--- title: 5 Signs Your Mixing Mill Should Be Modernized description: How to Recognize When Modernization by DEGUMA Makes More Sense Than New Equipment Purchase image: https://info.deguma.com/hubfs/Walzwerk%20Laptop%202016%20155112_neutral%20klein.png --- [Skip to content](https://info.deguma.com/en/blog/5-signs-your-mixing-mill-should-be-modernized#main-content) Close - [News](https://www.deguma.com/en/news.html) - [Conmpany](https://www.deguma.com/en/company/deguma-schuetz-gmbh.html) - [Machines](https://www.deguma.com/en/machines-overview.html) - [Purchase/Selling](https://www.deguma.com/en/purchasingselling/selling-of-machines.html) - [Services](https://www.deguma.com/en/services.html) - [References](https://www.deguma.com/en/references.html) - [Contact](https://www.deguma.com/en/contact/contact-details.html) - [FAQ](https://www.deguma.com/en/faq-terms/faq.html) SEARCH LANGUAGE – en [de](https://info.deguma.com/blog/5-anzeichen-dass-ihr-mischwalzwerk-modernisiert-werden-sollte) [es](https://info.deguma.com/es/blog/5-señales-de-que-su-molino-mezclador-debe-modernizarse) [fr](https://info.deguma.com/fr/blog/5-signes-qui-indiquent-que-votre-mélangeur-à-cylindres-doit-être-modernisé) CONTACT PHONE HOTLINE: [+49 (0) 36967 761-0](tel:+49%20(0)%2036967%20761-0) E-MAIL: [deguma@deguma.com](mailto:deguma@deguma.com) [Discover machines](https://www.deguma.com/en/) [![DEGUMA\_Logo-2022-RGB\_WEB-1](https://info.deguma.com/hs-fs/hubfs/DEGUMA_Logo-2022-RGB_WEB-1.png?width=235&height=40&name=DEGUMA_Logo-2022-RGB_WEB-1.png)](http://www.deguma.com) [![DEGUMA\_Logo-2022-RGB\_WEB-1](https://info.deguma.com/hs-fs/hubfs/DEGUMA_Logo-2022-RGB_WEB-1.png?width=235&height=40&name=DEGUMA_Logo-2022-RGB_WEB-1.png)](http://www.deguma.com) PHONE HOTLINE: [+49 (0) 36967 761-0](tel:+49%20(0)%2036967%20761-0) E-MAIL: [deguma@deguma.com](mailto:deguma@deguma.com) en [de](https://info.deguma.com/blog/5-anzeichen-dass-ihr-mischwalzwerk-modernisiert-werden-sollte) [es](https://info.deguma.com/es/blog/5-señales-de-que-su-molino-mezclador-debe-modernizarse) [fr](https://info.deguma.com/fr/blog/5-signes-qui-indiquent-que-votre-mélangeur-à-cylindres-doit-être-modernisé) [Discover machines](https://www.deguma.com/en/) ![Walzwerk Laptop 2016 155112\_neutral klein](https://info.deguma.com/hs-fs/hubfs/Walzwerk%20Laptop%202016%20155112_neutral%20klein.png?width=575&name=Walzwerk%20Laptop%202016%20155112_neutral%20klein.png) [Karina Meyer-Welker](https://info.deguma.com/en/blog/author/karina-meyer-welker) Jul 15, 2025, 3:00:00 PM 19 min read # 5 Signs Your Mixing Mill Should Be Modernized [Previous Post](https://info.deguma.com/en/blog/friction-mixing-mill?hsLang=en) [Next Post](https://info.deguma.com/en/blog/three-mixing-mill-types-compared?hsLang=en) # How to Recognize When Modernization Makes More Sense Than New Equipment Purchase The decision between purchasing new equipment and modernizing a mixing mill is not always straightforward. While buying new equipment may seem like the obvious solution at first glance, professional modernization can often be the more economical and sustainable alternative. In this article, we'll show you five clear signs that indicate modernization of your existing mill is the right choice. ## 1. Frequent Maintenance Work and Breakdowns **The Problem:** Your energy bills are continuously rising even though your production volumes haven't changed significantly? This is a clear sign of outdated drive technology. **The Solution:** Modern torque motors with 98 percent efficiency can reduce your energy consumption by up to 50 percent. These permanent magnet synchronous drives combine the advantages of hydraulic motors and three-phase motors without adopting their disadvantages. **Specifically, this means:** A mill that previously cost $60,000 annually in energy costs would only cost $42,000 after modernization – a savings of $18,000 per year. **Additional Benefit:** The regenerative drive power is reused, which further increases energy efficiency. ## 2. Frequent Maintenance Work and Breakdowns **The Problem:** Does your maintenance team know your mill better than their own workshop by now? When repairs and maintenance become routine, they not only consume time and money but also jeopardize your production planning. **The Solution:** Modernization can reduce maintenance requirements by up to 80 percent. Modern planetary gearboxes, for example, require only a fraction of the oil for annual changes – up to ten times less than conventional gearboxes. **The Calculation:** If you previously spent $15,000 annually on maintenance and repairs, these costs drop to approximately $3,000. The saved $12,000 annually pays for modernization