A Silicone Sealant Kneader (also known as a sigma mixer, Z-blade kneader, or vacuum kneader) is a specialized industrial mixing machine designed for kneading, mixing, and blending high-viscosity, elastic-plastic materials like silicone sealants (both acetoxy and neutral types).
Silicon Sealant Kneader Video
Key Features and Design
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Mixing Mechanism — It features two counter-rotating Z-shaped (or sigma-shaped) blades that move at different speeds, creating strong shearing, folding, stretching, and squeezing actions to thoroughly mix viscous pastes without dead zones.
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Construction — Typically made of stainless steel or carbon steel for the mixing chamber, blades, and jacket. Many models include a vacuum system to remove air bubbles (deaeration), improve product quality, and prevent oxidation.
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Heating/Cooling — Jacketed design allows temperature control via steam, electric, hot water, or oil circulation to manage the exothermic reactions common in silicone formulations.
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Discharge Options — Hydraulic tilt for dumping, screw extrusion for continuous output, or bottom valve for controlled release.
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Capacity — Ranges from lab-scale (e.g., 3L–100L) to large production units (e.g., 1000L–5000L+).
How It Works in Silicone Sealant Production
Silicone sealants are thick, paste-like adhesives requiring uniform dispersion of polymers, fillers (e.g., fumed silica), cross-linkers, and additives. The kneader excels at this by repeatedly shearing and folding the material under controlled conditions, ensuring homogeneity and preventing agglomeration. It’s often the first major step in production lines, followed by grinding (e.g., three-roll mill) and final packaging.
Applications
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Primary — Mixing base materials for silicone sealants (glass cement, structural sealants).
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Related — Silicone rubber, hot melt adhesives, chewing gum, butyl rubber, inks, pigments, and other high-viscosity products.
Salient Features of Sigma Mixer Machine
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Available in Stainless Steel 316, Stainless Steel 304 and Mild Steel materials.
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Stainless Steel polish to matt & mirror finish as per customer’s requirements.
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Mild Steel finish with one coat of red oxide and two coats of epoxy paint.
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Discharge option of hand wheel operated (manual) or hydraulic operated (automatic) offered.
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Jacket for heating or cooling application can be offered.
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Mineral wool insulation with cladding on jacket.
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Tangential designed ‘Z’ blades offered for uniform mixing.
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PTFE made shaft sealing provided for food grade compatibility.
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Minimum gap between trough inner shell & blades removes possibility of sticking product.
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On demand Spray system, vacuum system
Optional Features/Accessories of Sigma Mixer
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Liquid Spray System
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Vacuum System
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Blades Cooling Arrangement
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Screw System
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Automatic Valve Discharge System
Process Operation of Silicon Sealant Kneader
In Sigma mixer tangential action of mixing and kneading obtained by ‘Z’ type (SIGMA) shaped kneading blades, which rotates very accurately at different speed towards each other causing product to be transferred from one end to another end. Discharge of the finished product is achieved by tilting the container or through the valves at the bottom or by means of an extrusion screw beside the container.
The mixing action is a combination of bulk movement, stretching, folding, dividing, and recombining of the material. The shearing & tearing action of the material against blades and the side walls causes size reduction of the solids. After the time period required for sterilizing the batch has elapsed, the heating circuit shuts of the pneumatics damper (exhaust) opens and cooling operation commences.
In the tangential design, the blades rotate in the trough meeting tangentially. The front blade generally rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosities such as adhesives, rubber compounds, flush colors, dyes, and pigments.
In the overlapping design, the blades overlap above the saddle of the container. Due to the overlapping action, it is necessary that the relative position of the two blades is unchanged, and as a result, both the blades rotate at the same speed. Materials that flow freely or creep down into the blades are mixed using the overlapping blade action. This design offers a faster interchange of material from one blade compartment of the mixer to the other. Overlapping blade action is used for materials of lighter viscosities such as carbon pastes, clay coating, creams, and ointments. The overlapping blade produces a lower kneading and shearing compared to the tangential blade action.
Technical Specification of Sigma Mixer Kneader
| Model | Capacity – Liters | Motor (H.P.) | ||
| Working Capacity approx. | Gross Capacity approx. | General | Heavy Duty | |
| ASM – 50 | 50 Liters | 80 Liters | 5 H.P. | 7.5 H.P. |
| ASM – 75 | 75 Liters | 110 Liters | 7.5 H.P. | 10 H.P. |
| ASM – 100 | 100 Liters | 150 Liters | 10 H.P. | 15 H.P. |
| ASM – 150 | 150 Liters | 200 Liters | 15 H.P. | 20 H.P. |
| ASM – 200 | 200 Liters | 300 Liters | 20 H.P. | 25 H.P. |
| ASM – 400 | 400 Liters | 550 Liters | 30 H.P. | 40 H.P. |
| ASM – 500 | 500 Liters | 750 Liters | 40 H.P. | 50 H.P. |
| ASM – 750 | 750 Liters | 1150 Liters | 50 H.P. | 60 H.P. |
| ASM – 1000 | 1000 Liters | 1500 Liters | 60 H.P. | 70 H.P. |
| ASM – 1500 | 1500 Liters | 2100 Liters | 75 H.P. | 80 H.P. |
| ASM – 2000 | 2000 Liters | 2600 Liters | 80 H.P. | 90 H.P. |
| ASM – 3000 | 3000 Liters | 3800 Liters | 100 H.P. | 120 H.P. |
* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.
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