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IKA®
K n e a d i n g
IKA Kneading 25.07.2002 8:50 Uhr Seite 2
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Vertical kneading machines
PLANETRON® heavy-duty
vertical kneading machines are
always used when high-viscous
masses have to be kneaded
intensively and absolutely free
of contaminations. During the
kneading process the product
neither touches shaft sealings
nor bearings and thus remains
absolutely free of even the
smallest contaminations.
page 6
IKA Kneading 25.07.2002 8:50 Uhr Seite 3
IKA®
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Process control systems
The IKA® software team is
developing customer specific
and tailor-made control systems,
from a simple PLC-control up to
fully automatic process control
systems, even with voice control.
page 10
Continuous kneading machines
The fully automatic kneading
and extrusion machine
CONTERNA, an economic alter-
native to our batch kneaders.
It is a new procedure acc. to the
functional principle of an “inline
kneader”, which already gained
acceptance for many production
processes and replaced the
batch process with its known
disadvantages.
page 8
IKA® Heavy-Duty Kneading Machines
Horizontal kneading machines
The horizontally arranged kneading blades of
the IKA®-DUPLEX and ZETA heavy-duty
kneading machines are able to process
mixtures of highest viscosities. Due to the
increased shear forces achieved by the
DUPLEX blade geometry, the kneading time
can be reduced by up to 30% – at improved
product quality.
Already in the basic execution all IKA® knead-
ing machines are equipped with useful
options and interfaces. Thus IKA® is setting a
standard for kneading machines.
page 4
IKA Kneading 25.07.2002 8:51 Uhr Seite 4
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A very large viscosity range
from – for a kneading machine –
rather low-viscous glues (hot-
melts) up to extremely high-
viscous rubber mixtures can be
processed with the IKA® hori-
zontal kneading machines with
DUPLEX or ZETA blades.
The use of these kneading
blades patented by IKA® results
in a substantially improved
product homogeneity and a
saving of up to 30% of kneading
time compared to the classical
Z-kneaders.
Vacuum-tight and double
jacketed kneading bowls, high-
quality stainless steel for all
parts in contact with the product
and high-quality shaft seals with
easy access for service and
maintenance are part of the
IKA® basic equipment.
HKS / HKD
IKA Kneading 25.07.2002 8:51 Uhr Seite 5
IKA®
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Due to useful options like e.g.
discharge screw, removable
sidewall or removable kneading
bowl IKA® kneaders became the
standard machines for many
applications.
Applications
Glues (e.g. hotmelts)
Rubber masses
Plastic mixtures
Ceramic masses, porcelain
Colour mixtures
(e.g. printing inks)
Carbon pastes
Graphite mixtures
IKA® Horizontal Kneading Machines
Type Useful volume Drive power Dimensions with discharge screw,approx. (L x W x H)
I kW mm
HKD 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 request
IKA Kneading 25.07.2002 8:51 Uhr Seite 6
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PLANETRON® HKV
PLANETRON® heavy-duty
kneading machines are working
with kneading blades that are only
one sided running on bearings.
Thus the product to be kneaded
does neither come into contact
with seals nor bearings, resulting
in highest product pureness.
The use of several kneading bowls
enables a semi-automatic process.
Compared to the classical plan-
etary mixer with only one drive
motor, the IKA-PLANETRON®
vertical kneading machine in the
execution with 2 drive motors
enables – additionally to the speed
adjustment – a variable adjustment
of the speed relation of the two
kneading blades. Due to this fact
also very sticky masses like e.g.
hotmelts can now be processed in
a vertical kneading machine. In
standard planetary mixers these
masses climbed up at the knead-
ing blades and were thus no more
effected by the shear forces.
IKA Kneading 25.07.2002 8:51 Uhr Seite 7
IKA®
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Frequency controlled drives,
different types of controls, vacuum
emptying system or emptying by
means of a hydraulic pressure
plate, dosing tubes and viewing
glasses represent only an extract
from the rich offer of useful
options.
Applications
Dental masses
Ceramic masses
MIM / CIM
Pharmaceutical and
cosmetic products
Plastics
Food
IKA® Vertical Kneading Machines
Very easy cleaning of the kneading
bowls and – depending on product
viscosity – discharge through a
bottom outlet valve and under
vacuum may save one or several
process steps. The product can
directly be dosed from the
kneading bowl via a transport
system into the packing unit.
