Rubber Processing and Profiting: Compounding, Mixing, Vulcanization, Extrusion, Materials, Principles, Rubber Products, Natural Rubber Processing, Rubber Reclaiming

Rubber Processing
and Profiting
Compounding, Mixing, Vulcanization,
Extrusion, Materials, Principles
Rubber Products, Natural Rubber
Processing, Rubber Reclaiming

www.entrepreneurindia.co
Introduction
The production of rubber and rubber products is a large and diverse
industry. The rubber product manufacturing industry is basically
divided into two major sectors: tyre and non-tyre. The tyre sector
produces all types of automotive and nonautomotive tyres whereas
the non-tyre sector produces high technology and sophisticated
products like conveyor belts , rubber seals etc. The wide range of
rubber products manufactured by the rubber industry comprises all
types of heavy duty earth moving tyres, auto tyres, tubes, automobile
parts, footwear, beltings etc.

Rubber is a polymer which is majorly classified as natural rubber and synthetic
rubber. Natural rubber only contains the monomers of isoprene whereas; the
synthetic rubber may contain different types of monomers. Natural rubber is
coagulated latex obtained from certain types of trees that are grown in the
tropics. Whereas, synthetic rubber is obtained by mixing butadiene and styrene
which are two by-products of petroleum refining. About 70% of rubber
consumed belongs to the category of synthetic rubbers. Manufacturers of
synthetic rubbers can adapt to different chemical formulations in order to meet
specific requirements of end-use industries. Rubber is processed using several
chemicals to manufacture useful products such as rubber mats and automobile
tires.

The rubber processing chemicals help in improving the resistance of rubber
against effects of heat, oxidation, sunlight, ozone and mechanical stress. Rubber
processing chemicals also improve the overall process of vulcanization. Rubber
processing chemicals include a wide range of products such as antidegradants,
accelerators and processing aids among others.
The global rubber processing chemicals market is expected to reach USD 6.11
billion by 2024, increasing demand for rubber products, both tire, and non-tire,
exhibiting excellent durability, and superior performance under extreme
weather conditions, is expected to augment rubber processing chemicals
demand.

There are many reasons for the growth of the rubber additives market, such
as the rising number of automobiles, footwear and consumer goods
industries. The automobiles sector is growing faster with an impressive
CAGR owing to rise in demand for two- and four-wheelers, with rising
population as the key factor for the growth of the rubber additive industry,
as automobiles mainly require the rubber for manufacturing of tires. There
are a number of applications of rubber, like it’s used in making soles of
shoes, use in tape manufacturing which is acts as a thermal insulation
material and so on. Methods for processing rubber include mastication and
various operations like mixing, calendering, extrusion, all processes being
essential to bring crude rubber into a state suitable for shaping the final
product.

The former breaks down the polymer chains, and lowers their molecular mass so that
viscosity is low enough for further processing. After this has been achieved, various
additions can be made to the material ready for cross-linking. Rubber may be masticated
on a two-roll mill or in an industrial mixer, which come in different types.
Compounding
 Rubber is always compounded with additives
 Compounding adds chemicals for vulcanization, such as sulfur
 Additives include fillers which act either to enhance the rubber's mechanical
properties (reinforcing fillers) or to extend the rubber to reduce cost (non-reinforcing
fillers)
 It is through compounding that the specific rubber is designed to satisfy a given
application in terms of properties, cost, and process ability

The rubber industry has been growing tremendously over the years.
The future of the rubber industry is tied to the global economy.
Rapidly growing automotive sector in developing economies and
increased demand for high-performance tyres are expected to
contribute to the growth of the global industrial rubber market. The
current scenario reveals that there is a tremendous scope for the
development of rubber processing industries. The global market for
industrial rubber products is projected to increase 5.8 % per year.
Investment in rubber industry is expected to offer significant
opportunities in the near future and realizing returns to investors
willing to explore this sector.

