Sepl mixing plant presentation

SURENDRAELASTOMERS
PVT LTD- MYSORE
MIXING PLANT

COMPANY INTRO
• We Surendra Elastomers Pvt Ltd,Mysore is a leading manufacturer of rubber
compounds, specialising in technically demanding high quality products. As one of
few wholly dedicated custom rubber compounders, we have the necessary focus to
be a true leader in our field.
• We produces Synthetic rubber compound (EPDM, NBR, CR, HNBR, ACM, CSM,
AU, ECO, EU, AEM, IR, BR) and Natural rubber compounds (NR, SBR, SN), both
black and coloured.
• We produces special compound made with Silicon and Fluoro-carbon
compounds.
• Our R & D has always been one of our top priorities. Our R&D capabilities have
always been the backbone of robust competitiveness, We continually following
research findings in material development, design of new and novel anti-seismic
component, and new methods of manufacture for optimising the properties of the
component enabling it to offer wide technical support for it’s after sale service.

COMPANY INTRO
• What can we do for you?
Let us take care of your mixing
• The most successful companies recognise mixing is the heart of rubber processing. SPC
know and understands your compounds giving you more time to focus on your
customers and develop higher value added.
Design a rubber compound to suit you
• We carry out detailed work on compound development and ingredients. We cover the
common materials, EPDM, HNBR, NBR, NR, FKM – as well as unique recipes tailored
to your needs – and work with many downstream applications to tailor-make your
compound.
Reduce your current compound cost
• We work closely with our suppliers so that we can deliver the performance you need at
the best price.
Ask us a technical question
• We are always here to help we. Our technical team are on standby to answer your
technical questions. Please get in contact and ask us.

PRODUCT SELECTION
THE CHOICE OF COMPOUND DEPENDS VERY MUCH UPON THE APPLICATION, AND THE
VARIOUS PROPERTIES AND CHARACTERISTICS THAT IT REQUIRES TO PERFORM AS
SPECIFIED. WE SPECIALISE IN PROVIDING THE CUSTOMER WITH EXACTLY THE RIGHT
RUBBER COMPOUND FOR A GIVEN APPLICATION. TO MAKE THE CHOICE EASIER, WE OFFER
A WIDE RANGE OF MATERIALS. USUALLY THE BEST SOLUTION IS A CUSTOM COMPOUND,
HOWEVER, CREATED SPECIFICALLY FOR AN APPLICATION.

SNo. LIST OF MACHINERIES MAKE
1 K2A INTERMIX INDUS UTH HF MIXING SYSTEMS-BENGALURU,INDIA
2 DUMP MILL G.G.ENTERPRISES-MUMBAIINDIA
3 STOCK BLENDER MILL YI TZUNG PRECISION MACHINERY CORP-TAIWAN
4 BALE CUTTER MUMBAI,INDIA
5 AUTO WEIGHIENG POLYMER MOMSON INTELLISYS PVT LTD-CHENNAI,INDIA
6 AUTO WEIGHIENG CHEMICAL MOMSON INTELLISYS PVT LTD-CHENNAI,INDIA
7 AUTO WEIGHIENG FILLER AND CARBON MOMSON INTELLISYS PVT LTD-CHENNAI,INDIA
8 AUTO WEIGHIENG PLASTICIZER MOMSON INTELLISYS PVT LTD-CHENNAI,INDIA
9 CHILLER REYNOLD INDIA PVT LTD-BENGALURU,INDIA
10 COOLING TOWER-1 PERFECT COOLING TOWER-BENGALURU,INDIA
11 COOLING TOWER-2 PERFECT COOLING TOWER-BENGALURU,INDIA
12 AIR RECIEVER ELGI EQUIPMENTS LIMITED-COIMBATORE,INDIA
13 AIR COMPRESSOR BENGALURU,INDIA
14 AIR DRIER ATLAS COPCO-BENGALURU,INDIA
15 DUST COLLECTOR-1 POWER TECH POLLUTION CONTROL PVT LTD-
BENGALURU,INDIA
PRODUCTION -LIST OF MACHINERIES

16 DUST COLLECTOR-2 POWER TECH POLLUTION CONTROL PVT LTD-
BENGALURU,INDIA
17 DG SUPERNOVA ENGINEERS LTD-AHAMEDABAD,INDIA
18 ROPLANT RUPALI AQUATECH-MUMBAI,INDIA
19 PVC MIXER GAJJAR ENGINEER-AHAMEDABAD,INDIA
PRODUCTION -LIST OF MACHINERIES

K2AINTERMIX
Mixing Chamber Net Volume (in Liters)-40
Batch Sizes @ 70% Fill Factor and 1.0 SG (in Kg.)-34
This Machine is popular for productivity reasons
The polymer is added first to the mixer with proper time
or temperature.
Then chemical ingredients to be mixed along with
polymer.
After a period of mixing, the filler is added followed by
any plasticisers.
Final addition would be the curatives and accelerators
All Batches Time and Temperature Depends as per
Polymer Properties.