within just a few years. **Additional Advantage:** The compact design and minimization of forces transmitted into the machine frame by approximately 85 percent increases mechanical stability and reduces wear from fatigue. ## 3. Safety Standards No Longer Meet Current Regulations **The Problem:** Your employees' safety comes first. If your mill no longer complies with current safety guidelines of EN 1417:2023, urgent action is required. **The Solution:** Modernization brings your mill up to the latest safety technology standards: - Brakes with brake angle monitoring for wear-free braking during emergency stops - Safety switching rods on front and rear sides - Hydraulic nip gap adjustment for quick opening of the roll gap in emergencies - Optimized arrangement: The fixed roll is located on the operator side, the movable roll faces away – eliminating pinch point areas **The Risk:** Outdated safety technology not only endangers your employees but can also lead to costly operational interruptions and legal problems. ## 4. Limited Flexibility in Formulations **The Problem:** Your market demands increasingly individualized rubber compounds, but your mill can only work with fixed friction? This limits your product variety and thus your business potential. **The Solution:** Modern individual drives with variable frequency drives enable stepless friction adjustment. This allows you to: - Process various formulations flexibly - Precisely adjust compound parameters - Implement new product developments faster - Increase production efficiency through optimized settings **The Advantage:** A modernized mill can, through its variability, handle the tasks of several conventional mills. ## 5. Noise Pollution for Employees **The Problem:** Workplace noise is not only unpleasant but can also have health consequences and impair your employees' productivity. **The Solution:** Modern mills are installed at ground level on a base frame without requiring pits or extensive foundation work. This decoupling from the building minimizes: - Noise through reduced vibration transmission - Vibrations throughout the production area - Disturbances in adjacent work areas **Additional Benefit:** Ground-level installation offers greater flexibility during renovations and significantly reduces installation and assembly costs. ### Conclusion: Modernization as a Sustainable Investment Modernizing a mixing mill is more than just a repair – it's a strategic investment in your company's future. With up to 40 years of additional service life, 50 percent energy savings, and possible payback within three years, modernization often represents the more economical alternative to new equipment purchase. **Particularly Sustainable:** By reusing existing components, you not only save costs but also CO2 emissions and valuable resources. **Check Your Savings Potential Now** Do you recognize one or more of these signs in your mill? Then modernization could be the right solution. A thorough analysis of your current situation helps make the optimal decision. ## Next steps 1. Evaluate your current energy costs and maintenance expenses 2. Review your facility's safety standards 3. Analyze your flexibility requirements 4. Consult with experts **Do you have questions about modernizing your mixing mill? We are happy to help evaluate your individual situation and develop the optimal solution together with you.** [![Share on linkedin](https://7528302.fs1.hubspotusercontent-na1.net/hub/7528302/hubfs/raw_assets/public/mV0_d-web-default-modules_hubspot/img/linkedin-color.png?width=24&name=linkedin-color.png)](https://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Finfo.deguma.com%2Fen%2Fblog%2F5-signs-your-mixing-mill-should-be-modernized%3Futm_medium%3Dsocial%26utm_source%3Dlinkedin) [![Share on email](https://7528311.fs1.hubspotusercontent-na1.net/hub/7528311/hubfs/raw_assets/public/mV0_d-web-default-modules_hubspot/img/email-color.png?width=24&name=email-color.png)](mailto:?subject=Check+out+https%3A%2F%2Finfo.deguma.com%2Fen%2Fblog%2F5-signs-your-mixing-mill-should-be-modernized%3Futm_medium%3Dsocial%26utm_source%3Demail&body=Check+out+https%3A%2F%2Finfo.deguma.com%2Fen%2Fblog%2F5-signs-your-mixing-mill-should-be-modernized%3Futm_medium%3Dsocial%26utm_source%3Demail) ![avatar](https://info.deguma.com/hs-fs/hubfs/Karina%20Meyer-Welker%202020%20schmal.jpg?width=290&name=Karina%20Meyer-Welker%202020%20schmal.jpg) #### [Karina Meyer-Welker](https://info.deguma.com/en/blog/author/karina-meyer-welker) [mailto:k.welker@deguma.com](mailto:k.welker@deguma.com) ## RELATED ARTICLES ### [Daniela Vögler Mar 12, 2026, 4:30:01 AM 8 min read Stock Blender – Automated Mixing on the