This book deals with all aspects of rubber processing; mixing,
milling, extrusion and molding, reclaiming and manufacturing
process of rubber products. The major contents of the book are
rubbers materials and processing, mixing technology of rubber,
techniques of vulcanization, rubber vulcanization, rubber
compounding, rubber reclaiming, manufacture of rubber products,
latex and foam rubber, silicone rubber, polybutadiene and
polyisoprene, styrene butadiene rubber, rubber natural etc. The book
contains addresses of plant & machinery suppliers with their
Photographs.

It will be a standard reference book for
professionals, entrepreneurs, those studying
and researching in this important area and
others interested in the field of rubber
processing technology.

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Table of Contents
1 RUBBERS:MATERIALSANDPROCESSINGTECHNOLOGY
NaturalRubberPlantation
TappingofRubberLatex
PreservationandCoagulationof Latex
Chemical Natureof NaturalRubberHydrobcarbon
HydrogenatedRubber
CyclizedRubber
ChlorinatedRubber
RubbersfromStereo-regularPolymerizationofIsoprene andButadiene
Styrene-ButadieneRubber(SBR)
PolychloropreneRubber(CR)
Nitrile Rubber(NBR)
ButylRubber(IIR)

Ethylene-Propylene-DieneTerpolymer(EPDM)
PolysulphideRubber(PSR)
PolyacrylicRubberor AcrylateRubber(ACR)
FluorocarbonRubber(FKM)
Introduction
MasticationandMixing
Open Mill
InternalMixers
ReclaimedRubber
Fillers
Antidegradants
Accelerators
Retarders
Activators
Tyres
Belting andHoses
Cellular RubberProducts
Miscellaneous ApplicationsofRubber

PassengerTyre
TubeCompoundforCartyres
ConveyorBelts
InsulationCompoundforCables
ShoeSoles
2 MIXINGTECHNOLOGYOF RUBBER
Two-rollMills
InternalBatchMixers
ContinuousMixers
Advantagesofcontinuousmixing
Disadvantagesofcontinuousmixing
Development ofthe BanburyMixer
OperatingVariables
RamPressure
RotorSpeed
BatchSize
CoolantTemperature

Unit Operationsin Mixing
Single-PassVersus Multiple-PassMixing
TypesofMix Cycle
LateOil Addition
Upside-downMixing
SandwichMixes
AnalysisofChanges totheMix Procedure
Accelerationof First-passCompound
Mill Mixing ofSpecialityCompounds
Accelerationin Line withInternalMixing
Testing ofRawMaterials
Elastomersas RawMaterials
Fillers
PlasticisersandProcessOils
SmallIngredients
Controlof Composition
TrackingtheMix Cycle

CompoundTesting
BasicSPC Charting
RheometerDataandits Meaning
Mixing ControlSoftware
Peptisersin NaturalRubber
Effectsof Temperature
Effectsof Time
Effectsof UseLevel
Effectsof OtherAdditives
Peptisersin SBR
Peptisersin Sulphur-containingPolymers
Additives toIncreaseViscosity
Preventing UnwantedChemical Reactions
Filler Treatments
Bin StorageProblems
InspectionofBanburyMixers
Inspectionatthe MezzanineLevel
Side Cooling

RotorCooling
RotorsandBearings
RotorBearing Lubrication
DustStops
DropDoorandLatch
HydraulicSystem
GreaseSystem
DustStopLubrication
DriveGears
Couplings
Inspectionofthe BanburyPlatform
RamandCylinder
Heating Weight
PistonRod
Weight PinAssembly
HopperDoor
Air Line Filter
HopperOperation

MixerMaintenanceandLubrication
Eachtime themixeris started
Onceper shift
Onceper day
Onceper week
Onceper month
Everysix months
AnticipatingRequiredService
DustStopMaintenance
SSADustStops
Assembly
Lapping
Running
BanburyMixer HydraulicDustStops
Assembly
Run-in
Lapping
Production

