Lescuyer et Villeneuve

Roll mill: how does it work?

LescuyerVilleneuvewp2 — Wed, 09 Apr 2025 09:44:42 +0000

Essential for the homogenization of materials, roll mill ensure optimum dispersion of components and have a direct impact on the quality of finished products.

A more general article on the mixing process is available on our blog!

What is a roll mill?

A roll mill is an essential piece of industrial equipment for processing polymers, especially rubber. It consists of two parallel rolls rotating in opposite directions, used to mix, homogenize and prepare compounds for further processing. These machines are widely used in the rubber, silicone and plastics industries to ensure uniform dispersion of components and improve the quality of finished products.

Roll mill structure and components

Typically, a roll mill comprises :

Rotating cylinders : Two steel cylinders, arranged horizontally and rotating in opposite directions. The cylinders are hollow or perforated at the periphery to allow fluid circulation, ensuring precise temperature control during the mixing process

Gap adjustment system: Mechanism for adjusting the distance between cylinders to control the thickness of the material processed and the intensity of mixing.

Drive mechanism: a set of motors and gearboxes that rotate cylinders at controlled speeds, often with a differential speed ratio to optimize material shear.

Rubber limiters: Devices designed to direct the rubber mix between cylinders, ensuring uniform treatment of the material. They are placed at the ends of the cylinders to redirect the material towards the center and minimize losses.

Operating principle

The operation of a roll mill is based on the following steps:

Raw material feed: raw rubber or polymer is fed into the space between the two rotating cylinders.

Mixing and homogenization: counter-rotating cylinders exert shear forces on the material, promoting uniform dispersion of additives and fillers. Controlling the temperature of the cylinders is crucial to maintaining mixing properties and avoiding thermal degradation. Typically, operators are tasked with mixing the material by hand, using a knife. However, some companies, such as Lescuyer & Villeneuve, have developed systems that automatically mix the material, without operator intervention.

Parameter adjustment: The operator can modify cylinder spacing, rotation speeds and temperature to obtain the desired mixture characteristics.

Blend extraction: Once the process is complete, the homogenized blend is removed in sheet or strip form, ready for subsequent processing steps such as extrusion or calendering.

This process produces high-quality blends, essential for the performance of finished products in a variety of industrial applications.

Types of Lescuyer & Villeneuve roll mill

Lescuyer & Villeneuve divides its production into two main types of equipment: production roll mill and laboratory roll mill.

Lescuyer & Villeneuve production roll mill

The Lescuyer & Villeneuve production roll mill is specially designed to meet the requirements of manufacturers working with polymers such as rubber and silicone. Adapted to high production volumes, it guarantees optimum batch homogeneity, while ensuring precise mixing control, particularly in the presence of heat-sensitive additives.

Equipped with cylinders from 300 to 750 mm in diameter and a table from 650 to 2,500 mm, this equipment can handle batches from 15 to 250 kg. Its exclusive electric motorisation, a unique innovation on machines of this size, eliminates the constraints of traditional hydraulics and offers advantages in terms of maintenance, environmental impact, gauge accuracy and safety.

L&V production roll mill features

Compliant with the most stringent safety standards (EN 1417:2023), this roll mill offers the following features:

Electrical gap adjustment

Peripherally drilled cylinders for improved material cooling

Energy recovery system

Innovative non-energy safety system

As an option, they can be completed with automated solutions, automatic mixing systems, blenders, knives, etc…

The Lescuyer & Villeneuve laboratory roll mill

Lescuyer & Villeneuve laboratory roll mill are specially designed for small quantities of material, offering an ideal solution for research and development. They enable new mixes to be tested, material behavior to be studied, and formulations to be optimized before going into industrial production.

Equipped with cylinders from 55 to 250 mm in diameter and a table varying from 150 to 500 mm, these machines handle batches ranging from 0.1 to 8 kg, while ensuring precise mixing control, including for additives. Their compact monoblock design optimizes footprint, making them easy to integrate into any laboratory or research center environment.

Ergonomics and ease of use are at the heart of their design, with an intuitive touch-sensitive control panel for precise parameter adjustment.

Features of the L&V laboratory roll mill

This equipment also complies with the most stringent safety standards (EN 1417:2023), and offers the following features:

Electrical gap adjustment
Peripherally drilled cylinders for improved material cooling
Energy recovery system
Customization options

Our laboratory roll mills work on rubber, silicone and plastics. In addition, options can be added, such as automated systems, automatic mixing systems, etc…

Nanomaterials mixer: a specific equipment

The Lescuyer & Villeneuve nanomaterial mixer is an innovative solution designed for the automated, confined mixing of materials enriched with nanomaterials. It meets the industry’s growing demands for safety and precision, particularly in the face of the challenges posed by nanoparticles.

