Industrial Mixer for Colors, Masterbatch & Compounds
Color Powder Premixes
For optimum color application of pigments. Clean tool changes and highest mixing quality.
MIXACO industrial mixers guarantee optimum mixing techniques, which are extremely important in the production of powder coatings and paints. Our mixers are ideally suited for the wide range of products and applications in the field of paints and powder coatings.
The high precision and cleanliness in processing ensures perfect mixing qualities. Our mixers for the paint industry are based on over 50 years of experience in industrial mixing technology.
Stationary mixers and container mixers. Mixing paints and powder coatings perfectly.
In the production of powder coatings and paints, the optimum mixing technology is very important. This is because, in addition to the wide range of products and applications, precision and cleanliness in processing are particularly important here.
MIXACO has the optimum mixers and tools, as well as extensive know-how in the efficient and careful mixing of color powders and powder coatings.
Our specialists are very experienced in the practice of the paint industry. They know the requirements when dealing with individual color recipes and concrete formulations.
From this, they work together with our customers to develop targeted solutions for the industrial production of high-quality paints and powder coatings. Once MIXACO’s machines have been adjusted for the formulation, production can proceed perfectly and smoothly on a permanent basis.
All important parameters are already taken into account in extensive trial runs. During the mixing process, the focus is on dispersion in order to achieve the best possible color application of the pigments.
This makes it possible to use cost-intensive pigments economically. At the same time, processing quality can be improved in many areas. For example, effect pigments require very gentle handling due to their filigree form.
The bonding of the pigments to the powder coating particles is carried out very carefully with MIXACO’s mixers.
Convince yourself of the advantages of our industrial mixers for the production of paints and powder coatings:
- Mixer with double jacket for heating / cooling
- Airtight mixing vessels without dead spaces
- Designed according to hygiene standards of the chemical industry
- Shorter mixing times than commercially available mixing systems
- Homogenize dry & wet formulations in highest quality
- Realize several process steps in one mixer: Mixing, moistening, coating
- High throughputs, rapid discharge and fast formulation changeover
- Batch backtracking possible
- Very high degree of residual emptying
- Variable filling degree
- Batch sizes of our container mixers are scalable from 6 to > 10,000 liters and grow with your production capacities
- Intensive and excellent homogenization of the mixed material, often after only 3 minutes mixing time
- Mixing quality is guaranteed even with difficult components – for end products of consistent quality
- Extremely gentle mixing – without heating if required – allows even the most sensitive color particles to be homogenized
- Minimal cleaning effort for fast recipe changes: mixing elements and mixing tools easily accessible and demountable
- Low idle times due to quick and easy cleaning
- Solid and low-maintenance machine technology “Made in Germany” guarantees high availability of the production plant
- Specially coated mixing tools for long service life
- MIXACO mixers are available in various ATEX versions
- Low energy consumption due to innovative designs and tools
- Optimal application solutions through customized tests and mixing procedures
- Easy & safe operation of industrial mixers due to innovative machine concept
- Special mixer designs with special materials
From Bonding to SPC. We mix all paint powders and powder coatings.
We supply mixing systems for the development and production of powder coatings and paints in numerous dimensions and batch sizes.
As a leading manufacturer in this market, MIXACO offers maximum efficiency, highest mixing quality, optimum machine availability and unique know-how for the individual requirements of the paint industry.
Coatings can be made from metal powders for a range of metallic finishes – from silver to gold and with all degrees of gloss and profile. With the addition of metal powders and special pigments suitable for thermoplastic polymers.
- Powder coatings
- Color masterbatch
Processes and functions. Mixers for the high requirements in the production of color powders and powder coatings.
Applications in the paint industry such as color masterbatches or mono masterbatches or single pigment concentrates (SPC) constantly require new considerations around the starting materials, the processes and the working procedures.
The process knowledge of our specialists is also given in the decades-long production of powder coatings. Where clean mold changes, fast container exchange and the highest mixing quality come together, MIXACO proves its true greatness time and again.
With the holistic view of the workflows around mixing, our solutions simplify and optimize production sustainably. Even in small batches, mixing processes can be accelerated and batches of different sizes can be produced more flexibly.
MIXACO has well-founded know-how in the mixing of paints and powder coatings. We master all processes for all common products and processes in the paint industry. If the solution for a new idea is still missing, we will help you develop it immediately.
For the production of powder coatings, the extruders must be fed with premixed material. For this purpose, all raw materials with which the downstream (spraying) machines are to be fed must first be completely mixed to form a homogeneous mass.
MIXACO industrial mixers always provide the best alternative to traditional high-speed mixers when production conditions require a high degree of versatility and many different products are to be mixed with one and the same mixer.
Thanks to the special design, where the container mixer is divided into two separate units (mixing head + transportable container), the cleaning time between batches and therefore the risk of contamination when changing from one type of production to the next can be reduced to a minimum.
Mixing, storage and transport are optimized as they are carried out directly in the same containers. These can be effortlessly inserted into a metering system with both a scale and a metering device for discharge into an extruder.
Our container mixers are also ideal for mixing with metallic pigments (metal blending) following production, guaranteeing the distribution of the pigments in a safe, controlled environment inertized with nitrogen.
Additional functions. Mixing colors and powder coating individually.
