【Tech Column】Redefining Precision Mixing｜How Our Static Mixer Line Elevates Silicone Sealant Production
In industries like electronic encapsulation, curtain wall construction, and solar energy, sealants are no longer just about sticking things together — they must endure extreme temperatures, UV exposure, mechanical stress, and more.
All of this depends on precise material ratios and highly uniform mixing.
This article features a fully customized production line built by GR Machinery, combining the upgraded JTH-X4 Static Mixing System with a servo-driven automatic sausage packing machine — designed for high-mix, high-efficiency silicone sealant production.
? Two Materials, Two Modes: Silicone vs PU
Our client applies this system in two different workflows:
- ✅ Silicone Sealant Production: Uses the static mixer connected in-line with the sausage filler. Formula includes base + pigment + dual additives (2K) for high-performance industrial applications like structural bonding and photovoltaic sealing.
- ✅ Polyurethane Sealant (PU): Operates the sausage packing machine independently, with PU often being a single-component, pre-mixed material that doesn’t require in-line blending.
This explains the customer’s three formula ratio requirements during testing:
- Base + Catalyst (98% + 2%)
- Base + Pigment (98% + 2%)
- Base + Pigment + Catalyst (96% + 2% + 2%)
These formulas highlight the importance of custom catalyst and pigment combinations for silicone sealants, allowing fine-tuned control over curing, bonding strength, and even color matching.
⚙️ JTH-X4 Static Mixing System: A Technical Breakdown
The JTH-X4 is a four-component static mixer system, built to deliver accurate dosing and homogeneous mixing. Key design features include:
? Up to 4% additive ratio (23.6cc) via 20mm dosing cylinder
? As low as 1% additive ratio (5.9cc) via 10mm dosing cylinder
? Servo-driven additive compression for precision and consistency
? 10-recipe memory & locking feature via HMI touchscreen
? Advanced static mixing heads for tens of thousands of dispersions
? Optional auto feeding system for pigment and additives
The system achieves true simultaneous extrusion: the base, pigment, and additives are metered independently but extruded together, then instantly mixed through multi-stage static elements to ensure high uniformity.
VSE flowmeterVSE flowmeter
? Flexible Integration: One Line, Dual Functionality
To meet the customer’s dual production needs (in-line mixing for silicone, standalone packing for PU), our team engineered several smart adaptations:
- ? Guide rail system for easy connection/disconnection between machines
- ⚠️ Sensors detect whether the sausage filler is operating in standalone or in-line mode
- ?️ Touchscreen logic auto-adjusts machine behavior and parameters accordingly
With these features, the entire line becomes a flexible, modular solution capable of responding to different material demands and production volumes.
? Application Scenarios: The Rise of Industrial Silicone
This type of high-precision, multi-component mixing + automated packaging solution is ideal for:
? Structural silicone sealants — where bonding strength and color consistency are critical
? Solar frame adhesives — requiring anti-aging additives and controlled flow
? Electronic potting compounds — multi-component systems that require strict ratio control
? EV battery adhesives — needing different modulus/strength profiles by additive tuning
Especially in solar, electronics, and EV sectors, the trend is moving from standardized products to customized, small-batch, high-performance formulations — and flexible mixing systems like ours are key enablers.
✅ Final Thoughts: Precision Mixing as a Competitive Advantage
The value of a static mixing system is not just in blending — it’s in how well it enables recipe accuracy, formulation flexibility, and production efficiency.
This custom-built line by GR Machinery empowers our customer with:
- Multi-scenario adaptability
- Accurate multi-additive dosing
- Rapid recipe switching
- Reliable automation from mixing to packaging
If you’re looking to bring more formulation control and automation to your sealant or adhesive production, we’re here to help.
Let’s talk about how we can bring this precision to your plant.
?bd@geruijx.cn
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