CK Series Continuous Kneader Mixer
B&P Littleford's CK Series Continuous Kneader (Co-Kneader) is a flexible, proven solution for a wide range of compounding and mixing needs. The system features a single rotating and reciprocating mixing screw that processes material between the moving flights on the screw and stationary teeth in the barrel wall — delivering simultaneous dispersive and distributive mixing in a compact, efficient design. With an excellent torque to free volume ratio, the CK Series is ideally suited for thermally sensitive elastomeric adhesives, blowing agent formulations, and a broad spectrum of PVC, wire and cable, and specialty compound applications. The CK Series is available in ten standard sizes from 40mm to 800mm, with the flexibility to convert between cascade discharge and direct-flanged crosshead execution to meet changing production requirements — making it one of the most versatile Co-Kneader platforms available.
CK Series Features
B&P Littleford engineered the CK Series to deliver consistent, high-quality compounding output with minimal operator burden and maximum process flexibility:
- Highly automated for minimal operator intervention
- Flexible and versatile for use in a wide range of applications
- Reduced operating costs
- Easily and quickly cleaned for rapid material changeovers
- No dead spots — ensures a homogeneous mix throughout
- Virtually eliminates batch-to-batch variances
- Very low scrap rate
- Clamshell barrel design allows easy access for cleaning and inspection
- Designed for lower power consumption with better quality finished product than twin-screw designs
- Proven in installations worldwide
The Continuous Compounding Solution You Need
The CK Series is engineered for processors who require versatility, efficiency, and consistent quality at scale. It is ideal for operations that demand:
- Gentle, controlled shear for temperature- and shear-sensitive formulations
- Simultaneous dispersive and distributive mixing in a single continuous pass
- Separation of the kneading and pressurization steps for a wider processing window
- Improved mechanical energy efficiency — efficient mixing at high screw speed combined with efficient pumping at lower metering speed
- Lower overall melt temperatures compared to conventional twin-screw designs
- Rapid product changeovers without product contamination or material buildup
- Flexible discharge configurations to accommodate a range of downstream processes
How the CK Series Continuous Kneader Works
The B&P Littleford CK Series operates on a single-screw rotating and reciprocating principle. The interrupted flights on the screw interact with three rows of stationary kneading pins located in the barrel wall. As the screw rotates and reciprocates simultaneously, material is continuously split, folded, and recombined — delivering both dispersive and distributive mixing in a single step, with a peak shear rate that is lower than that of other compounders and comparatively lower internal operating pressure.
Pressurization and discharge shaping are handled separately from the kneading step via an independent metering device — such as a melt pump or a single-screw discharge extruder. This inherent separation of the kneading and pressurization functions results in greater process flexibility, a wider processing window, and improved overall mechanical energy efficiency. The result is a lower melt temperature and superior product quality compared to designs that combine these functions.
The clamshell barrel design provides quick, unobstructed access to the screw and barrel interior for cleaning and inspection, significantly reducing downtime during product changeovers.
Prove Your Process: The B&P Littleford Technology Center
Choosing a new compounding technology is a critical decision. We invite you to eliminate the guesswork and prove your results before you invest.
Located in Saginaw, Michigan, our 16,000-square-foot facility is one of the most comprehensive process laboratories in the United States.
- Confidential Evaluations: Our staff of experienced engineers and technicians handle dozens of confidential product evaluations every year.
- Empirical Analysis: Conduct a test run on the Co-Kneader to calculate precise performance metrics for your specific materials and formulations.
- Scale-Up Confidence: The data and operating parameters of your formulation are used to scale to the size needed for your full production requirements.
- Optimization with "Dead Stop" Analysis: The clamshell barrel design allows us to halt the process mid-stream and open the machine, enabling a direct, empirical evaluation of each unit operation for maximum optimization.
CK Series Machine Configurations
B&P Littleford offers the CK Series in ten standard sizes to match your output requirements, from pilot-scale development to maximum-throughput continuous production:
CK-40 / CK-60
Ideal for pilot-scale R&D, process development, and small-scale production validation.
CK-80 / CK-110
Mid-range production units suited for moderate-volume continuous compounding operations.
CK-150 / CK-220
High-capacity production for demanding compound programs requiring consistent, high-volume output.
CK-500 / CK-600 / CK-700 / CK-800
Maximum-throughput production for the most demanding large-scale output requirements.
