1. Product Introduction
Plough Shear Mixer is a high-precision, high-efficiency horizontal dry powder mixing equipment specially developed for high-end dry mortar production lines. Adopting mature single-shaft ploughshare blade structure with auxiliary high-speed flying cutters, the equipment forms a mechanical fluidized bed mixing state inside the cylinder. It effectively solves the mixing difficulties of fibrous materials, easy-agglomerated additives and materials with large differences in specific gravity and particle size, making up for the low uniformity defect of traditional paddle mixers and the insufficient shear dispersion ability of ordinary mixing equipment.
As the core high-end mixing host in the dry mortar industry, it supports homogeneous mixing of powder-powder, powder-granule and trace liquid-powder composite materials. It is perfectly matched with NE series bucket elevators, automatic batching systems and intelligent packaging equipment. Widely used for high-standard waterproof mortar, flexible anti-crack mortar, thermal insulation mortar, tile adhesive and high-end decorative mortar production, it is the preferred equipment for standardized, high-quality and multi-functional dry mortar industrial production bases.
2. Core Advantages
1. Fluidized Shear Mixing & Ultra-high Uniformity
The rotating ploughshare blades lift and flip materials in all directions to form a stable fluidized suspension state, while the high-speed flying cutters generate powerful shearing and crushing force. This dual mixing mode completely breaks material agglomeration, realizes zero dead-angle full mixing, and achieves a mixing uniformity of over 99%. It ensures uniform dispersion of ultra-trace functional additives and stable performance of finished high-end mortar products.
2. Powerful Fiber & Agglomeration Dispersion Ability
Different from ordinary mixers that are prone to fiber knotting and additive agglomeration, the plough shear mixer’s matching flying cutter group specially targets fibrous mortar raw materials and easy-absorbent powder additives. It rapidly disperses flocculent and clustered materials without damaging fiber structure, fully meeting the precise mixing requirements of anti-crack and flexible functional mortars.
3. Ultra-short Mixing Cycle & High Production Efficiency
The fluidized mixing principle avoids material layering and repeated stirring. A single batch of high-precision mixing can be completed within 2–4 minutes, which is significantly more efficient than paddle mixers and ordinary single-shaft mixers. It supports continuous high-frequency cyclic production and perfectly adapts to the high-efficiency operation rhythm of large-scale high-end mortar production lines.
4. Zero Residual & No Cross-contamination
The optimized arc-shaped cylinder inner wall and rational plough blade layout realize no material sticking wall and no dead-angle accumulation. Equipped with a professional cleaning structure, the material residual rate is lower than 0.03%. It supports frequent switching production of multiple mortar formulas, completely avoiding cross-contamination between different products and meeting the flexible production needs of multi-variety high-end mortars.
5. Reinforced Wear-resistant Structure & Long Service Life
The key contact parts adopt thickened wear-resistant alloy ploughshare blades and high-strength flying cutters, with strong impact resistance and abrasion resistance. The main shaft and transmission system adopt heavy-duty reinforced design, matching high-stability hard-tooth reducer. It adapts to long-term high-frequency heavy-load operation, with low failure rate and ultra-long service life of core components.
6. Fully Sealed Dust-free & Green Environmental Protection
The whole machine adopts fully enclosed seamless sealing structure, with high-precision shaft-end sealing devices and reserved standard dust removal interfaces. There is zero dust overflow and material leakage during high-speed operation, fully complying with modern industrial environmental protection standards and meeting the green and dust-free production requirements of high-standard mortar factories.
7. Ultra-wide Material Adaptability & Strong Versatility
It can flexibly adapt to dry mixing of powder, granules, fibers and trace liquid materials, covering all conventional and high-end functional dry mortar products. It supports customized speed regulation and structural configuration, adapting to various complex formula mixing processes and diverse production scenarios.
3. Technical Specifications
Plough Shear Mixer has multiple standard models to match medium and large high-end dry mortar production lines, with industrial high-precision stable parameters:
|
Test Item
|
Unit
|
Standard Technical Parameters
|
|
Effective Mixing Volume
|
L
|
500–5000 (Customizable)
|
|
Main Shaft Rotating Speed
|
r/min
|
35–45
|
|
Flying Cutter Speed
|
r/min
|
1400–1600
|
|
Single Batch Mixing Time
|
min/batch
|
2–4
|
|
Mixing Uniformity
|
%
|
≥99
|
|
Material Residual Rate
|
%
|
≤0.03
|
|
Matching Motor Power
|
kW
|
15–75 (According to model)
|
|
Discharging Mode
|
/
|
Pneumatic Full-open Automatic Discharging
|
|
Sealing Grade
|
/
|
High-precision Full Dust-proof & Leak-proof
|
|
Main Material
|
/
|
Carbon Steel / Stainless Steel Customized
|
|
Failure-free Operation Time
|
h
|
≥38000
|
4. Operation & Maintenance Precautions
1. Pre-operation Comprehensive Inspection
Before startup, fully inspect the tightness, wear and deformation of ploughshare blades and high-speed flying cutters to ensure no looseness, damage or blade deviation. Check the shaft-end high-precision sealing components, feeding ports and pneumatic discharging doors to confirm complete sealing without gaps. Verify the lubrication status of the heavy-duty reducer and high-load bearings, and clean all foreign matters inside the cylinder to avoid blade collision and equipment jamming.
