In the world of industrial mixing, there are two kinds of mixers commonly used ,they are : Intensive Mixer and Internal Mixer. Both of these two mixer are used to process high-viscosity materials like rubber compounds, plastic , ceramic pastes, color master batch ,chemical industries and thermoplastics etc.
Although these two types of mixing mixer machines may appear similar and serve overlapping functions, they differ significantly in design, function , mixing principles, industrial application, and performance.
Here , in in this blog ,let us talk and understanding their differences.

1. Best Mixer for Plastic and Elastomer Blending

✅ Intensive Mixer

An intensive mixer machine is a type of high-shear mixing and kneading machine ,which are specially designed for lab-scale or pilot-scale mixing.
The “intensive” means the high energy input and fast mixing time under strong mechanical force in a short time.
Such intensive mixer machine usually features sigma or spiral blades in a horizontal chamber , it is very ideal for batch mixing of highly viscous, dense,polymer, thermoplastics, elastomers ,ceramics and other sticky materials.

The design of such Intensive mixer machine generally includes:

* Z-shaped or Sigma blades inside a closed mixing chamber
* High-speed rotors or blades for intense shearing action
* Jacketed chamber for heating or cooling
* Controlled pressure and vacuum options

✅ Internal Mixer

While internal mixer is also known as a Banbury mixer, it is a heavy-duty, production-scale mixing machine , usually feature with two large rotors in a closed mixing chamber.
The Rubber compounding banbury mixer is highly effective for shear,mix and knead raw rubber, distributing fillers like carbon black, and mixing additives with polymers.
This bunbury internal mixer applies high pressure and shear through two rotor to mix rubber, plastic, chemical ,color masterbatch and filled materials rapidly in the mixing chamber .

While , the Internal mixer machine usually features:

* Two rotors inside a closed mixing chamber
* Ram or pressurized lid to push the material down
* Motor-driven rotors for high-torque mixing
* Chamber with heating/cooling jacket

Which High Shear Mixer Should You Choose?

Both intensive mixer equipment and internal mixer machine are powerful mixing machine in industrial material processing. But the main difference are their scale, mixing strength, and various application .
It depends of your specific needs and application for different material ,then choose the most suitable mixer .
Choose an Lab Intensive Mixer if you need:

* Quick dispersion of high-viscosity materials
* Compact or small batch processing
* Precision in vacuum and temperature control
* Small-batch mixing for R&D or custom compounds
* Frequent cleaning/changeover needed
* Ceramic or specialty paste mixing

Choose an Internal Mixer if you need:

* High-output rubber/plastic production
* High pressure & shear required for fillers or carbon black
* Efficient rubber or plastic compounding
* Continuous or large-scale batch processing
* Strong shear and compression for breaking down raw rubber

In summary , both internal mixer and banbury mixer offer powerful mixing capacity ,they play vital roles in material processing. So So understanding the two mixing machine for your application and specific material, they can boost your productivity, consistency, and processing efficiency.
If you work with rubber ,plastic, or chemical compounds, an internal mixer or banbury mixer may be essential equipment for high-throughput industrial compounding due to its strong shear force .
If you want to process elastomers, adhesives or your precise formulation development & specialty batches , an intensive mixer may be your better choice for its feature of flexibility, high-viscosity control, and small batches.

If you are in the plastic ,rubber or chemical industries and want to know about the intensive mixer or Rubber internal mixer,welcome to contact us ,at Simptek ,we are very happy to help you .

We can custom and tailored rubber machinery as per your needs .