How to solve the problem of material wrapping during industrial multi-shaft mixer runtime

Material wrapping is particularly common during the stirring process, especially when processing complex systems such as polymer glue, hot melt glue, modified resin, nanocellulose, high viscosity oils and certain plant extracts. Due to the wire drawing, adhesion and long-chain structure of the material, if the equipment design and process control are improper, it is very easy to cause the material to be partially attached to the surface of the agitator and form wrapping. As the stirring shaft continues to operate, the wound material gradually thickens, which may eventually lead to problems such as increased blade load, stirring imbalance, and expansion of shear dead corners, and even mechanical failures such as deformation of the stirring paddle and bearing damage.

In order to effectively solve the material entanglement problem, optimizing the mixing paddle structure is one of the key measures. For high-tightening materials, anti-winding stirrers are recommended, such as variable-section blades with smooth surfaces, non-adhesive paddles with special coatings, or stirring arms and ribbon blades with self-cleaning structures. These designs can significantly reduce the adhesion interface between the material and the blade, thereby reducing the risk of winding. Through computational fluid dynamics (CFD) simulation technology, the flow field and shear distribution of materials in the stirred tank can be simulated and analyzed, and the angle, quantity and arrangement of the blades can be optimized, thereby improving the overall convection path of the material and enhancing the peeling and self-cleaning functions of the material.

In terms of the control of stirring parameters, a reasonable operating strategy is also crucial. For material systems that are prone to wrap, it is recommended to adopt a phased loading method to avoid full input of raw materials under high-speed conditions. By stirring at low speed first to make the material premix evenly, and then gradually upgrade to the high-speed dispersion stage, it can effectively avoid material aggregation and entanglement caused by local uneven shearing. At the same time, by adjusting the start and stop sequence and operating speed of the stirring shaft by frequency conversion, it can dynamically adapt to the changes in material viscosity, significantly reducing the load fluctuations and winding risks during the stirring process. In a system that requires long-term mixing, an intermittent stirring procedure is set up to promote the natural fallback and desorption of the material through a short stay time, effectively reducing winding and accumulation.

The introduction of an auxiliary mixing mechanism is also an effective means to prevent material entanglement. In a multi-axis agitator, a wall scraper, a bottom scraper or an auxiliary rotating arm can prompt the material to constantly turn and keep it sliding relative to the blade, thereby enhancing the material's desorption effect and preventing the blade from becoming a pile point of material. In addition, a industrial multi-shaft mixer with a vacuum system reduces the system bulk density by vacuuming at an appropriate stage, which helps to loosen the structure of the viscoelastic material, thereby unwinding the structure and restoring the flowability. Auxiliary measures such as intermittent nitrogen filling can also effectively inhibit the viscosity strengthening of the material due to oxidation or heating.

In terms of reasonable adjustment of material formulation and pretreatment process, adding an appropriate amount of dispersant, lubricant, swelling control agent or structural regulator can effectively reduce the wire drawing and adhesion of the material, thereby inhibiting excessive entanglement between polymer chain segments. For formulations containing long fibers or micelles, it is recommended to cut off, pre-soluble or premix the raw materials before mixing to avoid large particles or bundled components entering the main mixing stage. In addition, for multiphase systems, optimizing the feeding sequence and feeding speed so that each component is coated layer by layer instead of concentrated aggregation can weaken the basic conditions for material winding from the physical level.