Polymer compounding & shaping equipment
Micro compounding systems
Micro compounders are specialized miniaturized extruders used in small scale polymer processing that involves mixing, blending and modification of polymeric materials. This enables researchers and manufacturers to develop and test polymer formulations in small batches, typically ranging from a few grams to a few hundred grams.
Reliable and Reproducible
Separate heating zones offer perfect control of temperature resulting in reproducible processes.
High Quality
A fluid-tight, abrasion and chemical resistant barrel works flawlessly for many years.
Cost Efficient
Use of small sample volumes, fast processing time and easy cleaning contribute to a cost-efficient system.
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Streamline Polymer Blending Scale-up
Micro compounding mimics the large-scale twin-screw extrusion process but operates on a micro-scale, making it ideal for material development, additive dispersion studies, and rapid prototyping before scaling up to full-scale production. The use of micro compounders has several key advantages including minimizing waste, precise process control, rapid formulation testing and most importantly the results are scalable to full size systems.
Xplore’s line of micro compounders are high-quality, reliable systems that are ideal for cost efficient R&D leading to shorter time-to-market. Xplore has three different micro compounders, MC 5, MC 15HT, and MC 40, primarily differentiated by the maximum volume of materials that they can process. The vertical design of the mixing screws delivers significantly more thorough mixing compared to the commonly used tangential screw mixers. Every cubic centimeter of material exhibits identical properties, ensuring unparalleled consistency. Tangential screw designs often struggle to produce uniform samples, making consistency a persistent challenge.
Application Areas:
Xplore Micro Compounders
Micro Compounder Configurations
MC 5
The MC 5 Micro Compounder is designed for compounding and testing small batches of materials, up to 5 ml. This is ideal in situations where costly synthesized materials and additives are used in the formulation. The MC 5 also has the proprietary Vari-Batch™ feature that allows users to select a batch volume between 2 ml and 5 ml. The MC 5 Micro Compounder includes a pneumatic front feeder, a cooled feeding top hopper, and elongated forced feeding screws for enhanced processing. It supports a maximum operating temperature of 450°C and delivers maximum torque of 6 Nm per screw.
MC 15 HT
The micro compounder MC 15 HT is designed to enhance and streamline the R&D process. The MC 15 HT is specifically optimized for processing high viscosity and concentrated polymer compositions, up to 15 ml in volume. MC 15HT is ideal for processing rubbers and elastomers, even when using fully intermeshing screws.
MC 40
The micro compounder, MC 40, is a 40 ml lab compounder, designed to simplify and accelerate R & D. It offers robust shear strength, the ability to handle high viscosities, and supports larger batches while delivering fine dispersion, excellent mixing, and high operational stability. Its powerful 24-bit drive ensures stable screw torque, all within a compact footprint that fits neatly on the laboratory bench or in a fume hood.
Xplore Micro Compounders
Micro compounding Applications
Polymers
Micro compounders accelerate formulation development and feasibility studies, reducing both time and costs. Additionally, post-die shaping instruments streamline and expedite polymer materials testing.
Polymer Composites
Micro compounders aid in the development of polymer composites by incorporating functional additives such as stabilizers and antioxidants, enhancing material stability and performance.
Rubbers and Elastomers
Micro compounders provide a faster and more cost-effective alternative to traditional Banbury-type internal mixers, making them ideal for feasibility studies and formulation screening.
sustainability
Micro compounders are essential for developing sustainable and recyclable polymers, enabling the optimization of polymer properties, improving recycling quality, and reducing production costs.
Biomedical
Micro compounders play a crucial role in formulating and evaluating plastic compounds for biomedical applications. They enable rapid prototyping and performance screening, facilitating the development of advanced materials.
Nutrition
Micro compounders and extruders are effective tools for converting raw materials into structured, nutrient-dense products. One key application is the modification of plant proteins, such as soy, pea, and wheat gluten, to create textures that closely resemble meat.