casing.

Aspiration (accessory option)

• Vertical mixer ventilation system also available for the Jet Filter.
• To exhaust exceeding humidity of the mixture.
• Consisting of fresh-air intake, Jet Filter, swivelling flap and ventilator.

• A MUST for good mixing quality and good pourability of the compound.
• Reduces wall deposits and lid films and thus the cleaning effort.

g - Bearings / Shaft Seals / Standstill Control

Mixer shaft bearings:

• Generously dimensioned shaft bearing above and below the pulley.
• The large distance between bearings and mechanically machined bearing seats on both sides on the drive frame make the long mixer shaft typical for MTI possible.
• Good maintenance and repair options with good access and simple assembly/dismantling of the shaft bearing.
• Bearing exchange without dismantling of the mixing vessel - optional with additional large service bottom.
• Optimal distribution of the tractive forces of the V-belt drive and thus very long bearing life.

Shaft seals:

• Standard radial shaft sealing with air-heterodyned slip ring.
• Compact casing variants for easy maintenance.
• Heat resistant to 170°C.
• Sealing lips run on replaceable run sleeves that are mounted on the mixing shaft.
• Special seals and ceramic coated run sleeves are used for special applications and vacuum operation.

Speed- / standstill control: Interrogation of mixer speed sensor and check, whether the mixer shaft has stopped completely after switching off the machine. The mixer can only be opened if the mixing tools have come to a complete stop.

h - Drive Frame with V-Belt Drive / Intermediate Drive

Drive frame / V-belt drive:

• Drive frame in rugged welded construction, mechanically machined on both sides, for supporting shaft bearings and V-belt drive.
• V-belt drive designed depending on the installed motor size with sufficient safety reserves.
• V-belt stretched to ensure optimal belt balance.
• Easy belt tightening by flexible motor carriage with tensioner.

Intermediate drive (from 355 kW motor size): Installation of intermediate drives for relieving radial tractive forces torque by larger drive motors, consisting of:

• Additional bearing for V-belt pulley on the motor side.
• Flexible coupling between motor and intermediate bearing / V-belt drive.
• Increased drive motor durability with no radial forces.
• Design easy to maintain, V-belt replacement and ball bearings without motor dismantling.
• At the same time, fast and easy motor dismantling for maintenance purposes, since the V-belt drive does not need to be dismantled.

i - Machine Base / Platform

Machine base:

• Steel substructure for supporting the drive frame.Standard rubber-bonded metal damping between drive frame and machine base.
• Steel machine base for positioning the vertical mixer above the Horizontal Cooling Mixer (level adjustment).
• Required for mixer platform and motor type V3 (IM 3031).

Mixer platform:

• Consisting of steps, platform and rail.
• Mounted on machine base for easy mixer cleaning and maintenance.

j - Cooling- / Horizontal Mixing Vessel / Mixing Tools

The design of the Cooling Mixer tools together with the appropriate speed ensure a three-dimensional material flow in the ring layer. A constant exchange of the cooling medium with the cooling surface occurs.

Forced water guidance in the double jacket is of critical importance. Energy is quickly dissipated with a turbulent flow of cooling water. Depending on the size of the Cooling Mixer, the double jacket is divided into multiple zones. Mixers beginning with size K 3300 are offered with cooled side plates.

With the new Cooling Mixer design, the front is implemented as flat bottoms. The resulting radii improves the product circulation and also optimizes wear.

Mixing Vessels

• All parts coming into contact with the product made of stainless steel 1.4301.
• Industrial polish 180 to 360 grid, depending on customer specification.
• Wall thickness depending on mixer sizes of 5 mm - 8 mm.
• Double jacket made of mild steel 1.0037.
• Discharge pistons made of high-grade steel 1.4470.

Mixing Vessel Options

• Double jacket completely made of 1.4301.
• Inspection- / cleaning flange for double jacket on the lower side of the vessel.
• 2 different discharge types depending on the field of application.
• Position and number of discharges according to customer requirements.
• Additional inlet sockets in various sizes.
• High-speed chopper, mounted in the side wall of the Cooling vessel.

Mixing Vessels

Mounted on rugged tool arms with tensioners mounted on the mixer shaft. Cooling mixer tools adapted to the vessel contour, made of 1.4301.

k - Speed- / Standstill Control

Speed- / standstill control:

Interrogation of mixer speed sensor and check, whether the mixer shaft has stopped completely after shutting down the machine. Other safety functions are explained in

-m - Safety Lid .

l - Lid Lifting Device / Two-Hand operation

Gas springs:

The opened cleaning flap is being supported by gas springs when opening and closing and ensure that the lid does not shut by itself.

Mixers sizes K 2400 and larger also support closing and opening with pneumatic cylinders.

In addition closing and opening with pneumatic cylinders will be supported. 2-hand operation, mounted on the side wall of the mixer.

m - Safety Lid / Safety Shoe

Safety lid: The safety interlock of the lifting device is released after the machine has stopped (check by means of standstill control - point k) and the mixer lid can be opened.

Safety shoe:

The safety shoe is stretched after opening the vessel on the lower edge of the cleaning flap, thus preventing the tools from manually turning while cleaning.

n - Horizontal Mixer Discharge / Alternatives

Horizontal Mixer Discharge

• Generously dimensioned for fast product discharging.
• Number depending on the vessel size
  (K 5000 or larger with 2 discharges standard).
• Pneumatically operated with limit switch control.