2. Standard Startup & Feeding Specifications
Adopt strict no-load startup procedure: start the main shaft and flying cutters successively, and run stably for 1–2 minutes before feeding materials. Full-load startup and instantaneous overload feeding are strictly prohibited to prevent motor overload and transmission component damage. Maintain uniform and continuous feeding, and strictly follow the rated filling volume to ensure sufficient fluidized mixing space.
3. In-operation Safety & Process Management
It is forbidden to open the cylinder cover or touch internal high-speed operating parts during equipment operation to avoid safety accidents. Hard foreign matters such as iron blocks and stones are prohibited from entering the mixing cavity to prevent blade breakage and equipment failure. For fiber-containing and easy-agglomerated mortar formulas, control feeding speed reasonably to ensure full shear dispersion and uniform mixing.
4. Standard Discharging & Shutdown Procedures
After the mixing cycle is completed, fully open the pneumatic discharging door for thorough discharging to avoid residual material caking inside the cylinder. Clean the inner wall and blades timely after each batch production to eliminate cross-contamination risks for different formulas. Shut down the equipment only after all materials are completely discharged, and sudden shutdown with materials inside is prohibited.
5. Daily Maintenance & Regular Inspection
Regularly lubricate the main transmission shaft, bearings and reducer to ensure stable power transmission. Periodically check the wear degree of plough blades and flying cutters, and replace severely worn parts in time to guarantee mixing precision. Inspect sealing accessories regularly, replace aging seals, and maintain long-term dust-free and high-precision stable operation of the equipment.
5. Application Scenarios
1. High-end Functional Dry Mortar Production
Specially applicable for mass production of high-standard mortar products including flexible anti-crack mortar, polymer waterproof mortar, thermal insulation mortar, high-strength tile adhesive and self-leveling mortar. It meets the high-precision mixing requirements of fiber-containing and polymer additive formulas that ordinary mixers cannot handle.
2. High-precision Building Material Powder Processing
Suitable for uniform mixing of modified mineral powder, polymer powder additives, high-purity quartz sand and other high-grade building materials, supporting customized processing of high-quality building powder materials.
3. Chemical New Material & Additive Mixing
Widely used for mixing powder and granular chemical raw materials, building polymer additives and new environmental protection materials. The high-shear fluidized mixing mode ensures uniform dispersion of trace additives, meeting high-precision industrial production standards.
4. Multi-variety Flexible Batch Production
Ideal for mortar factories with frequent formula switching and multi-variety small-batch and medium-batch production. Its ultra-low residual rate completely avoids cross-product pollution and ensures stable quality of customized mortar products.
5. High-standard Green Building Material Projects
Adapt to standardized and dust-free production requirements of modern green building material industrial parks, suitable for supporting high-end automated dry mortar production lines and intelligent processing projects.
6. FAQ
Q1: What is the difference between Plough Shear Mixer, Paddle Mixer and Double-shaft Gravity-free Mixer?
A1: Paddle Mixer is cost-effective for ordinary conventional mortar with general mixing precision; Double-shaft Gravity-free Mixer has high efficiency for most medium and high-end mortars; Plough Shear Mixer adopts unique fluidized shear mixing with auxiliary flying cutters, featuring the highest mixing precision and strongest fiber dispersion ability. It is exclusively used for high-standard functional mortars with fiber, polymer and trace additives, solving the agglomeration and uneven dispersion problems of other mixers.
Q2: Why is plough shear mixer suitable for fiber-containing mortar?
A2: Equipped with high-speed flying cutter groups, the equipment generates powerful shearing and dispersing force during fluidized mixing. It can fully disperse flocculent fibers and clustered polymer additives without damaging fiber structural performance, ensuring uniform fiber distribution in finished mortar and stable anti-crack and flexible performance of products.
Q3: How to ensure long-term high-precision mixing effect?
A3: Regularly check and replace worn plough blades and flying cutters to avoid reduced shearing and flipping capacity. Strictly standardize feeding volume and mixing time, clean residual materials after each production, and maintain intact sealing performance. These measures can permanently maintain the equipment’s 99% high mixing uniformity.
Q4: What are the core advantages compared with ordinary single-shaft mixers?
A4: Ordinary single-shaft mixers have mixing dead angles, low uniformity and poor fiber dispersion. Plough Shear Mixer realizes fluidized zero-dead-angle mixing with high-speed shear dispersion, shorter mixing cycle, higher finished product quality, lower residual rate and stronger material adaptability, fully meeting high-end mortar quality standards.
Q5: What is the service life of core wearing parts?
A5: Under standardized operation and daily maintenance, the wear-resistant ploughshare blade service life is 3–4 years, and the flying cutter service life is 2–3 years. The overall failure-free operation time reaches 38,000 hours, with stable long-term operation and low comprehensive maintenance cost.
Q6: Can it be perfectly matched with NE series bucket elevators?
A6: Fully compatible. All models of Plough Shear Mixer can be perfectly matched with NE15/NE30/NE50/NE100 series bucket elevators to form a high-precision automatic feeding-mixing-discharging production system, realizing synchronous and stable operation of high-end dry mortar full-automatic production lines.
