Case Study: The Original MX500 Mixer Returns for a Full Overhaul

Background

In 2010, Air Tool Services developed the MX500 Automated Packaged Sealant Mixer in collaboration with a long-standing aerospace customer. The goal was simple but critical: deliver a robust, easy-to-use solution for mixing Semkit® aircraft sealants — one that would meet the precision demands of the aerospace sector whilst standing up to daily, heavy-duty use.

The result was the RJD MX500 a fully pneumatic, plug-and-play mixer designed to deliver precise, repeatable mixing by time/stroke count — a key requirement for high-integrity aerospace applications, where hand mixing introduces unacceptable variability.

This first production model has been in continuous service since delivery, operating across multiple shifts in a demanding aerospace environment.

The Ongoing Success of the MX500

The initial success of the first unit sparked interest across other departments. Over time, more MX500 mixers were introduced into different areas of the customer’s operation, each one proving its value through:

Exceptional reliability
Minimal unscheduled maintenance
Simple operation
Long-term performance

In fact, each department has become a kind of internal ambassador for the machine — endorsing its effectiveness, affordability, and ease of maintenance

Why It Came Back to Us

Our team provides regular annual servicing onsite, the original mixer recently returned to our workshop for something more in-depth: a full overhaul and deep clean. Not because of failure — but simply due to the impressive number of years in service.

“It’s always great to get a tool looking spick and span. It gives you a real feeling of a job well done. The key to these mixers is they’re stripped back to the essential components — no overly complex, fiddly bits. Just solid engineering.”
Mick, Engineer

During the service, the mixer was fully stripped, cleaned, checked and reassembled using genuine quality parts — ensuring it’s ready for another decade of service.

Conclusion: Built to Last

The MX500 stands as a clear example of what well-engineered, application-specific tools can achieve when designed with durability and usability in mind. With minimal daily maintenance and proper annual servicing, it continues to deliver consistent, precise sealant mixing — vital in applications where performance, safety, and compliance are non-negotiable.

For aerospace manufacturers and MRO teams, the MX500 remains the standard. It’s not just about mixing sealant — it’s about doing it right, every time.