New Insights for Industries from Banbury’s Process Analysis
Copyright: ST-One
To address industry challenges, it is necessary to make data analysis in an innovative way. It is possible to find intelligent results in the most different sectors through data visualization methods, such as discovery and exploration. The replicability of data and applications plays an important role in optimizing the production process, resulting in creative solutions due to greater visibility.
An example of this flexibility is the data analysis applied to the Banbury Mixer. This equipment features two rotors that operate inside a closed chamber. The rotors have threads with either “Banbury” geometry for elastomers or a “Roller” type for thermoplastics. It produces polymeric materials intermittently, in batches. Also, Banbury is used for its capacity to incorporate a small amount of additive into a thermoplastic material, and processing rubber compounds with numerous ingredients.
This type of mixer is widely used in the rubber industry and is considered one of the most modern equipment in the world for this sector. He is known for being able to mix rubber compounds in high quality, even when mixing materials such as elastomers, activators, and peptizers.
According to the newspaper Globo (2022), the rubber industry moves R$ 28 billion per year in Brazil. The country stands out because, during the Rubber Cycle, Brazil became the largest rubber producer in the world. During that time, this product was responsible for 40% of total exports at its peak. Worldwide, the natural rubber market is estimated to be worth US$ 18 billion in 2024, and it could reach up to US$ 22 billion by 2029. Finally, it is important to say that rubber is essential for the automobile industry, and it has revolutionized the footwear industry by making it possible to create softer shoe soles.
Copyright: ST-One
Data Analysis on a Banbury Mixer
As seen, the Banbury mixer is an equipment of great importance in the manufacturing industry, as it mixes various compounds with high quality. This way, data science is a great ally to further optimize its process through different types of analysis:
- Rheological analysis: Used to study materials’ flow behavior in the Banbury mixer. It helps to understand how different process conditions affect the viscosity and elasticity of the material;
- Shear analysis: Monitoring variables such as temperature and pressure assist in dispersing materials such as polymers in opposite directions;
- Analysis of key process indicators: Helps to understand how these variables affect the mechanical properties of an elastomeric compound. This includes the analysis of temperature, pressure, rotation speed of the rotors, mixing time, etc;
- Energy Efficiency Analysis: It can be applied to understand how energy consumption affects the Banbury mixer efficiency and product quality. For products like rubber, which rely on driving force, the amount of energy consumed during mixing can indicate aspects such as viscosity. This parameter directly impacts the product quality, and if it falls outside the established range, there is a risk of it being considered unsuitable for use;
The last topic, regarding Banbury’s energy efficiency analysis, deserves special attention. This is because its dynamics can be applied to other industry sectors, as seen below, resulting in new insights that lead to improvements and optimization.
The use of energy in industry
Beyond Banbury, energy efficiency analysis holds general importance in the manufacturing industry. For example, electrical energy is used to move supplies and power motors, as well as to heat or dry products on the production line, etc. However, when it comes to the rubber industry, where Banbury mixers are primarily used, the function and use of this resource are intensified.
This is particularly true because latex, which has a vegetable origin, is transformed into rubber only through industrial processing. So, it is possible to say that energy in this sector is used in both the production and processing stages. In production, it is used for both natural and synthetic rubber. In the case of natural ones, energy is used to extract latex from rubber trees. Synthetics are used to produce raw materials such as oil, oil, and natural gas.
In the processing step, energy is essential in processes such as mixing, extrusion, and vulcanization. The Banbury mixer utilizes this energy to mix and knead the rubber, while in extrusion, it increases the flow velocity.
Due to its dual importance in this sector and Banbury’s direct impact on product quality that energy efficiency analysis is indispensable. As explained, depending on the product type, the amount of energy consumed during mixing can indicate crucial productive aspects such as viscosity. The production is considered improper if this indicator is not within the parameter. From the critical perspective of a data scientist, this same analysis can be applied to other sectors, optimizing other products beyond rubber.
Copyright: ST-One
Data replicability: energy efficiency analysis applied to all industries
The analysis that was applied to the Banbury mixer is applicable in several types of industry, such as:
- Chemical industry: Banbury mixer is suitable for mixing chemical industrial raw materials, such as cable materials, color master batch, EVA, PVC, heat shrink tube, etc. In this context, energy affects heat transfer, as the rotors generate a lot of friction with the material, characterizing it as an exothermic process, but some mixtures can absorb and dissipate the heat;
- Polymer industry: vulcanization is a chemical process where cross-links are formed between polymer chains to give more durability to the material. Heat is essential in this process, and the Banbury mixer helps ensure that it is evenly distributed;
- Cosmetics industry: It is used to mix ingredients to create the product’s base and in the incorporation of pigments and other additives. Energy efficiency analysis helps with energy management and quality in industry;
In addition, energy efficiency affects other aspects of production. In terms of machine operation, potential fluctuations in power quality can lead to unexpected shutdowns, resulting in financial losses. Also, the lack of energy consumption monitoring can result in excessive energy spending, causing non-compliance in ESG strategies.
Copyright: ST-One
Data science as the key to energy efficiency and other improvements
In summary, the energy efficiency analysis in Banbury mixers is an example of an application that can be used across different industry sectors. Its implementation leads to several optimizations such as improved mixing and advanced technology. The digitalization of the production line and precise data collection further enhance its impact. It also influences the mechanical and rheological properties of the compound, which directly affects the quality of the final product.
The monitoring of these and other variables contributes to the implementation of sustainable development, promoting the efficient use and conservation of natural resources. It also allows quick detection of instabilities and the application of predictive maintenance through studying data patterns. Data science is also responsible for better management, by establishing a flexible routine for resource reallocation and supply order planning. Beyond production, its impact is also on the administration area, by creating a culture of more assertive, data-driven decision-making. This approach allows for the identification of growth opportunities and risk reduction.
Finally, according to the National Confederation of Industry (2023), energy efficiency can lead to savings of R$ 10 billion for the industrial sector by 2050. The substantial figure serves as an incentive to search for technologies that yield such result, including data science, which increased competitiveness. Besides economic gains, these actions also have a positive impact on the environment as a whole, ensuring industry compliance with ESG strategies. Learn more about us.
