Extrusion Static Mixers
High-Performance Melt Blender Technology
Promix extrusion static mixers are advanced engineering solutions developed to homogenize polymer melts, balance temperature and viscosity distribution, and significantly improve product quality. Based on the principle of static mixing, the melt is continuously split and recombined within the flow channel without any moving parts, resulting in a uniform distribution across the entire cross-section of the melt stream.
Installed downstream of the melt pump and filtration system, directly before the die, the melt blender eliminates temperature fluctuations, color inhomogeneity, and surface defects, ensuring stable and consistent production performance.
Key Process Benefits in Extrusion
Promix static mixing technology delivers measurable improvements in both process efficiency and product quality:
• 20-30% reduction in masterbatch and additive consumption
• Annual cost savings of USD 1,000 - 10,000 depending on the application
• Up to 30% increase in line capacity (e.g., from 120 kg/h to 160 kg/h)
• Productivity gains reaching up to USD 300,000 annually
• Lower scrap rates and tighter thickness tolerances
• Elimination of flow lines and surface defects
• Increased use of regrind material
• Homogeneous temperature and viscosity distribution
These benefits provide clear production advantages in film, sheet, profile, pipe, and blow molding applications.
Melt Homogeneity and Temperature Control
In extrusion processes, temperature variations typically occur along the screw, filter, melt pump, and pipeline. Promix melt blenders redistribute the melt across the entire flow cross-section, balancing both temperature and velocity profiles.
Thermal analysis shows:
• Without static mixer: Tmax deviation ≈ 18°C
• With Promix melt blender: Tmax deviation ≈ 3°C
This directly improves surface quality and thickness consistency of the final product.
Technical Performance and Operating Parameters
Promix extrusion static mixers are designed for stable operation under demanding pressure and temperature conditions:
• Maximum operating temperature: 350°C
• Maximum pressure drop (SMB-H example): up to 200 bar
• Small throughput applications: up to 150 kg/h
• Number of mixing elements: 2-6
• Installation: before the die, inline, retrofit for existing lines
These parameters ensure stable mixing performance for high-viscosity and high-molecular-weight polymers.
Application Areas
Promix extrusion static mixers are widely used across various extrusion processes:
• Blown film and flat film lines
• Sheet and panel extrusion
• Profile and pipe production
• Cable coating lines
• Co-extrusion processes
• Foam extrusion and sandwich structures
The melt blender provides significant advantages particularly in multi-channel systems where melt flow is divided before the die.
Process Stability and Product Quality
Key quality improvements achieved with static mixer integration include:
• Homogeneous color distribution
• Uniform film and sheet thickness
• Increased mechanical strength
• Homogeneous foam cell structure
• Reduced viscosity fluctuations
These improvements allow higher production speeds while eliminating quality-driven capacity limitations.
Installation and Integration Advantages
Promix melt blender systems are delivered as ready-to-install solutions:
• Housing, adapters, heating and sensor options
• Fast integration into existing extrusion lines
• Typical installation time: a few hours
• Suitable for retrofit and new production lines
This minimizes production downtime and shortens return on investment.
Why Promix Extrusion Static Mixers?
• CFD-optimized mixer geometry
• Narrow residence time distribution
• Prevention of dead zones
• Self-cleaning flow structure
• High process safety and reliability
Promix has more than 50,000 reference applications in plastics processing and has integrated its technologies into hundreds of extrusion lines worldwide.
