Chemical Kit

Tough, abrasive chemicals and catalyst materials can accelerate wear on standard mixing and extrusion components, shortening service life, increasing maintenance requirements, and compromising process consistency and data accuracy.

The Chemical Kit is engineered for demanding applications, combining specialist mixer and extruder components designed to minimise wear, extend component life, and deliver reliable, repeatable processing of challenging materials.

Exrtrudate and Pellets

Key Benefits of the Chemical Kit

The Caleva Mixer Torque Rheometer, Multi Lab Scientific and Multi Lab Classic are used extensively for formulation development across a range of chemical applications including battery development, catalysts, carbon capture sorbents and advanced ceramics.  These materials can be highly abrasive and place significant demands on processing equipment, leading to accelerated wear of critical mixing and extrusion components. To address these challenges, our engineers have developed the Chemical Kit: a range of specialist mixer and extruder components designed to meet the demands of chemical applications.

  • Increased wear resistance – Components of the Chemical Kit are made from harder-wearing materials to withstand abrasive materials more effectively, helping to reduce component wear and extend operational their lifespan*.
  • Reduced Motor Load - The optimised blade profile in the Chemical (Sigma) Mixer maintains effective mixing performance while reducing strain on the drive system, helping to minimise mechanical stress and support longer motor life*.
  • More efficient material transfer – Twin-flight pressing cams in the Chemical Screw Extruder create dedicated transportation and processing zones, promoting more consistent material flow and improving extrusion performance with challenging formulations*.
  • Improved material flow – The Chemical Screw Extruder features a grooved barrel interior to increase friction during extrusion, enhancing material transfer and enabling smoother processing of difficult-to-extrude materials*.
  • Improved product uniformity - Reduced wear of critical processing component helps maintain process consistency, producing beads with a narrower size distribution and reducing batch-to-batch variability*
  • Improved process reliability and yield - By helping to reduce issues such as shark‑skinning, binder loss and performance variability, the Chemical Kit supports more reliable processing, improved yields and a stronger return on investment*.

*Compared to standard Caleva mixer and extruder attachments

Sigma-Water-Jacketed-Bowl-ES

Sigma-Blades-MLX-ES

Designed for demanding chemical and catalyst applications, the Chemical (Sigma) Mixer Attachment is engineered to process abrasive materials that can accelerate component wear and increase mechanical load on standard mixing systems. 

The attachment features 304 stainless steel blades with enhanced wear resistance to support longer component life. An optimised blade profile effective mixing performance while reducing load on the motor, helping to minimise mechanical stress during processing.

For heat-generating formulations, the water jacketed bowl can be connected to a recirculating pump to maintain a controlled processing temperature, supporting greater process consistency and material stability. 

The Chemical Mixer Attachment is fully compatible with the Multi Lab Classic (MLC)Multi Lab Scientific (MLS) and Mixer Torque Rheometer (MTR) providing straightforward integration without modification. It is also compatible with the original Caleva Multi Lab (CML).

Chemical Extrusion Set 45 1000pxDesigned for demanding chemical and catalyst applications, the Chemical Screw Extruder is engineered to process tough, abrasive formulations that can accelerate wear and challenge material flow in standard extrusion systems.

The attachment features a twin-flight screw and grooved auger tube that work together to improve material transport. The twin-flight screw creates dedicated transport and processing zones, while the grooved auger barrel interior increases friction to promote efficient movement of difficult-to-extrude materials.

To withstand abrasive formulations, both the screw and auger tube are manufactured from 17-4 PH stainless steel to help reduce component wear and extend service life.

Together, these features support smoother material flow, improved extrusion consistency and more reliable processing performance when working with challenging chemical formulations. 

Compatible with the Multi Lab Classic (MLC), Multi Lab Scientific (MLS) and original Caleva Multi Lab (CML), the Chemical Screw Extruder integrates seamlessly without the need for additional modifications.

Caleva - 041-34

The Chemical Screw Extruder is compatible with a range of die configurations to support different product requirements.

The Chemical Kit replaces the standard 1.0mm x 1.0mm die face with a deeper 1.0mm x 4.0mm die, creating a longer extrusion path that increases compaction.

Additional die sizes are available from 0.5mm to 3.0mm, providing flexibility for different formulation and process development requirements.

For applications requiring increased surface area, optional trilobe and quadrilobe dies are available. These die designs can improve mass transfer during catalytic reactions and support the development of products with targeted surface area, density, mechanical strength, MOF length and pressure-drop characteristics for reactor applications.

Die options are compatible with all extruder attachments for the Multi Lab Classic (MLC), Multi Lab Scientific (MLS) and original Caleva Multi Lab (CML) 

For applications involving abrasive formulations, elevated processing temperatures or chemically aggressive materials, optional PEEK bushes are available across the Caleva range.

Manufactured from high-performance polyether ether ketone (PEEK), these bushes offer excellent wear resistance and chemical compatibility, making them well suited to demanding formulation development applications.

When used alongside the Chemical Kit, they provide an additional level of protection against wear, helping to maximise equipment life and maintain reliable processing performance.
Testimonial

Using the CML and MTR in combination we’re learning a lot about our catalyst material. The machines are easy to use, and we have achieved very accurate measurements, giving us precise repeatability. The MTR has been a massive advantage in our research and we’re doing things with the material we didn’t think were possible. The speed and ease of use have allowed us to conduct numerous experiments in a single day - we’ve accumulated vast amounts of data to inform our scale up. Both the CML and MTR are manufactured to a very high standard and are very dependable.

IGTL Technology LTD

When transferring a new technology from R&D into production, process flexibility and equipment adaptability are key. Caleva was a true partner, working with us to find a creative solution to a difficult engineering problem.

Erik Koep Chief Executive Officer at Worn Again

In pig iron manufacturing, the physicochemical properties, such as particle-size distribution, wettability, and porosity, of raw powders often vary. This results in a large variation in the optimum water content for wet granulation of fine iron ore powders. We have demonstrated that the optimum water content for wet granulation of fine ore powders can be determined using the MTR, even when the raw ore powders varied.

Dr Nakamura Osaka Metropolitan University

Caleva were extremely nice and knowledgeable through presenting new technology and reliable products that achieve our client’s needs and satisfaction.

Qusay Kareem Knowledge House Engineering Supplies
MTR Pouring MCC Into Bowl

Published papers

Read published papers featuring Caleva equipment used to mix and extrude tough, abrasive materials.
Caleva training

Spare parts and service

Maintain the accuracy of your data by replacing worn parts when required.
 

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