DUMP MILL
• Roller Size is 16 D * 42 L.
• A mixing mill consists of two hollow metal
cylinders (rolls) placed horizontally and rotating
towards each other as shown In image.
• The two rolls are revolving with different speed
where front roll rotates slower than the back roll.
The difference in speed of two rolls is called as
friction ratio.
• Rubber is masticated due to shearing action
between the two rolls and friction ratio allows this
shearing action at nip to disperse different
ingredient with rubber and to hold the rubber
compound on one roll that is front roll.
• Mixing time will get vary as per compound
properties.

STOCK BLENDER MILL
ROLLER SIZE IS 16 D * 42 L.
MAIN MOTOR CAPACITY IS 50 HP.
THE STOCK BLENDERS ARE INSTALLED ON THE TWO ROLL
OPEN MIXING MILL TO ASSIST THE OPERATOR IN THE MIXING
OF RUBBER MATERIAL AND CHEMICAL POWDER. IT
FEATURES AUTOMATIC CONTINUOUS OPERATION, REDUCING
LABOUR REQUIREMENT, PROVIDING SAFE WORKING
CONDITIONS, LOWERING THE MATERIAL TEMPERATURE,
SPEEDING THE MIX RATE AND MAINTAINING QUALITY. THE
ACTION OF TRAVEL GUIDE HOLDER FOR THIS MACHINE IS
GUIDE BAR TYPE.
A STOCK BLENDER HELPS IN HOMOGENEOUS MIXING AND
REPEATABILITY OF THE MIXING OPERATIONS

BALE CUTTERMACHINE
• Rubber Bale Cutters are specially designed for economy,
durability, ease of use and versatility. These machines
are widely used for cutting rubber bales in different sizes.
The steel hardened rollers ensure smooth movement of
the bale through the machine. Semi and fully automatic
cutters are perfectly suitable for toughest natural and
synthetic rubber bales.
Inclined cutters are fed with continuous bales. The steel
alloy blades cut the bales into pre-determined size of
selected thickness. Bales are automatically discharged
with the help of rollers..

AUTO WEIGHIENG POLYMER
All Polymers are stored at respective racks.This is PLC controllable AUTO weighing of
Polymers,i.e.weighing happened as per plan of PMS software
SNo. Auto Weighing Polymer Quantity/De
scription
1 Total Number Of Polymer Racks 6 + 6
2 Storage Capacity MS Mesh
Rack
3 Weighing Capacity and Accuracy 30 kg with
5gm
Accuracy
4 Weighing Method PMS plan
weighment
with Operator
Guidance
5 Receiving Bag Bale in Bag

AUTO WEIGHIENG CHEMICAL
• All Chemicals are stored at respective Bins.This is PLC controllable AUTO weighing of
Chemicals,i.e.weighing happened as per plan of PMS software
SNo. Auto Weighing Chemical Quantity/Des
cription
1 MB/FB Chemical 30 No.s
2 Bin Capacity SS Bin-50/25
litres Two Tier
Bins
3 Weighing Capacity and Accuracy 15 kg with
1gm Accuracy
weighment
with Operator
Guidance
5 Receiving Bag 15kg/25kg/50
kg

AUTO WEIGHIENG FILLER & CARBON
• All Fillers and Carbon bags Feeding at respective silos and AUTO weighing of Fillers and
Carbons happened Automatically as per plan of PMS software.
SNo. Auto Weighing Filler/Carbon Quantity/De
scription
1 Silos –Carbon/Filler 4 No.s+ 8
No.s
2 Storage Capacity MS Silos
with 500 litre
Capacity
3 Weighing Accuracy +/- 100 gms
4 Weighing Method Auto
Charging(3
Load Cells
with 50kg
Capacity
0kg

AUTO WEIGHIENG-PLASTICIZER
• All Oils Feeding at respective silos and AUTO weighing of respective oils happened Automatically as per plan of
PMS software.
SNo. Auto Weighing Oil Quantity/De
scription
1 Total Number of Oil Bins 5 No.s
2 Storage Capacity MS Silos
with 100 litre
Capacity
3 Weighing Capacity and
Accuracy
6kgs with 1
gm accuracy.
weighment
with
Operator
Guidance

CHILLER
• REYNOLD-MAKE-R-22 useful for
maintaining Water Inlet/Outlet
Temperature of Intermix and Dump Mill.
• Evaporator: Adopt snake-and-tube type (or
shell and tube) of seamless bronze tube.
High performance of evaporate completely
the refrigerant for chilling water.
• Pump: High-flow pump in smooth operation
with minimum noise and no leakage.
• Control system: Adopt the PID control
system which can be remote controlled and
support to output the alarm message.
• Feature of thermostatic chiller: High
precision ±1°C controlled.

