Optimizing Anti-Tack Applications
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Covers the belting, equipment and chemistry issues related to the optimal use of anti-tack for rubber and proposes solutions.
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Optimizing Anti-Tack Applications
- 1. intralox.comintralox.com Optimized Anti-tack application Jointly presented by Intralox and the Polymer Solutions Group Tire Technology Expo, 21 February 2018 Hannover, Germany
- 2. intralox.comintralox.com Agenda • Welcome and introductions • Challenges currently facing in your plants • 3 components of a successful anti-tack application process • Intralox solutions – overview • Polymer Solutions Group – overview • Questions and Answers
- 3. intralox.comintralox.com • Paul Timmer, Application Engineer, Intralox Member of Intralox Tire Team with technical focus on tire applications, 10 years with Intralox • Ed Juline, EMEA Sales Director, Polymer Solutions Group 8 years with SASCO/PSG Introductions
- 4. intralox.comintralox.com • What current challenges are you facing in your anti-tack application process? • What upcoming initiatives or objectives are you focusing on? Let’s Hear From You
- 5. intralox.comintralox.com • Personnel training and problem solving • Mixing inconsistencies • Porosity Issues • New challenges with stickier, softer compounds • Line cleanliness • Inconsistent application • Backside coverage • Foam • Solids / concentration • Sedimentation / separation • Blisters • Stuck rubber • Downstream process issues • Impact to production • Product quality • Scrap • Unscheduled downtime • Cost incurred to reprocess rejected rubber – Line time, labor, energy, health and safety Challenges
- 6. intralox.comintralox.com Controlled and CONSISTENT process. Even application, good backside coverage, consistent quality, limited downtime, limited waste / reprocessing Chemistry Belting Equipment Optimized Anti-Tack Application Components
- 7. intralox.comintralox.com Optimized Anti-Tack Application Components • Equipment • Belting • Chemistry
- 8. intralox.comintralox.com Belt recommendation Considerations for belt choice: • Abrasive anti-tack solution (wear) • Hot rubber slab, 110-140°C (230-284°F) • Small contact surface for optimal backside coverage • Open surface required for drainage • Strong belt to handle ball-ups • Belt speeds: 10-40 m/min (32-130 ft/min) • Typical belt width: 1000-1400 mm (40-56 inch)
- 9. intralox.comintralox.com Belt recommendation Belt and sprocket recommendations: • S1700 FG NT Nylon with Nylon rods (dual rod system) • S1700 FG Nylon with Nylon rods (dual rod system) • S1700 Ultra Abrasion Resistant (Split) Sprockets - 16T, 14T or 12T • Other options available… S1700 FG NT
- 10. intralox.comintralox.com Belt recommendation Advantages S1700 FG NT: • Increased belt and sprocket life • Improved backside coverage • Decreased liquid carry-over • Better clean-ability • Reduced and easier maintenance 37% open area and nub pattern: easier flow of liquid through the belt 8% contact area between rubber slab and belt: More contact of liquid with rubber Rubber slab
- 11. intralox.comintralox.com Conveyor Design Gravity Take-up Min. Ø 6 inch / Ø 150 mm Stroke: Min. 2 %, ideally 4% of total belt lengthReturnway rollers Min. Ø 6 inch / Ø150 mm Belt edge guides (both sides) Carryway support: Stainless Steel wearstrips in chevron configuration Sufficient space for ball-ups to pass Dunk roller with position limiter Ensure sufficient back-tension (avoid sprocket disengagement) and storage capacity for belt elongation (minimal maintenance) Hugger strips designed such that it can deal with possible ball-ups
- 12. intralox.comintralox.com We suggest looking at the cost of using anti-tack in terms of total cost of use. What it costs to USE, not what it costs to BUY. 1. Rubber producers typically consume 20-50% more anti-tack than the optimal amount needed 2. Actual product purchase cost of anti-tack is a small percentage per ton of rubber (<$4 per ton of rubber) 3. The improper use of anti-tack causes extrusion, calendaring and molding problems that are often unjustly blamed on the downstream processes 4. Rubber producers modify their processes to adapt to their anti-tack instead of finding the best anti-tack for the compound and optimizing the equipment Total Cost of Use of Anti-Tack
- 13. intralox.comintralox.com • Depletion or Take-Up Rate: Amount of anti-tack solution used per ton of rubber • All anti-tacks deplete at different rates • Field Study – Competitor’s powder anti-tack and SASCO PolyCoat RLS-40 diluted to 4% solids (500 gallons) – 500 gallons of PolyCoat RLS-40 covered twice as much rubber as the competitors dip Not All Anti-Tacks Are the Same
- 14. intralox.comintralox.com Not All Anti-Tacks Are the Same Powder with Calcium Stearate Low-Shear Dispersed into Water Slurry with Calcium Stearate Prepared Under High-Shear Mixing
- 15. intralox.comintralox.com Objective • Cost per pound • Preparation – Mix time/hot water • Activity – Take-up or depletion rate • Drying • Dispersion – Down stream effects • Hazards Subjective • Coating – Back side coverage – Slip – Tack • Foam • Settling – Phase separation – Hard packing • Flaking/dusting Multiple complex evaluation criteria
- 16. intralox.comintralox.com “Hope for the best” strategy Suppliers Customers
- 17. intralox.comintralox.com PSG Automated Mixing System Layout H2O Air
- 18. intralox.comintralox.com You can do better…MUCH BETTER!
- 19. intralox.comintralox.com Controlled and CONSISTENT process. Even application, good backside coverage, consistent quality, limited downtime, limited waste / reprocessing Chemistry Belting Equipment Optimized Anti-Tack Application Components
- 20. intralox.comintralox.com Questions & Answers Intralox Booth 9020 Hall 21 Polymer Solutions Group Booth C238 Hall 19 Come and see us at our booths