The traditional production methods for highly filled bitumen compounds are by processing on batch internal mixers. These established methods offer advantages such as flexibility, easy offline dosing of even small ingredients, as well as variable dwell times and mixing times. However, limitations such as interim storage times and variations in characteristics between individual batches allow continuous processes to exploit their advantages: Uniform process conditions, narrow residence time distribution and the integration of process steps are part of the typical strength profile. The BUSS Kneader can also score with precise temperature control, the handling of large differences in viscosity between bitumen and polymers/elastomers, and the possibility to perfectly mix even the highest filler proportions.
Recently, a wide range of extended application fields has been added, thanks largely to the integration of process steps such as inline processing on carrier substrates and the use of alternative recipe components. In the Buss technical centre, the sophisticated procedures used to accommodate and implement these high standards can be developed and optimized. The first plants with a throughput factor of 10 have been realized industrially and are successfully in operation. In a throughput range of 1:6, the products are directly processed in line. The split barrel of the BUSS Kneader furthermore ensures fast access and high system availability. Together with broadly based Buss process expertise, the modular and thus adaptable design of the entire system make the Buss Kneader system an excellent choice and sound investment for compounding highly filled bitumen compounds and their future substitution materials.