IKA-PLANETRON® vertical
kneading machines are available
in many different sizes. They can
thus be used from research (e.g.
development of recipes) with mini-
mum useful volumes starting from
100 ml up to mass production with
useful volumes up to 1600 l.
Type Useful volume Drive power Dimensions, approx. (L x W x H)I kW mm
HKV 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 request
IKA Kneading 25.07.2002 8:51 Uhr Seite 8
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CONTERNA HKC
An HKC 6/2,5 with 6 chambers of each 2,5 l
useful volume. This size is especially suited
for development of recipes, parameter
optimization or as a pilot plant. A machine
of this size is available for trials in the pilot
plant of the IKA® process equipment
division.
An HKC 12/10 with 12 chambers
of each 10 l volume for the
production of different silicone
rubber masses. Due to the
increased number of chambers
the optimum viscosity can be
adjusted at the end of the
kneading process.
HKC 6/50 with 6 chambers of each 50 l
useful volume. Up to 1 t/h of rubber-
masterbatch is processed in this
CONTERNA. All renowned European
masterbatch producers changed over to
this continuous production process.
Type Throughput Drive power per chamber Dimensions, approx. (L x W x H)I/h kW mm
HKC 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 request Dimensions with hydraulic opening of chamber block and extruder
Since already several years the CONTERNA,
IKA®´s continuous kneading and extrusion machine,
is doing an excellent job in numerous production
processes, which in former times could only be
managed batchwise at high cost and with a great
number of personnel.
There are different industrial branches where this
so-called “inline-kneader” gained acceptance as
the standard machine within a few years. Great
profitability by reduction of kneading times and
higher product quality.
IKA Kneading 25.07.2002 8:51 Uhr Seite 9
Applications
Rubber masterbatches
Plastics masterbatches
Glues
Sealing masses
Food, animal food
Silicone rubber
IKA®
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IKA® Continuous Kneading
The constructional principle of the
CONTERNA allows to arrange as
many kneading chambers “in line”
as necessary for the respective
task.
There is the same variability
regarding the geometry of the
kneading blades, the execution
of the drives of each chamber, the
cooling resp. heating possibilities
and many other machine para-
meters.
The CONTERNA can replace several former
process steps, at reasonably shorter kneading
time and improved product quality. The
homogeneous repartition of the raw materials in
a finished rubber masterbatch has e.g.
been much improved compared to the
batchwise processing in piston kneaders.
IKA Kneading 25.07.2002 8:51 Uhr Seite 10
The process control system
developed by IKA® does not
only control the kneading
machine or the mixing
process itself, but also all
other process steps like
dosing and the downstream
equipment of the kneading
machine.
Together with our customers
the IKA® software team
elaborates individual
solutions.
Process control systems
10
IKA® Process Control
Schema
IKA Kneading 25.07.2002 8:52 Uhr Seite 11
Spare parts and repairs
For securing a quick and smooth
supply of spare parts, also in
case of repairs, IKA®-WERKE
is keeping a modern parts
stockroom with continuous
stock supervision.
Research and development
A well equipped pilot plant with
all necessary trial machines as
well as measuring and docu-
mentation possibilities is at our
customers’ disposal. Existing
processes can be optimized by
trials and new procedures can
be developed.
This pilot plant is of course
also intensively used by our
own design department for
optimization of existing and
development of new machines
and processes.
Quality assurance
Every single IKA® product
is submitted to a final quality
assurance control before it
leaves our workshop, in order
to test its complete function-
ality and to ensure a smooth
integration into the customer’s
production line.
11
IKA® Service
IKA®
IKA Kneading 25.07.2002 8:52 Uhr Seite 12
IKA®-WERKE GMBH & CO. KGJanke & Kunkel Str. 10 D - 79219 Staufen
Phone 49 (0) 76 33 / 8 31-0 Fax 49 (0) 76 33 / 70 87E-Mail: process@ika.de Internet: www.ikaprocess.com
IKA®
subsidiaries world-wide
IKA®-WERKE
Staufen, Germany
IKA®
WORKS ASIA
Kuala Lumpur, Malaysia
IKA®
WORKS Japan
Osaka/Nara
IKA®
WORKS
Guangzhou, China
IKA®
WORKS USA
Wilmington, North Carolina
DIN EN ISO 9001Reg. Nr. 20602-01
IKA®
WORKS do BRASIL
Rio de Janeiro
IKA®-WERKE
Liaison Office India
Cochin, Kerala
KN
/06/
02-G
B
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