The entire process is automated using a robotic arm and the Vomery automatic mixing system developed by Lescuyer & Villeneuve. This automation enables precise, controlled integration of additives, while optimizing blend homogeneity and guaranteeing operator safety.

Compact and powerful, this roll mill can be fitted with advanced instrumentation, including a thermal camera for real-time monitoring of temperature variations.

Like all Lescuyer & Villeneuve equipment, the nanomaterials mixer complies with the most stringent safety standards (EN 1417:2023) and can be customized to meet specific user requirements.

Conclusion

Roll mills are essential for homogenizing polymers such as rubber, silicone and plastics. Their robust, technological design optimizes material processing.

Lescuyer & Villeneuve offers solutions tailored to industrial needs: a high-performance production roll mill for large volumes, a laboratory roll mill ideal for research, and an innovative, safe nanomaterials mixer. This modular, safety-compliant equipment improves manufacturing processes and the quality of finished products

Interested in a roll mill?

L’article Roll mill: how does it work? est apparu en premier sur Lescuyer et Villeneuve.

Polymer mixing process

LescuyerVilleneuvewp2 — Thu, 31 Oct 2024 07:51:08 +0000

The polymer mixing process: machines and innovations

Polymer mixing is a fundamental process for many industries, enabling the creation of materials with unique properties suitable for a wide range of applications.

Whether it’s to improve the strength, elasticity or durability of materials, the mixing process plays a crucial role.

In this article, we look at the machines suitable for this task, their integration into production lines and the latest innovations in the field.

What is the purpose of polymer mixing?

Material blending is used to optimise production processes by ensuring a homogeneous distribution of components. The process also allows unique blends to be created by incorporating various additives such as colourants, stabilisers or fillers.

These blends are essential to meet specific requirements such as heat resistance, elasticity or impact strength.

Machines adapted to mixing

The choice of polymer mixing equipment depends on the volume of material to be processed and the technical specifications of the end products.

Here are the main types of mixers used in the industry:

Internal mixer

Internal mixers are particularly effective for more difficult materials.

Two versions are used:

Intermeshing rotor: Used to maximise the dispersion of the components, it produces a homogeneous mixture by applying a high force during mixing.

Tangential rotor: This type of rotor is used for materials requiring higher shear rates, such as hard elastomers, to ensure efficient deformation of materials and optimum dispersion of additives.

Two-roll mill

Roll mill are widely used in industry for their simplicity and efficiency in mixing materials. There are two main types:

Laboratory Roll Mill: Used for small quantities of material, these machines are ideal for research and development. These machines can be used to test new mixes and study the behaviour of materials before going into full-scale production.

Production Roll Mill: Suitable for larger volumes, these mill ensure the homogeneity of production batches. They are often used in the manufacture of rubber, silicone and other polymer products.

Integration of roll mill into production lines

Roll mills are often the first step in the manufacturing process. After mixing, materials can be fed directly into additional equipment such as extruders, calenders or presses.

This allows materials to be formed to the desired dimensions and properties.

Integrating these machines into a fully automated production line not only improves productivity but also ensures consistent quality.

Modern systems offer advanced automation options, limiting human intervention to monitoring and quality control.

Innovations in polymer mixing

The polymer compounding sector has seen the emergence of new technologies aimed at improving the precision and efficiency of the production process.

Here are two key innovations developed by Lescuyer & Villeneuve:

The VOMERY system

This innovative system, patented by Lescuyer & Villeneuve, makes it possible to fully automate the mixing process, particularly for rubber.

The motorised rubber limiters move the material precisely over the cylinders, eliminating human intervention and reducing repetitive manual tasks for operators.

As well as improving productivity, the VOMERY system guarantees more accurate and reproducible blends.

Nanomaterials mixer

With the increasing use of nanoparticles as additives, Lescuyer & Villeneuve has developed a nanomaterial mixer that confines the process within a safe enclosure.

This system limits the diffusion of potentially harmful particles into the air and guarantees the safety of the operators. Combined with a robotic arm and the VOMERY system, this mixer makes it possible to process complex mixtures while minimising risks.

Conclusion

Polymer mixing, whether using roller mixers or internal mixers, remains a key process for many industries.

Recent advances, such as the VOMERY system and the nanomaterial mixer, reflect a constant drive to optimise processes and meet growing demands for safety, efficiency and precision.

These innovations enable companies like Lescuyer & Villeneuve to position themselves as leaders in polymer processing.

Interested in a roll mill?

L’article Polymer mixing process est apparu en premier sur Lescuyer et Villeneuve.

Rubber extrusion process

LescuyerVilleneuvewp2 — Tue, 22 Oct 2024 10:06:43 +0000

Extrusion is an industrial process used to transform materials, mainly polymers, metals or foodstuffs, by forcing them through a die or orifice that gives them a defined shape.

