Polymer powders mixing part I: Mixing characterization in rotating cylinders

In the production of rotomolded parts, the distribution of particle sizes in the form of polymer powder is highly important to produce parts of good quality. In the case of polymer blends, the particle size distribution becomes even more important to assure that good mixing occurs before the polymer melts. In this work, the mixing of free flowing polymer powders in a horizontal rotating cylinder has been studied. Special attention is given to the initial moments of mixing and the transition from a standstill to a fully developed rolling regime. The parameters studied include Froude number (rotational speed), cylinder loading, relative powder composition and particle sizes. For the first time, mixing dynamics are quantified using two image analyzes: grey-level co-occurrence matrix (GLCM) and Threshold methods. Using the experimental data, a model is proposed to follow the mixing dynamics and to determine the equilibrium time. The results also indicate that the Froude number is not enough to characterize the flow regime and the filling ratio must be accounted for.