Standard Machine Specifications:
- Screw sizes: 40–800mm standard
- Process lengths: 8 to 20 L/D
- Compact high-performance gearbox — screw speeds up to 750 rpm
- Cored screw shaft option for fluid tempering
- Electric heating and water cooling (standard); fluid cooling (optional)
- Wide range of customized supporting equipment available: top feeders, side feeders, vacuum vent stuffers, vacuum connection chute, melt pump, discharge extruders, and die face pelletizer
- Configurable from cascade discharge to direct-flanged crosshead execution for extreme versatility across changing products
CK Series Production Rates by Machine Size (kg/hr)
|
Compound |
Type |
40mm |
60mm |
80mm |
110mm |
150mm |
220mm |
|
FLEXIBLE PVC COMPOUNDS |
|||||||
|
Cable Insulation Compounds |
Cc |
70–120 |
225–350 |
500–800 |
800–2,000 |
1,800–3,500 |
5,000–8,000 |
|
Cable Sheathing Compounds |
Cc |
70–120 |
225–350 |
500–800 |
800–2,000 |
1,800–3,500 |
5,000–8,000 |
|
RIGID PVC COMPOUNDS |
|||||||
|
Blow Molding (Bottle) Compounds |
Cc |
55–110 |
100–200 |
250–450 |
600–1,200 |
1,500–3,000 |
4,000–9,000 |
|
Calander Film & Sheet |
C/CcFC |
NA |
NA |
200–400 |
600–1,100 |
1,500–2,750 |
4,000–8,500 |
|
WIRE AND CABLE COMPOUNDS |
|||||||
|
Halogen-free FR Compounds |
XH |
15–35 |
55–100 |
150–230 |
320–560 |
500–950 |
1,300–2,200 |
|
Semiconductive Compounds |
GP |
30–65 |
100–180 |
200–400 |
300–800 |
1,000–1,700 |
2,400–3,500 |
|
Peroxide XLPE Compounds |
Cc |
15–35 |
55–110 |
135–250 |
300–550 |
550–1,000 |
1,200–2,100 |
|
Sioplas XLPE Compounds |
Cc |
45–75 |
125–240 |
300–575 |
800–1,250 |
1,250–1,950 |
3,000–4,000 |
|
TPO, TPE, Specialty Compounds |
XH |
15–30 |
55–100 |
150–225 |
350–550 |
600–950 |
1,200–2,200 |
Type = Gear Pump Extrusion (GP), Crosshead Execution (XH), Calander Execution (C), Cascade Execution (Cc), Cascade+Filter+Calander Execution (CcFC)
Let's Connect!
CK Series Application Areas
The B&P Littleford CK Series is well-proven in applications requiring gentle kneading, dispersive mixing, and distributive mixing across a broad range of materials and industries.
|
Application Area |
Description |
|
PVC Wire & Cable |
Pre-mixing, conveying, gravimetric feeding, compounding, and pelletizing/sheeting for flexible PVC cable insulation and sheathing compounds |
|
Rigid PVC |
Blow molding compounds and calander film & sheet production |
|
Powder Coatings & Toners |
Precision compounding for consistent particle dispersion and uniformity |
|
EVA |
Ethylene-vinyl acetate compounding for a range of end-use applications |
|
Color & Black Masterbatches |
High-quality pigment dispersion with no dead spots and virtually zero batch-to-batch variation |
|
Bio- & Natural-Fiber Based Compounding |
Gentle processing of sensitive bio-based and natural-fiber reinforced formulations |
|
Food & Confectionery |
Food-grade compounding applications requiring hygienic design and easy cleanability |
Process Control System
B&P Littleford's process control system provides full visualization functions to regulate and monitor the CK Series in real time. The system features a clearly arranged touch display and membrane keyboard that enables:
- Failsafe interlocking
- Large view of selectable running data with trends representation
- Fault message system with visual representation and archiving
- Convenient operating help in clear text
- Graphic and tabular representation
- Multi-step login
- Language changeover
- Recipe management of all process parameters
Put the CK Series to Work for You
B&P Littleford is prepared and equipped to help you find the right Co-Kneader solution for your compounding and mixing needs. The CK Series has a very successful track record in processing shear- and temperature-sensitive compounds across industries and applications — and we invite you to see what it can do for yours.
Whether you're looking to validate a new formulation, scale up from pilot to production, or replace an underperforming twin-screw line, we're ready to prove the performance of the CK Series with your specific materials.
Take advantage of our decades of experience and proven technology by contacting us to discuss your process requirements.
Let's Connect!Frequently Asked Questions About the CK Series Continuous Kneader
What is a Continuous Kneader?
The B&P Littleford CK Series Continuous Kneader (Co-Kneader) is a moderate-shear, rotating and reciprocating single-screw compounding system ideally suited for shear- and temperature-sensitive compounds. The interrupted flights on the screw interact with three rows of stationary kneading pins in the barrel wall, delivering simultaneous dispersive and distributive mixing in a single continuous pass.
How does the Continuous Kneader differ from a twin-screw extruder?
The CK Series operates at a lower peak shear rate and lower internal pressure than twin-screw extruders, making it better suited for heat-sensitive and shear-sensitive formulations. It also separates the kneading function from the pressurization step — handled by a downstream melt pump or discharge extruder — which results in a wider processing window, better mechanical energy efficiency, and a lower overall melt temperature.
What materials can the CK Series process?
The CK Series is well-proven in flexible and rigid PVC compounds, wire and cable compounds (including XLPE, halogen-free FR, and semiconductive), powder coatings, toners, EVA, color and black masterbatches, bio- and natural-fiber based compounds, and food and confectionery applications.
What sizes does the CK Series come in?
The CK Series is available in ten standard sizes: 40, 60, 80, 110, 150, 220, 500, 600, 700, and 800mm. Process lengths range from 8 to 20 L/D, and configurations can be converted between cascade discharge and direct-flanged crosshead execution.
Can I test the CK Series before purchasing?
Yes. B&P Littleford's Technology Center in Saginaw, Michigan is available for confidential process evaluations using your specific materials and formulations. Our experienced engineers and technicians will work with you to generate empirical performance data that can be used to confidently specify and scale the right CK Series machine for your production needs.