A more general article on the extrusion process is available on our blog!

We use this process extensively in a wide range of industries, including the automotive, food, construction and other sectors.

Rubber, a unique polymer for extrusion

Rubber, a natural polymer, has remarkable elastic properties, exceptional wear resistance and the ability to absorb shock.

Unlike synthetic polymers such as plastics, rubber extrusion requires a crucial additional step: vulcanization.

This chemical process, which involves heating the rubber in the presence of sulphur, gives the material its final properties of elasticity and strength. There are several key stages in rubber extrusion:

1. Material preparation: Raw rubber is mixed with various additives, such as vulcanising agents, fillers, antioxidants and pigments. This mixture must be carefully formulated to ensure optimum vulcanisation.

2. Material temperature: The extrusion temperature must be precisely controlled, at lower temperatures than for thermoplastics, to avoid pre-vulcanisation in the extruder.

3. The extrusion screw: Rubber screws are specially designed to handle the high viscosity and specific behaviour of the material.

4. Vulcanisation: After extrusion, the material is subjected to high temperatures (150-190°C) to stabilise its geometry and mechanical properties. This stage can be carried out in autoclaves, molten salt baths or hot air tunnels. You can find out more about this process on the MDC Engineering website.

Variety of possible applications

When rubber is extruded, it can be transformed into a wide variety of products for a wide range of industrial applications.

The main types of extruded product include:

Tyres: Tyres are one of the most common products made from extruded rubber. Rubber compounds are extruded to form treads, which are then assembled to form the different layers of a tyre.
Pipes and Tubes: Used in plumbing, irrigation and fluid delivery systems, extruded pipe is designed to withstand high pressures and varying environmental conditions.
Profiles: Extruded profiles are widely used in the construction industry, particularly for windows, doors and load-bearing structures.
Bands: Depending on the extrusion head selected, extrudates can be in the form of rubber strips or sheets. These sheets offer interesting properties such as flexibility, temperature and chemical resistance.
Elastic components: In the case of rubber, extrusion is used to produce seals, belts and other flexible parts, ideal for industrial applications requiring good wear resistance.
Common items: Rubber extrusion is also used to make items that we use frequently in our daily lives. These include gloves, which are widely used in the medical and industrial sectors, and shoe soles. Here, extrusion is used to produce items that are flexible, durable and suitable for a wide range of practical applications.

The various types of rubber extruder

The choice of extruder is critical to the production of high quality elastomer products. Each type of extruder offers specific advantages adapted to different elastomer formulations and applications. Here are the main types of extruders used to process elastomers, particularly rubber:

Single screw extruder: A single screw is used to feed, melt and form the material. It is often used for standard applications where simple mixing of the material is sufficient. Single-screw extruders are particularly suitable for standard rubber compounds and are renowned for their efficiency and ease of operation.
Twin screw extruder: With two parallel screws rotating in opposite directions, these machines offer improved mixing and precise temperature control. Ideal for complex formulations and heat-sensitive materials, they enable efficient processing of elastomers while ensuring uniform dispersion of additives.
Conical screw extruder: Used for low-viscosity materials, conical screw extruders facilitate the transport and packaging of rubber. They are particularly effective in the production of small diameter profiles and tubes where precision is essential.
Variable pitch screw extruder: This type of extruder allows the screw pitch to be varied during extrusion to match the changing properties of the material. This is particularly useful for complex elastomer formulations that require frequent adjustments to achieve optimum mechanical properties.
Degassing filter extruder: Lescuyer & Villeneuve patented extruder combining filtration and continuous degassing. The level of material purity and yield is higher than with standard equipment.
Pintle extruder: This extruder is useful for specific needs, particularly formulations that require more intensive mixing of additives.
Co-extrusion line: Process for combining multiple polymer streams in a single production stream to create multilayer products with specific properties.

Benefits of rubber extrusion

Rubber extrusion is used to make products that are durable, flexible and resistant to temperature changes and mechanical stress. In the automotive sector, for example, rubber extrusion is often used to make seals, radiator hoses and protective bellows.

This process also enables the mass production of parts with precise dimensions, while ensuring the uniformity of the finished product.

Interested in an extruder for rubber?

L’article Rubber extrusion process est apparu en premier sur Lescuyer et Villeneuve.

Extrusion process

LescuyerVilleneuvewp2 — Tue, 22 Oct 2024 10:06:34 +0000

Extrusion is an industrial moulding process used in many sectors to produce objects from a wide range of materials, including polymers, metals, foodstuffs and especially rubber (one of our articles is devoted entirely to rubber extrusion).

The process offers flexible and efficient solutions for manufacturing products in large quantities, while allowing precise customisation of shape and material properties.

