Kneader scale-up and process design

Investigation of molding powder production on two different-sized Buss kneaders is presented. The storage moduli, energy consumption, and the pressure profiles were observed at different material loads, screw revolutions, and material fills. Experimentally measured data were compared to calculated ones using previously developed flow model and two parameters; storage moduli and complex viscosity were calculated for different process conditions. Additionally, optimal process conditions and scale-up procedure for two different-sized Buss kneaders were proposed. The results may contribute to better understanding of kneading processes in industrial plants with respect to operation costs, energy consumption and environmental care.