UCP : Industrial continuous kneader for viscous applications
- HASLER Group
- KNEADING
- UCP : Industrial continuous kneader for viscous applications
ULTIMATE CONTINUOUS PROCESSOR (UCP) : Industrial kneading equipment for viscous applications
The UCP (Ultimate Continuous Processor) is an industrial kneader designed to mix powders and liquids homogeneously and adjust the rheology according to the degree of viscosity of the application.
This unique industrial kneading solution is intended for high-viscosity mixtures combining several stages in a single process: continuous kneading, homogenisation, kneading, micro-kneading, shearing, chemical reaction, degassing, purification, crystallisation, baking, compacting, densification, disintegration and grinding.
This industrial kneading system is capable of processing a wide variety of ingredients, whatever their shape, state or proportions, over a viscosity range exceeding 10,000,000 cP.
Technical sheet
ADVANTAGES OF THE UCP INDUSTRIAL CONTINUOUS KNEADER
Continuous performance
The UCP continuous kneader features two co-rotating axes for slow automated homogenisation to promote mixing, without forcing the material and guaranteeing product quality.
Compact footprint
Compact equipment that is easy to move around.
Robustness and strength
Its robust design enables continuous processing of high-viscosity materials.
Abrasion and corrosion resistance
Small gaps between the elements prevents the accumulation of material (moving elements/walls - elements/elements), optimises shearing operations and heat exchange while ensuring better control of rest times. Very little wear on paddles & shells, so very little maintenance is required.
Multiple infeed and degassing points
They allow greater optimisation of recipe operations (component introduction or temperature adjustment) and the possibility of removing undesirable constituents from the kneading system.
Skid solutions
Dosing equipment is available to complement the UCP to ensure optimum material accuracy.
Mobile element configuration tailored to your needs
The organisation of the mobile elements on the paddles enables execution of successive phases, leading to the desired end product. The two co-rotating axes ensure better homogenisation and consistent quality of the final product.
An infeed section
That can introduce materials with a wide range of particle sizes, as well as components with low bulk density.
A double jacket
This enables temperature regulation (heating or cooling). This extends the possibilities of the UCP (reaction, melting, crystallisation, controlled change of state) and optimises quality (consistency).
Constant, optimised process volume
The outlet hatch allows optimum use of the process zone volume. The small gaps between elements in the process zone prevents the build-up of material between dead zones and also guarantees a constant process volume.
High torque and low rotation frequency
The UCP continuous kneading equipment operates at high torque without generating pressure. Its features reduce energy and maintenance costs, while enabling it to work on demanding material transfer processes.
Low energy consumption
Its performance-to-power ratio (high torque) and optimised heat exchange make the UCP industrial kneader a low-energy system.
Instrumentation and control system
Using the SCMIII controller, which incorporates recipe control software, the UCP ensures batch traceability and precise production monitoring.
APPLICATIONS OF THE UCP CONTINUOUS INDUSTRIAL KNEADER
COATINGS AND ADHESIVES
Resins, adhesives, solvents, polymers, pigments, plaster…
BATTERIES
Lithium, nickel, cobalt, electrolytes, polymers…
CERAMICS
Clay, alumina, silica, ceramic pigment…
HYDROMETALLURGY
Copper, gold, silver, zinc, aluminium…
FERTILISERS
Nitrogen, phosphorus, potassium, calcium, magnesium, sulphur…
PHARMACEUTICAL
Active ingredients, sorbitol crystallisation, zeolite paste, excipients, solvents, compression agents…
CHEMISTRY
Sealants, technical silica, silica gel, specialised polymers and resins, radioactive waste, aluminium and Bayer alumina, plastics, carbon and graphite, glues, sealants, adhesives, paints, pigments, plastics, SMC-BMC, ink, colour, toner, sodium bicarbonate encapsulation, silicone, WC blocks, chemical additives, resins, fibre refining…
COSMETICS
Essential oils, waxes, emulsifiers, preservatives, colourings…
PLASTICS
Polyethylene, polypropylene, polystyrene, additives…
FOOD
Powders, sugars, preservatives, food colourings, chocolate, sweets, chewing gum, additives, crystallised fruits…
Description of the UCP continuous industrial kneader
Specially designed for viscous substances, the Ultimate Continuous Processor (UCP) kneading machine ensures continuous kneading.
This development tool provides you with thousands of combinations to design and assess the feasibility of your high-viscosity recipes. This industrial kneader is the all-in-one solution for managing different production phases in a single process:
- Continuous kneading
- Homogenisation
- Kneading
- Micro-mixing
- Chemical reactions
- Shearing
- Degassing
- Purification
- Crystallisation
- Baking
- Compacting
- Densification
- Disintegration
- Grinding
The key features of this kneading equipment include a flexible arrangement of moving paddles, a double jacket to regulate temperature from -20°C to +300°C and total resistance to abrasion and corrosion. Easy to customise to suit every need, the UCP also offers easy accessibility to facilitate the cleaning process. It can be coupled with a downstream extruder for profiled extrusion.
In addition to this continuous kneader, we offer complete solutions (via partner companies) for granulation and shaping, including equipment such as industrial extruders, gear pumps and mechanical systems. This industrial continuous kneading equipment is usually combined with HASLER dosing equipment to ensure accurate product processing. This innovation support tool is equally suited to low throughput applications and high production volumes.
The UCP kneading system is equipped with the SCMIII instrumentation and control system with integrated recipe software, capable of ensuring traceability of events and precise monitoring of production.
HASLER Group global support services for HASLER kneading solutions
To optimise the performance of your equipment and the availability of your kneading machine, our experts can assist on your project with:
- Assisted tests in our laboratory
- Tests at your site with equipment hire (with or without assistance, depending on your requirements)
The tests are carried out with complete confidentiality, focusing on innovation around the formulation or process, to assess feasibility, effectiveness and/or design objectives.
Our specialists also deliver a comprehensive range of services, including:
/ Services ranging from installation to commissioning of your equipment.
/ Support for the upkeep of your machines, from maintenance and repair to remote assistance.
/ Audits and dosing precision tests, kneading performance and finished product definitions to guarantee optimum efficiency of your kneading solutions.
/ Supplies of spare parts: kneader shafts and arms, feed or extrusion screws, moving parts, gearboxes, shielding, sealing braids and temperature sensors, etc.
/ Services to upgrade/revamp equipment in order to:
- Improve the reliability of your kneading systems by treating wear and tear on your equipment
- Optimise your processes by adapting them to new requirements
- Enhance the robustness of your kneading equipment for use in harsh environments (ATEX compatibility, saline or corrosive atmospheres).
/ Mechanical retrofit services to replace damaged parts and guarantee the service life of your equipment.
/ Training modules on using and optimising your equipment.