Mixing Mill Stock Blender – Automated Mixing on the Mixing Mill The stock blender is a proven device for mixing mills that automates to a ... Start Reading](https://info.deguma.com/en/blog/stockblender?hsLang=en) ### [Daniela Vögler Jul 29, 2025, 3:00:00 PM 27 min read Three Mixing Mill Types Compared: Which One Fits Your Operation? DEGUMA neo basic, plus or premium - the right choice for every application Selecting the right mixing mill is crucial for the ... Start Reading](https://info.deguma.com/en/blog/three-mixing-mill-types-compared?hsLang=en) ### [Sebastian Bein Jun 9, 2025, 7:30:00 AM 5 min read When it comes to mixing mills, quality is critical. Top Quality in Mixing Mills – Or It Gets Expensive! Are you looking for high-performance, durable machinery for rubber and ... Start Reading](https://info.deguma.com/en/blog/quality?hsLang=en) [![DEGUMA\_Logo-2022-neg\_WEB](https://info.deguma.com/hs-fs/hubfs/Logo/DEGUMA_Logo-2022-neg_WEB.png?width=250&height=43&name=DEGUMA_Logo-2022-neg_WEB.png)](http://www.deguma.com) | **Office Chicago** DEGUMA-SCHÜTZ 150 North Michigan Avenue, 35th Floor Chicago, Illinois 60601 USA +1 773 493 4872 [deguma@deguma.com](mailto:deguma@deguma.com) | **Headquarter** DEGUMA-SCHÜTZ GmbH Industriestraße 4–8 36419 Geisa Germany +49 (0) 36967 761-0 [deguma@deguma.com](mailto:deguma@deguma.com) | | --- | --- |   Energy-efficient machines, full-service provider, safety consultancy and second-hand machinery for producing elastomer products. - [Contact](https://www.deguma.com/en/contact/contact-details.html) - [FAQ](https://www.deguma.com/en/faq-terms/faq.html) - [News](https://www.deguma.com/en/news.html) - [LinkedIn](https://www.linkedin.com/company/deguma-sch-tz-gmbh/) - [YouTube](https://www.youtube.com/c/DegumaSchuetzGmbH) - [Imprint](https://www.deguma.com/en/imprint.html) - [Privacy Statement](https://www.deguma.com/en/privacy-statement.html) ```json { "@context" : "http://schema.org", "@type" : "Organization", "address" : { "@type" : "PostalAddress", "addressCountry" : "Germany", "addressLocality" : "Geisa", "addressRegion" : "Thüringen", "postalCode" : "36419", "streetAddress" : "Industriestraße 4–8" }, "email" : "deguma@deguma.com", "knowsLanguage" : "en", "logo" : { "@type" : "ImageObject", "url" : "https://26034645.fs1.hubspotusercontent-eu1.net/hubfs/26034645/DEGUMA_Logo-2022-RGB_WEB-1.png" }, "name" : "DEGUMA-SCHÜTZ GmbH", "telephone" : "+49 (0) 36967 761-0", "url" : "https://info.deguma.com/en/blog/5-signs-your-mixing-mill-should-be-modernized" } ``` ```json { "@context" : "http://schema.org", "@type" : "BlogPosting", "abstract" : "How to Recognize When Modernization by DEGUMA Makes More Sense Than New Equipment Purchase", "author" : { "@type" : "Person", "name" : "Karina Meyer-Welker" }, "dateModified" : "August 24, 2026 5 PM", "datePublished" : "July 15, 2025 1 PM", "headline" : "5 Signs Your Mixing Mill Should Be Modernized", "image" : "https://26034645.fs1.hubspotusercontent-eu1.net/hubfs/26034645/Walzwerk%20Laptop%202016%20155112_neutral%20klein.png", "inLanguage" : "en", "keywords" : "[pre-owned machine, rubber]", "mainEntityOfPage" : { "@type" : "WebPage" }, "name" : "5 Signs Your Mixing Mill Should Be Modernized", "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://26034645.fs1.hubspotusercontent-eu1.net/hubfs/26034645/DEGUMA_Logo-2022-RGB_WEB-1.png" }, "name" : "DEGUMA-SCHÜTZ GmbH" }, "text" : "How to Recognize When Modernization Makes More Sense Than New Equipment Purchase The decision between purchasing new equipment and modernizing a mixing mill is not always straightforward. While buying new equipment may seem like the obvious solution at first glance, professional modernization can often be the more economical and sustainable alternative. In this article, we'll show you five clear signs that indicate modernization of your existing mill is the right choice. 1. Frequent Maintenance Work and Breakdowns The Problem: Your energy bills are continuously rising even though your production volumes haven't changed significantly? This is a clear sign of outdated drive technology. The Solution: Modern torque motors with 98 percent efficiency can reduce your energy consumption by up to 50 percent. These permanent magnet synchronous drives combine the advantages of hydraulic motors and three-phase motors without adopting their disadvantages. Specifically, this means: A mill that previously cost $60,000 annually in energy costs would only cost $42,000 after modernization – a savings of $18,000 per year. Additional Benefit: The regenerative drive power is reused, which further increases energy efficiency. 