mixing granulator

The mixing granulator is a multifunctional integrated mixing and granulating equipment specially developed for high-end modified dry mortar and special building material production lines. It combines precise powder mixing, uniform wetting dispersion and spherical granulating molding functions in one single closed unit, solving the technical bottlenecks of traditional separate mixing and granulating equipment such as complicated procedures, low molding rate, unstable particle uniformity and serious powder floating. As the core processing equipment for granular functional mortar products, it realizes one-stop processing from powdery raw materials to uniform round mortar particles.

Different from ordinary mortar mixers that only complete powder blending, this all-in-one mixing granulator adopts dual-motion composite working principle of bottom stirring mixing and high-speed rotary granulating cutting. It can evenly disperse cement powder, quartz sand, functional additives and polymer binders, and process loose powder materials into regular spherical granular mortar with good fluidity. The fully enclosed one-chamber operation mode avoids material secondary pollution and component segregation, effectively improving the compactness, construction performance and anti-crack ability of finished mortar, and is the key intelligent equipment for producing high-quality granular repair mortar, waterproof mortar and special architectural mortar.

This equipment innovatively integrates high-precision mixing and uniform granulating molding technology, completing dry powder uniform mixing, quantitative liquid wetting, material softening and spherical granulating in one closed chamber. It cancels intermediate material transferring links of traditional separate units, simplifies the production process, avoids material loss and ingredient deviation caused by multiple transfers, and greatly improves overall production efficiency and product consistency.

Equipped with low-speed stirring paddles and high-speed granulating flying knives, the machine forms a three-dimensional circulating turbulence field inside the cavity. The materials are fully sheared, rolled and rounded, producing mortar particles with uniform size, regular spherical shape and dense internal structure. The molded granular mortar features excellent fluidity, no agglomeration, good water resistance and stable gelling performance, effectively solving the problems of uneven mixing, easy layering and poor construction effect of traditional powdery mortar.

The precise proportional wetting and micro-granulating technology enables each powder particle to be evenly coated with adhesive materials, reducing redundant binder dosage by about 20% compared with traditional processes. There is no fine powder residue or material waste during the whole process, and the material molding rate is as high as 99%. It significantly reduces raw material cost while ensuring the bonding strength and durability of finished mortar products.

The whole machine adopts fully sealed integrated structure with negative pressure dust removal interface. The entire mixing and granulating process is carried out in a closed cavity, completely eliminating powder flying and material leakage. It improves workshop operating environment, meets industrial environmental protection standards, and avoids raw material waste and environmental pollution caused by dust overflow, realizing green and clean mortar production.

The mixing paddles, granulating flying knives and inner tank lining are made of high-strength wear-resistant alloy materials, which can resist long-term high-speed friction and impact of mortar raw materials. The reinforced transmission structure runs stably with low vibration and low noise. The optimized structural design reduces vulnerable parts and failure points, greatly lowering later maintenance frequency and operational cost for mortar enterprises.

Equipped with PLC intelligent control system and humanized touch screen interface, the equipment presets multiple granulating formulas for different mortar types. Users can freely adjust mixing speed, granulating time and particle size parameters. It can be seamlessly linked with automatic batching systems, bucket elevators and packaging machines to form a fully automatic granular mortar production line, realizing unmanned intelligent production.

• Working Principle: Integrated stirring mixing + high-speed cutting granulating
• Batch Capacity: 50L–2000L (customizable)
• Production Capacity: 80–1200kg/batch
• Batch Cycle Time: 3–6 minutes
• Mixing Power: 5.5kW–37kW
• Granulating Power: 4kW–30kW
• Finished Particle Size: 0.5–5mm (adjustable)
• Molding Rate: ≥99%
• Control System: PLC intelligent automatic control + touch screen operation
• Inner Tank Material: Wear-resistant alloy / stainless steel optional
• Discharging Mode: Pneumatic fully automatic quick discharge
• Sealing Performance: Full closed dust-proof and leak-proof
• Working Condition: 24-hour continuous industrial operation

Before startup, comprehensively check the fastening status of mixing paddles and granulating flying knives, the tightness of transmission components and the sealing integrity of the inner tank. Confirm no foreign sundries inside the cavity and normal operation of motor, pneumatic system and electrical control system. Check the smoothness of liquid spraying and wetting system to ensure uniform binder atomization. Overload startup and empty-load high-speed operation are strictly prohibited to avoid equipment damage.