How Extrusion works

The extrusion process is based on the idea of forcing a heated or semi-solid material through a die (mould) to give it a specific shape. The different stages are described below:

1. Feeding: The process begins with the raw material being fed into the extruder. This can be in the form of powder, granules or paste, depending on its properties and intended application.

2. Melting and homogenisation: Inside the extruder, the material is gradually heated and melted by the action of one or more rotating screws. This crucial stage not only melts the material, but also homogenises it, guaranteeing consistent quality in the final product.

3. Forming: The material is forced under pressure through a die. The geometry of this die determines the final shape of the extruded product, whether it is a sheet, tube or complex profile.

4. Post-treatment : Immediately after passing through the die, the extruded product is subjected to heat treatments, which may include gradual cooling or annealing depending on the material and the intended application, to ensure optimum geometric and functional specifications.

5. Finishing: Depending on the specifications of the final product, extrusion may be followed by additional operations such as cutting to length or winding for continuous products.

Extrusion process variants

There are several types of extrusion, each adapted to specific materials and applications:

Hot extrusion: Used mainly for plastics, metals and rubber, this process involves heating the material to make it malleable before passing it through the die.
Cold extrusion: Mainly used for metals, this technique involves extruding the material at room temperature, thereby preserving its mechanical properties.

There are also two main approaches to extrusion: continuous and semi-continuous.

Continuous extrusion produces the material without interrupting the material flow, while semi-continuous extrusion produces a series of separate parts.

Materials used in extrusion

Extrusion can be applied to a wide range of materials. Polymers such as plastics and rubber are most commonly extruded, but other materials such as metals can also be transformed by this process.

Finished products from the extrusion process

Extrusion is used to produce a wide range of items and products used in many industries. Here are some typical examples of extruded products:

Tubes and pipes: Used in the construction, plumbing and automotive sectors, extruded pipes are made from plastic or metal, depending on the need for durability or flexibility.
Profiles: Extruded profiles, whether plastic or metal, are used in the construction of windows, frames and other architectural structures.
Plastic films: Often used for food or industrial packaging, plastic films are produced continuously by extrusion, ensuring thin, uniform layers.

The outlook

The extrusion process continues to evolve through the integration of new technologies. Recent advances in composite materials and improvements in energy efficiency are increasing the importance of extrusion in the industry. In addition, the increasing use of recycled materials is opening up new prospects for the sustainable production of extruded products.

Rubber extrusion is also at the forefront of innovation, for example, Lescuyer & Villeneuve has patented a filter-degasser extruder that combines filtration and continuous degassing.

Interested in an extruder?

L’article Extrusion process est apparu en premier sur Lescuyer et Villeneuve.

Co extrusion

LescuyerVilleneuvewp2 — Tue, 22 Oct 2024 09:57:02 +0000

Co extrusion: an advanced technology for polymers

Co extrusion is an advanced process that allows multiple polymers to be combined in the same production stream to create multi-layer products with specific properties. The process involves the use of multiple extruders, each feeding a separate stream of molten polymer.

These streams come together in a single die where they coalesce to form a homogeneous multi-layer structure with unique properties.

A competitive advantage

This process is particularly useful for creating composite products with specific characteristics, combining the properties of different materials in a single part.

In the context of rubber and elastomer extrusion, co extrusion makes it possible to obtain products with improved properties, such as better wear resistance, improved sealing or improved durability.

How does co extrusion work?

The co extrusion line is equipped with a number of feed channels, which feed different materials into the extruder. Each stream comes from its own extruder, which heats the material before sending it to the die. The streams flow through different channels before meeting and mixing at the complex die geometry. The thickness and composition of each layer can be adjusted as required.

This process allows multiple layers to be applied to the same product, offering great design flexibility. For example, a tube could be made with an inner layer of rubber for flexibility and an outer layer of plastic for UV or oxygen resistance.

Necessary expertise and applications

To ensure stable production, the common structure of the co extrusion extruders must be designed to minimise pressure losses in each flow channel to ensure consistent quality of the finished products.

There is has a wide range of applications in different industries.

In the automotive sector, for example, it is used to produce seals that combine flexibility and rigidity. In the packaging sector, co extrusion is used to produce multi-layer films that offer a better barrier against moisture and gases, thus ensuring the preservation of food products.

Properties of coextruded products

The products resulting from this process have a number of mechanical and functional characteristics, including:

Excellent adhesion between layers: The fusion of the polymers at their contact zones ensures a strong bond between the different layers, creating a homogeneous structure.
High shear resistance: Co extruded products are particularly resistant to deformation and breakage.
High elongation resistance: These products can withstand a large amount of deformation before breaking, which is particularly useful in applications where flexibility and resilience are required.

Interested in a co extrusion line?

L’article Co extrusion est apparu en premier sur Lescuyer et Villeneuve.