I'm mixing a very basic SBR compound on our 270 liter Banbury mixer. The compound has carbon black, the standard small powders, some synthetic resin for tack and no oil. It really is a basic formulation. But I'm having an issue with the compound discharging from the mixer in pieces rather than as one single mass, which is always the ideal scenario for reduced milling time. I tried single stage initially but ended up switching to two-stage to allow higher temperatures. I have tried various fill factors, different mix steps, different order of loading and different rotor speeds on discharge - all to no avail. Has anyone any tips on improving this?
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