Continuous mixers (mainly twin-shaft forced continuous mixing machines) differ from batch mixers in that they achieve simultaneous and uninterrupted continuous operations of feeding, mixing, and discharging.
The material is fed into the cylinder at one end at a constant speed. Two counter-rotating mixing shafts equipped with spiral wear-resistant blades shear, knead, and convectively mix the material while pushing it axially along the cylinder. The material stays in the cylinder for 30–120 seconds to achieve uniform mixing, and is continuously and stably discharged from the other end. The entire process is carried out without downtime or waiting cycles, forming a constant material flow.
A complete set of continuous mixing system is provided: batching silo → variable frequency metering belt/screw conveyor → mixing mainframe → finished product belt, with full-process linkage speed regulation, ensuring real-time matching between input ratio flow and output yield.
1. Mixing cylinder: Thickened wear-resistant casing, fully sealed to prevent dust emission, multiple sets of maintenance doors with safety locks for easy maintenance and cleaning; inner wall lined with high-chromium wear-resistant lining plate.
2. Dual-agitator spindle assembly: Two parallel heavy-duty agitating shafts operate in sync but in opposite directions; the blades are made of reversible wear-resistant alloy, allowing for reuse after wear by flipping over, thereby reducing accessory costs.
3. Drive and transmission system: hardened gear reducer + flexible coupling, high torque output, material jamming buffer to protect the motor; dual motors independently drive, ensuring balanced power.
4. Multiple seals at the shaft end: A combination of labyrinth seals and skeleton oil seals ensures no leakage or dust ingress under dry powder, wet material, and slurry conditions, thereby extending the lifespan of the bearing.
5. Water supply/admixture system: A variable frequency flowmeter continuously supplies water, with atomized spraying ensuring even moisture penetration into the mixture, eliminating dry clumps and water accumulation.
6. PLC fully automatic control system: It integrates with front-end batching and metering, adjusts the conveying speed of various materials in real time, monitors flow, output, and current online, and automatically alarms in case of abnormalities.
1. Extremely high production capacity, suitable for ultra-large continuous working conditions without intermittent “feeding – mixing – discharging – emptying” waiting cycles, allowing for 24-hour full-load continuous operation; mainstream models have a production capacity of 300–1000t/h, which is 3–8 times higher than that of intermittent mixers under the same footprint, suitable for uninterrupted paving construction on roads, dams, and large-area base layers.
2. The production line is seamlessly integrated, ensuring a smooth process that can directly link the entire automated production line, including batching, conveying, forming, and paving. The continuous conveyance of materials without intermediate buffering and transfer reduces material stacking and secondary transportation, significantly simplifying the layout of the factory area and shortening the construction period.
3. Lower energy consumption and operational cost. Eliminate the impact loss caused by frequent start-stop of motors, resulting in a 10%–20% lower power consumption per unit of material compared to intermittent equipment for the same output. The integrated blade pushing and mixing design ensures high power utilization efficiency, leading to significant energy savings in long-term mass production.
4. The discharged materials are uniform and stable, with good consistency in finished products. The materials stay in the cylinder for a uniform duration, and the mixing shear force remains constant, ensuring that the mixed materials have no batch color difference or strength fluctuation. The coefficient of variation for mixing uniformity is ≤5%. Stabilized soil, lean concrete, and backfill materials exhibit no segregation or agglomeration, and the strength of the base layer after paving is uniform.
5. Compact structure, smaller footprint: The horizontal, elongated, integrated design results in a low overall height, requiring less investment in the construction of the accompanying mixing station building. Modular disassembly allows for separate transportation, rapid disassembly and assembly, enabling the mobile continuous mixing station to be transported for construction at different sites.
6. The wear-resistant and durable blades, which are easy to maintain, can be flipped 180° for secondary use, and the lining board has a long wear life; with multiple side-opening doors, quick replacement of vulnerable parts can be achieved upon shutdown; the overall fully sealed structure ensures minimal dust leakage and a clean workshop environment.
7. Automated and flexible variable frequency linkage speed regulation, with aggregate, cement, and water flow adjusted proportionally and synchronously; remote modification of mix proportions, real-time production statistics, storage of production data, and compatibility with intelligent mixing plant management.
Engineering infrastructure construction (the most mainstream)
1. Road base: cement stabilized macadam, lime-fly ash stabilized soil, lime soil, graded sand-gravel mixture (with WCZ/WBC stabilized soil mixing plant of 500/600/800 type)
2. Roller Compacted Concrete (RCC), lean concrete, subgrade backfill solidification material, tunnel filling material
3. Continuous casting projects for airport runways, dam cofferdams, and river slope protection
Building materials / Environmental protection / Mining industry
1. Dry mortar, permeable brick base material, slag stabilization and solidification, and sludge harmless mixing
2. Continuous premixing of organic fertilizer, compound fertilizer, mineral powder, and graphite powder
3. Continuous mixing of ceramic raw materials, chemical particles, and solid waste recycling mixtures
Adaptive operating condition characteristics
Suitable for projects involving single formula, long-term continuous mass production; not suitable for frequent switching between multiple specialized formulas, high fiber content, or ultra-high performance UHPC fine mixing (for this scenario, the vertical planetary intermittent mixer is preferred).
1. Match the hourly production capacity with the daily paving volume of the project, and reserve 10% margin to cope with peak construction;
2. Long term dry material dust conditions are equipped with a complete set of dust removal devices;
3. Thickened wear-resistant lining plates and strengthened shaft end seals are selected for high humidity and mud materials;
4. Multiple project transition construction can choose a mobile integrated continuous mixing station;
5. Only producing a single stable soil base layer with priority for double horizontal axis continuous type; Multiple special materials and fiber products are selected using intermittent planetary/double horizontal axis equipment.