Alternative 1:

• Aluminium casting with discharge pistons adapted to the mixer vessel contour.
• Size and numbers dependent on mixer size.
• Discharge pistons made of material 1.4552.

Alternative 2:

• discharge with rotary flap.
• Size and number depentent on mixer size and type.
• rotary flap made of stainless steel 1.4301.

Alternative 3 - Vertical mixer discharge:

• Implementation as described unter point d.
• Aluminium housing with discharge piston adapted to the contour of the vessel. Also available in swivel design with key transfer system made of stainless steel.
• Discharge closing against product stream possible.
• Particularly recommended for partical discharging.

o - Cooling Water Installation / Double Jacket

Number of cooling zones depends on the mixer size:

• K 400 - K 1600: Cooling vessel and cleaning flap placed in rows.

• K 2400: Cooling vessel and cleaning flap connected in parallel to two cooling zones.

• K 3300 - K 4250: Cooling vessel divided in two halves and connected with the cleaning flap parallel to three cooling zones.

• K 5000 - K 8000: Cooling vessel divided into three cooling zones and connected with the cleaning flap parallel to four cooling zones.

Cooled side windows:

Cooled side windows are offered for K 3300 or larger that are then integrated as additional cooling zones in the cooling circuit.

General workmanship:

• Horizontally arranged water channelling.

• Water fed by hand valve with downstream, electromagnetic shut-off valve.
• Water volumes of individual cooling zones adjustable via butterfly valve.
• Water return via uptake with free flow.
• Analog thermometer in the total flow and in the uptake of each cooling zone.
• Total flow equipped with analog manometer.

p - Temperature Measurement

Temperature Measurement

• Sensors mounted on the side of the vessel wall.
• Embedded in PTFE sleeve for isolation.
• Available as PT 100 or Fe-Cu-Ni.
• Evaluation devices installed in the control cabinet.

q - Jet Filter

Jet Filter in compact design (optional)

• Available in 4 sizes with 1 - 4.8 sq.m.
• Conical filter cartridges with quick-change function.
• Compressed-air filter cleaning after loading and discharging.
• Size depends on vessel size and field of application.
• Steel filter casing.

r - V-Belt Drive / Gear Drive

MTI offers two different drive variants for the horizontal / cooling mixer series.

Gear drive:

Compact implementation for easy mixer assembly and maintenance. Drive unit on rugged welded construction mounted laterally to the vessel.

Structure and action:

1. Flexible coupling between mixer shaft and gear unit to prevent shock loading and vibration transfer from the mixing area.
2. Siemens Geared Motors (FLENDER®) brand gear unit with optional cooling to ensure optimal gear temperature.
3. V-belt drive between transmission and motor to prevent damage to gears if overloaded.

V-belt drive:

• special design on request against surcharge.
• Small pulley on the motor side, large pulley on the mixer side.
• Transmission system via narrow V-belt, number dependent on motor size.
• Mounted under split protective cover.
• Motor mounted in extended base of the vertical mixer.

s - Mixer Shaft Bearings / Seals

Mixer shaft bearings:

• Generously dimensioned shaft bearings on the left and right of the vessel.
• Self-cleaning, self-aligning ballbearings are used.
• Mounted on bearing seats welded on the side of the vessel.
• Protected with dust covers against dust contamination and intrusion.
• Easy assembly/disassembly with open access.

Seals:

• radial shaft seal rings with air-heterodyne reliably.
• Compact casing variants for easy maintenance.
• Heat resistant to 170°C.
• Sealing lips run on replacable run sleeves that are mounted on the mixing shaft.
• Special seals and ceramically coated run sleeves are used for special applications.

t - Special Accessories

Special accessories:

MTI offers a number of options and accessories for the horizontal / cooling mixers. These include among others:

• High-speed chopper, front-mounted in the vessel wall.
• Nozzles for liquid injection.
• Sampler device for small quantities.
• Front-mounted vertical mixer discharge for samplings.

u - Control Boxes on Vertical Mixers

Control box on the heating mixer:

• Connected by Profibus DP and SafetyBUS.
• Decentralized peripheral system Siemens Step 7 with digital and analog inputs/outputs (acuators/sensors on the mixing equipment).
• Control unit for operating the pneumatic equipment on the vertical mixer.

v - Vertical Mixer Motor Variants

Vertical mixer motor variants:

The vertical mixer motors can be implemented in V1 (IM 3011) or V3 (IM 3031) depending on the desired mechanical implementation of the machine.

V1 (IM 3011) = Motor upward (no mixer stage)

V3 (IM 3031) = Motor downward (version for mixers with stage)

The following are available:

• Single speed motors
  Constant speed during the mixing process
• Two speed motors
  Speed I while loading and discharging
  Speed II during the mixing process.
• Single speed motors with frequency converter and external fan
  Variable speed for optimal formula adjustment.

w - Control Boxes on Horizontal Mixers

Terminal box on cooling mixer:

• Connected by terminal strip
• Control and signaling elements wired to terminal strip.
• Control unit for operating the pneumatic equipment on the horizontal mixer.

x - Horizontal Mixer Motor Variants

Horizontal mixer motor variants:

Motors for gear drives and optional for V-belt drives depending on the desired mechanical implementation of the machine are available.

The following are available:

• Single speed motors
  Constant speed during the entire mixing process
• Single speed motors with frequency converter and external fan
  Variable speed for optimal formula adjustment.

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