We’re discussing a common challenge in dual planetary mixing: material climbing.

Описание: This often occurs with high-viscosity materials, especially those with good metal adhesion, such as epoxy resins. It not only reduces mixing efficiency but also increases cleanup time and lowers overall productivity.

If you’re experiencing this issue, begin by verifying the following:
First. Is the filling level appropriate?
The recommended working volume is 70%–80% of the designed volume. For example, a 60L dual planetary mixer has a design volume of 88L. Do not exceed 85% of the design volume or 115% of the effective volume.
Second, Is the material viscosity within the suitable range?
Low-speed mixing is suitable for 0–1,000,000 cps. High-speed dispersion is suitable for 0–400,000 cps. If viscosity is too high, high-speed dispersion is not recommended.
Third, Is the scraper functioning properly?
Under high viscosity, material tends to accumulate between the scraper and mixing blades. It is advised to reinforce the scraper structure or temporarily disable it.

If the basic troubleshooting is correct, then we can proceed to solve the problem from two aspects: equipment adjustment and process optimization.
Solution 1: Adjust Mixing Speed
Reducing the speed—especially of the high-speed dispersion blade—significantly minimizes climbing. Tests show that proper speed reduction leads to smoother material flow and greatly alleviates the issue.
Solution 2: Optimize Blade Structure
Adjust blade diameter, spiral angle, kneading area, and other parameters to improve mixing efficiency and prevent climbing. Begin with low-speed mixing to fluidize the material and lower its viscosity before engaging high-speed dispersion. This avoids instant overload and improves process stability.

In one customer’s adhesive production line, silicone and polyurethane materials experienced frequent climbing, leading to increased cleanup time and reduced output. Our technical team conducted onsite optimization using a combined approach of speed reduction and blade redesign. After implementation, climbing was virtually eliminated, and production efficiency improved by approximately 30%.

Material climbing is not an unsolvable problem. With the right equipment selection, proper process parameters, and expert support, you can overcome it efficiently. If you’re facing similar challenges, feel free to reach out. We’re here to provide customized solutions for your mixing needs.