Customer: Panasonic is one of the largest electronics material manufacturers in the world. They produce thermosetting resin mold material to make insulation application in circuit board.
Project Name: New Building Plant in Guangzhou, China for supplying resin mold material in East Asia.
Raw Material Information: Thermosetting resin molding material will not get melted if meet heating.
Bulk Density: 0.7 g/cc
Corrosive: A bit
Angle of repose: 33 degree
Flow-ability: Not good
Solutions we offered to customer:
1. Plant structure dimension issue
Considering the plant is old existing one which was built by concrete floor structure, the plant dimension is very limited for placing two ribbon blenders in it. Through site dimension measure and discussion with customer, we designed chain drive type and motor installed on side and U vessel installed on platform directly to keep minimum height of the mixer.
2. Abrasive and corrosive issue
Due to raw material with big abrasive feature and corrosive, normal stainless steel is not suitable for this kind of material. So, we analyze the chemical component feature of steel and choose duplex stainless steel (S22053) for ribbon agitator, vessel and all material contact part. Duplex stainless steel is extremely corrosion resistant and hardenable alloys. Strengths of duplex stainless steel is double than normal austenitic stainless steel.
3. Seal Part issue
The customer’s material is very fine and light. If we use normal packing seal + air purge seal for ribbon blender, it will make much air go into vessel which will not good for material. So, we choose double layer packing seal adding air purge seal to avoid much air blow in vessel and we keep air pressure around 0.1-0.2 Mpa.
4. Ribbon Clearance
As we know that ribbon blender consists of U shape vessel, the bottom is semi-circle shape. Considering the resin material is a bit sticky, the customer want make the clearance between ribbon and semi-circle vessel (180 degree) around 5mm. So, it is a big challenging for us because generally speaking, the clearance is between ribbon and bottom of vessel not semi-circle vessel. In order to meet customer’s requirement, we make following steps:
A. We increased the thickness of vessel first and use Tensioning Device to keep roundness of semi-circle vessel.
B. Then, in order not to make deformation of vessel during open inspection door on side, we use laser cutting to keep shape and minimize deformation.
C. We use machine tool to process shaft and ribbon. After ribbon welded on shaft, we use machine tool to handle finished shaft finally.
After tested the ribbon blender by customer, the final product residues in ribbon blender after mixing is only 1% which is happy with it by Panasonic Production Manager.
Through Vortex hardworking and cooperation with customer, these two ribbon blenders have been used for three years and haven’t any problems for using. Panasonic worker is happy with our mixer’s quality and good performance which can replace their Japanese local mixer. Panasonic production manager Mr. Masahiko plan to build a new resin molding material product line in Thailand in 2015 and we are discussing details of ribbon blender with customer since June 2014. They want to increase production capacity of their product by 30% at the beginning of 2016.