Flushing
EPDMExpansionJoint Cover
ExpansionJoint IntermediateLayer
TrafficCounterTreadleCover
SBR/IRBelt Cover
EPDMLowVoltageElectrical Connector
Peroxide-curedBlack-filledEPDMCompounds
EPDMConcretePipe Gasket
Injection-mouldedNBRGasket
CR/SBRBlend
LowDurometerCR/SBRBlend
Non-blackCRforInjection Moulding
HardRubberIndustrialWheel
High DurometerNBRMasterbatch
NBR/PVCCableJacket
NBR/PVC/SBRBlend
ButylMasterbatch
ButylMasterbatch,Heat Interacted

Chlorobutyl/NRBlend
CSMCORDJacket
Non-blackMillable Urethane
Some MajorChanges
Tempered Water
Power-controlledMixing
EnergyConservation
Compositionof EPDMElastomers
Variablesin EPMandEPDMElastomers
AverageMolecular Weight
Molecular Weight Distribution
Ethylene/PropyleneRatio
TypeofDiene
Diene Level
How Processing RelatestoStructureandRheology
PracticalGuidelines forMixing EPElastomers
Using InternalMixers

PolymerCompositionandForm
Filler/Oil Levels andTypes
CureSystems
Processing Aids
Mixing Process
Mixing Instructions
Fill Factor
Mixing Temperature
Machine Parameters
RamPressure
CoolantTemperature
Automation
Machine Condition
DownstreamProcessing Equipment
Using Two-rollMills
Summary
Rework

PhaseMixing
NaturalRubberViscosityReduction
Measurement ofMixing Efficiency
SpecialConsiderations
RawMaterials
TypicalFormulations
InternalMixing
Mill Mixing
Summary
AccountingMethods
Farrel ContinuousMixer
OperatingPrinciplesofthe FCM
Commercial Applicationsforthe FCM
Farrel Mixing Venting Extruder(MVX)
Designing theRotor
AnalysisofDispersive Mixing

3 TECHNIQUESOF VULCANIZATION
PressurelessVulcanization
RubberMoulding
FactorsofMouding
Mouldin
CompressionMoulding
TransferMoulding
Injection Moulding
Helicure
BuffedTreadCrumb
IncinerationandPyrolysisofTyres
ReclaimedRubber
4 RUBBERVULCANIZATION
PhysicalPropertyTests
Free SulphurDetermination
Solvent-swell Method

Mooney-RivlinEquilibriumModulus
DifferentialScanningCalorimetry
DeterminationofSpringConstant
SulphurVulcanization
PeroxideCrosslinking
ResinVulcanization
ElectronBeamVulcanization
NitrosoCompounds
Metal Oxides
5 RUBBERCOMPOUNDING
General CompoundingPrinciples
Tensile Strength
TearResistance
The CrescentTearTest
TheHardnessofRubber
Set

AbrasionResistance
Flex CrackingResistance
Resilience
Heat Build-up
TemperatureResistance
Tyres
RetreadingMaterials
ConveyorBelting,TransmissionBelting andHose
Footwear
RubberRoller
Medical Applications
rings andSeals
RubberBlends
MasterBatches
ChoiceofRubber
Fillers
VulcanizingAgents

Peptizers
Accelerators
Activators
Anti-oxidants
Retarders
SoftenersandPlasticizers
RubberCrumb
Factice
Processing Aids
SpecialPurposeAdditives
Unvulcanizedcompoundproperties
Vulcanizedcompoundproperties
6 RUBBERRECLAIMING
7 MANUFACTUREOF RUBBERPRODUCTS
Classification
Components

Partsofa ConveyorBelt
Coverrubber
ManufacturingProcess
Finished belt testing
PVC Belting
Steel CordBelting
Design ofHoses
HoseManufacture
Braided/spiralledhoses
Testing ofHose
Constructions
V-BeltManufacture
Main TypesofPowerTransmissionBelts
PreparationofIngredients
StabilityofLatexCompounds
ManufactureofLatexProducts