Via various additional options, our mixers are perfectly matched to the production of your paints and powder coatings:
- Temperature measurement of the mixed material
- Aspiration heating mixer / jet-filter cooling mixer
- Ventilation and feeding during the mixing process
- Dosing of liquids and gases during the mixing process
- Data recording and evaluation
- Remote maintenance
- Compatibility with existing plants
- Advanced stainless steel design
- Wear protection of the tools
- Possibility of addition in mixing position
- Special coating
- AGV (automatic guided vehicle) compatibility
- ATEX/NEC execution
- MIXACO Control Center
- and more
Mixer Quotation Configurator: Just 2 minutes to the perfect mixer for your raw materials.
Simply tell us your requirements and we will recommend you the optimum mixer for your raw materials and applications. Use our configurator.
With your details on quantities, mixtures, temperatures, additional functions and other information, we will prepare a customized quotation for you.
Metallic powder coating. Bonding in the production of powder coating.
Metallic powder coatings are best produced by the bonding process, which is relatively safe and, if done correctly, will not leave free metal particles in the powder.
The bonding process can be described as complete adhesion of metal pigments to the thermosetting base. Problems associated with separation and agglomeration disappear with the simultaneous possibility of recycling the powders as with normal powder coatings without metal pigments.
The metallic effect is constant even with large product batches and surfaces. The risk involved in mixing pigments, especially those made of aluminum, is eliminated by creating a safe base for the process (inerting using nitrogen) and using the best equipment approved for use in explosive ATEX environments for production.
The bonding process can be divided into different sections:
This is achieved with the help of heat and softening of the powder coating and subsequent mixing of the metal pigments until all particles literally “stick” to the surface of the powder particles.
To obtain this effect, turbo mixers are most commonly used: For this purpose, the powder coating and the metal pigments are loaded into the high-speed turbo mixer (which is usually jacketed to allow control of the process temperature) and then mixed at high speed for a few minutes.
The mixing energy leads to an increase in the temperature of the powder until the softening temperature is reached (TG: 40 to 60 °C), which allows the metallic pigments to adhere to the surface of the powder. After reaching the end point of the mixing process, the mixture is quickly drained into a cooling device to counteract premature hardening/solidification.
The hot mixture must be cooled as quickly as possible (25 °C). This is done with the help of a separate cooler with low intensity and water-cooled jacket, which is sufficient to reduce the temperature of the mass.
In most cases, the amount of material subjected to the bonding process corresponds to a small portion of a larger batch, and thus the cooler can also cool up to 3 batches from the bonding line simultaneously.
Since the powder coating is exposed to heat during the bonding process and can therefore form lumps, these may have to be removed from the end product. A 130 -150 micron mesh screen is usually sufficient for this.
The final requirements for an optimal bonderized powder coating are: optimal recycling of the powders during the application process thanks to the solid bond between the metallic pigments and the base of bonderized powder; no separation of the powder coating during the application by spraying; uniform application also of the metallic effect on the workpiece.
Further Information see https://de.wikipedia.org/wiki/Pulverlack
Premixing of raw materials https://www.interpon.com/de/artikel/die-pulverlackherstellung
All raw materials used in powder coatings are in a solid state when mixed. The polymer and the other ingredients (such as pigments, fillers, crosslinkers, etc.) are precisely weighed out and poured into a mixing vessel. The substances are then mixed to produce a homogeneous substance.
This premix is then fed into the extruder, whose barrel is kept at a precisely defined temperature. The barrel temperature is set so that the polymer just liquefies.
Too high a temperature will result in low melt viscosity with low shear and poor pigment distribution, so the coating would not have the desired performance properties.
Now the feed rate at the hopper and the speed of the extruder screw are adjusted so that the screw is always well filled. By carefully tuning these three parameters, high shear forces are maintained so that thorough mixing occurs in the extruder.
The molten extrudate is passed between chill rolls and emerges as a thin sheet about one millimeter thick before being broken into pieces about 10 to 20 mm in size (https://www.neuman-esser.de/unternehmen/media/dosieren-und-dispergieren/).
In powder coating preparation, additives such as aluminum oxide (AI2O3) or silicon dioxide (SiO2, silica), i.e. silica, are used to improve the flowability of the solid particles.
The cost of additives in powder coating production can be reduced by improving the dispersion of the additive in the powder coating. This reduces the amount of additive required, while maintaining the desired flowability.
Additives in powder coatings include leveling agents, matting agents, structural additives, flowability agents and waxes that affect the surface. Most powder coating additives are combined with the premix and incorporated into the formulation during extrusion.
However, additives that influence flowability, such as alumina and silica, are mixed with the powder coating only after extrusion. These post-blend additives are added either before, during or after grinding .
For the application of the powder coating, the flowability is particularly important. The additives, mainly aluminum oxide and silica, facilitate the transport of the powder coating, avoid surface defects and spitting during the application of the powder coating. Alumina also improves storage stability, it prevents moisture absorption of powder coatings and improves edge coating of substrates. In addition, aluminum oxide increases the electrostatic positive chargeability of tribo powders .
As a rule, approx. 20 t to 50 t of additives are required per 10,000 t of powder coating. The aim is to reduce the amount of aluminum oxide or silica added to the powder coating during production.
The quality of the powder coating is also to be improved. White spots on the coating surface, caused by agglomeration in the powder coating, are to be reduced or avoided.