2. Frequent Maintenance Work and Breakdowns The Problem: Does your maintenance team know your mill better than their own workshop by now? When repairs and maintenance become routine, they not only consume time and money but also jeopardize your production planning. The Solution: Modernization can reduce maintenance requirements by up to 80 percent. Modern planetary gearboxes, for example, require only a fraction of the oil for annual changes – up to ten times less than conventional gearboxes. The Calculation: If you previously spent $15,000 annually on maintenance and repairs, these costs drop to approximately $3,000. The saved $12,000 annually pays for modernization within just a few years. Additional Advantage: The compact design and minimization of forces transmitted into the machine frame by approximately 85 percent increases mechanical stability and reduces wear from fatigue. 3. Safety Standards No Longer Meet Current Regulations The Problem: Your employees' safety comes first. If your mill no longer complies with current safety guidelines of EN 1417:2023, urgent action is required. The Solution: Modernization brings your mill up to the latest safety technology standards: Brakes with brake angle monitoring for wear-free braking during emergency stops Safety switching rods on front and rear sides Hydraulic nip gap adjustment for quick opening of the roll gap in emergencies Optimized arrangement: The fixed roll is located on the operator side, the movable roll faces away – eliminating pinch point areas The Risk: Outdated safety technology not only endangers your employees but can also lead to costly operational interruptions and legal problems. 4. Limited Flexibility in Formulations The Problem: Your market demands increasingly individualized rubber compounds, but your mill can only work with fixed friction? This limits your product variety and thus your business potential. The Solution: Modern individual drives with variable frequency drives enable stepless friction adjustment. This allows you to: Process various formulations flexibly Precisely adjust compound parameters Implement new product developments faster Increase production efficiency through optimized settings The Advantage: A modernized mill can, through its variability, handle the tasks of several conventional mills. 5. Noise Pollution for Employees The Problem: Workplace noise is not only unpleasant but can also have health consequences and impair your employees' productivity. The Solution: Modern mills are installed at ground level on a base frame without requiring pits or extensive foundation work. This decoupling from the building minimizes: Noise through reduced vibration transmission Vibrations throughout the production area Disturbances in adjacent work areas Additional Benefit: Ground-level installation offers greater flexibility during renovations and significantly reduces installation and assembly costs. Conclusion: Modernization as a Sustainable Investment Modernizing a mixing mill is more than just a repair – it's a strategic investment in your company's future. With up to 40 years of additional service life, 50 percent energy savings, and possible payback within three years, modernization often represents the more economical alternative to new equipment purchase. Particularly Sustainable: By reusing existing components, you not only save costs but also CO2 emissions and valuable resources. Check Your Savings Potential Now Do you recognize one or more of these signs in your mill? Then modernization could be the right solution. A thorough analysis of your current situation helps make the optimal decision. Next steps Evaluate your current energy costs and maintenance expenses Review your facility's safety standards Analyze your flexibility requirements Consult with experts Do you have questions about modernizing your mixing mill? We are happy to help evaluate your individual situation and develop the optimal solution together with you.", "url" : "https://info.deguma.com/en/blog/5-signs-your-mixing-mill-should-be-modernized", "wordCount" : "2594" } ``` ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Karina Meyer-Welker", "url" : "https://info.deguma.com/en/blog/author/karina-meyer-welker" }, "dateModified" : "2026-08-24T17:20:11.828Z", "datePublished" : "2025-07-15T13:00:00.000Z", "headline" : "5 Signs Your Mixing Mill Should Be Modernized", "image" : [ "https://info.deguma.com/hubfs/Walzwerk%20Laptop%202016%20155112_neutral%20klein.png" ], "mainEntityOfPage" : { "@id" : "https://info.deguma.com/en/blog/5-signs-your-mixing-mill-should-be-modernized", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://info.deguma.com/hubfs/DEGUMA_Logo-2022-RGB_WEB-1.png" }, "name" : "DEGUMA-SCHÜTZ GmbH" } } ```