Foaming andGelling
Vulcanization
ClassificationandTerminology
FabricLinedWater-proofShoes
CanvasShoes
Micro-cellular Soling
Manufacturingprocedure
TypesofMountings
8 LATEXANDFOAM RUBBER
Selection ofRawMaterials
PreparationofRawMaterials
CompoundingandDesign
Maturation
Processing andshaping
DippedGoods
LatexThread
Vulcanisation

Hot Air Cure
Hot WaterVulcanisation
AutoclaveVulcanisation
RadiationVulcanisation
UltrasonicWaveCuring
Testing ofRubberProducts
PackingandMarketing
ConclusionsandRecommendations
ManufactureofLatexFoam
DunlopProcess
Mechanism ofGelling
Compounding
Foaming andGelling
ConstructionofMoulds
Curing
Washing
Drying

Finishing
CommonDefects in FoamMaking
Shrinkage
FoamCollapse
Setting
CompleteDistortionoftheFoam
Proteinestimationprotocol
Conlusion
9 SILICONERUBBER
ElectronicsandElectricalIndustries
SiliconeRubberstoMimic Flesh
SiliconePolymers
SiliconeRubberElastomers
ReinforcingFillers
Semireinforcing orExtendingFillers
Additives
Curing Agents

Mixing
Freshening
Moulding
Extrusion
Calendering
DispersionCoatingofFabric
Heavy-dutyHose
Bonding
BondingUnvulcanised Silicone Rubber
BondingVulcanised SiliconeRubber
Post-baking
CondensationCureOne-component
CondensationCureTwo-component
AdditionCure
10POLYBUTADIENEANDPOLYISOPRENE
Polyisoprene
Cyclopolyisoprene

Gel andBranching
Polybutadiene
Isoprene
Butadiene
11STYRENEBUTADIENERUBBER(SBR)
RawMaterials
ProductionofHydrocarbonRubber
ManufactureofEmulsionSBR
Vinyl ContentandBlockiness
Molecular Weight andBranching
ManufactureofSolutionSBR
PropertyControl
Branching
Blending
Properties
Tg Measurement
Molecular-weight Measurement

DynamicMechanical Measurements
Applicationsof SBR
12RECLAIMEDRUBBER
WholeTyreReclaim
DrabandColouredReclaims
ButylReclaim
Scrap-rubberPreparation
ReclaimedRubber
DigesterProcess
ReclaimatorProcess
PanProcess
EngelkeProcess
Testing andEvaluationsof ReclaimedRubber
MillroomOperations
SpecialStrengthsThroughReclaiming
FurtherAdvantagesofReclaiming- Applications

MajorUses ofReclaimedRubber
Automobilefloormat
Semi-pneumatictyre
Butylinnertube
Innerliner
Carcass
Applications
Process
CharacterisationofReclaimedWasteLatexRubber(WLR)
13NITRILEANDPOLYACRYLICRUBBER
Uses ofNitrile Rubber
Mixing andProcessing
LatestDevelopments
Composition
RawPolymerCharacteristics
PhysicalCharacteristics

Heat, Fluid, Low-temperatureResistance
Applications
CureSystems
ReinforcingAgents
Plasticiscrs
ProcessAids
Antioxidants
Mixing
Extrusion/Calendering
CompoundStorageStability
Vulcanisation
BondingCharacteristics
SolutionCharacteristics
Blends
FutureDevelopments

14RUBBERNATURAL
Agriculture
Exploitation
LatexComposition
TypesandGrades
Production
LatexConcentrate
Processing
Chemistry
PhysicalProperties
EconomicAspects
Applications
15.ADDRESSESOF PLANT& MACHINERYSUPPLIERS
16.PLANT&MACHINERYPHOTOGRAPHS

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Rubber Processing and Compounding
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