Operate strictly in accordance with the preset mortar formula parameters. Complete dry powder pre-mixing first, then perform quantitative liquid spraying and granulating molding. It is forbidden to open the sealing cover or touch internal moving components during equipment operation. Do not arbitrarily modify speed ratio and time parameters to avoid uneven mixing or unqualified particle size. Stop feeding and liquid spraying first before shutdown, and discharge all materials completely to prevent internal bonding and caking.

Clean residual mortar particles and bonded materials inside the tank after each production batch to prevent material hardening from affecting subsequent granulating accuracy. Regularly check the wear degree of paddles and flying knives every week, and replace severely worn parts in time. Lubricate transmission bearings and rotating components periodically to ensure flexible operation. Keep the liquid pipeline unobstructed and clean the nozzle regularly to avoid blockage.

The equipment must be reliably grounded during operation to ensure electrical safety. Keep the supporting dust removal system running normally to maintain workshop cleanliness. All maintenance, debugging and troubleshooting work must be carried out after complete power cutoff and equipment shutdown. For long-term shutdown, thoroughly clean the inner tank and liquid pipeline, and keep the equipment dry and ventilated to prevent corrosion and material deterioration.

The multifunctional mixing granulator is specially tailored for special granular dry mortar production, widely used in high-precision building material processing fields:

• Repair & Reinforcement Mortar: Granulating production of highway repair mortar, concrete repair mortar and structural reinforcement mortar
• Waterproof & Anti-Corrosion Mortar: Particle molding processing of polymer waterproof mortar, anti-corrosion mortar and impermeable mortar
• Functional Special Mortar: Production of self-leveling granular mortar, thermal insulation granular mortar and anti-crack decorative mortar
• Building Material Powder Granulation: Granulating and molding of various modified building powder, polymer composite materials and mineral powder
• High-End Mortar Factory Upgrading: Core supporting equipment for new intelligent special mortar production lines and traditional powder mortar line upgrading

Traditional mixers only realize simple powder blending, with single function, easy material segregation and poor product construction performance. The mixing granulator integrates mixing, wetting and granulating in one machine, producing uniform spherical mortar particles with high density and good fluidity. It simplifies production procedures, reduces material waste, and effectively improves the bonding strength and construction effect of special mortar, which is irreplaceable for high-end functional mortar production.

Uneven particle size is mainly caused by inconsistent liquid spraying volume, abnormal granulating knife speed, worn cutting blades or uneven feeding. It can be solved by calibrating liquid spraying parameters, adjusting rotating speed matching, replacing worn parts and maintaining uniform feeding speed.

Yes. The equipment supports flexible parameter adjustment and multi-formula storage. By adjusting mixing time, liquid ratio and granulating speed, it can produce various repair mortar, waterproof mortar, self-leveling mortar and modified granular building materials, with strong versatility and flexible switching.

No. The fully enclosed negative pressure structure completely avoids dust overflow. The one-step molding process has no intermediate transfer loss, with a molding rate up to 99%. It realizes zero dust pollution and ultra-low material loss, fully meeting modern environmental protection production requirements.

Absolutely. The PLC intelligent system supports seamless linkage with automatic batching equipment, bucket elevators and packaging machines. It realizes fully automatic unmanned operation from feeding, mixing, granulating to discharging, greatly improving the overall automation level of the production line.

Daily cleaning of residual materials and nozzles is required after production; weekly inspection and lubrication of transmission parts; quarterly replacement of worn blades and seals. The maintenance process is simple and efficient with low technical threshold and low operating cost, suitable for long-term continuous industrial production.