COOLING TOWER-1
• A cooling tower is a heat rejection device, which extracts
waste heat to the atmosphere though the cooling of a
water stream to a lower temperature. The type of heat
rejection in a cooling tower is termed "evaporative" in that
it allows a small portion of the water being cooled to
evaporate into a moving air stream to provide significant
cooling to the rest of that water stream. The heat from the
water stream transferred to the air stream raises the
air''''s temperature and its relative humidity to 100%, and
this air is discharged to the atmosphere. The cooling
potential of a wet surface is much better than a dry one.
• Circulates water throughout Plant Water Line to
Mixing Mills,Intermix and Chiller

COOLING TOWER-2
• A cooling tower is a heat rejection device, which
extracts waste heat to the atmosphere though the
cooling of a water stream to a lower temperature.
The type of heat rejection in a cooling tower is
termed "evaporative" in that it allows a small
portion of the water being cooled to evaporate into
a moving air stream to provide significant cooling
to the rest of that water stream. The heat from the
water stream transferred to the air stream raises
the air''''s temperature and its relative humidity to
100%, and this air is discharged to the
atmosphere. The cooling potential of a wet surface
is much better than a dry one.
• Circulates water throughout Plant Water Line
to Mixing Mills,Intermix and Chiller

AIR RECIEVER & COMPRESSOR
• The Single-Stage Belt Drive Reciprocating
Compressors are designed for continuous duty
application. These single-stage cylinder belt driven
reciprocating compressors are reliable workhorses
and can generate up to 20kgf/cm2 pressure
suitable for all Machineries in Plant.
• Designed for continuous duty Deep finned cast
iron cylinder Low expansion aluminium alloy
piston Forged steel crankshaft Sturdy, robust
cast iron crankcase Optimal operating speed
Aluminum cooler tubes and aerodynamically
designed fan for efficient cooling Air receiver,
conforming to ASME design Pressure relief valve
for extra safety Automatic start and stop loop
control

AIR DRIER
• Useful for Maintaining Air Flowing Line Temperature.

DUST COLLECTOR-INTERMIXAREA
• Useful for collecting dust/fume particles circulate from intermix drop door

DUST COLLECTOR-FILLER AREA
• Useful for collecting dust/fume particles circulate from all silos.

DG
• We provide Change Over switch for Non Stop
Production during Power shutdown
• Open Generator Set - - 1500 rpm/50 Hz/400 Volts
DM0627 Package Performance Genset Power rating @
0.8 pf
• Genset Power rating with fan 825 kVA 580 ekW
• Fuel Consumption 100% load with fan 75% load with fan
50% load with fan 153.7 L/hr 40.6 Gal/hr 117.5 L/hr 31.0
Gal/hr 82.5 L/hr 21.8 Gal/hr
• Emissions3 NOx mg/nm3 CO mg/nm3 HC mg/nm3 PM
mg/nm3 2932.1 mg/nm³ 171.7 mg/nm³ 102.6 mg/nm³ 45
mg/nm³

RO-PLANT
• Reverse Osmosis Plants / RO PlantsReverse
osmosis is the process of forcing a solvent from a
region of high solute concentration through a
membrane to a region of low solute concentration
by applying a pressure in excess of the osmotic
pressure. This is the reverse of the normal
osmosis process, which is the natural movement
of solvent from an area of low solute
concentration, through a membrane, to an area of
high solute concentration when no external
pressure is applied. The membrane here is
semipermeable, meaning it allows the passage of
solvent but not of solute.
• We Using this RO water for Circulation of
water inside all Plant Machineries.

SEPL-PVC MIXER
• PVC Mixers are highly quality oriented. These PVC
Mixer Machines are acknowledged for their
durability, exceptional performance, low
maintenance and rigid construction. these PVC
Mixer machines comply with the established norms
and standards of the industry.
• With an aim to manufacture high quality PVC
Mixer we are examined on certain established
parameters of quality & performance

CHEMICAL AND FUNCTIONAL TESTING LAB
1 OZONE CHAMBER EKTRON-YOUNG CHEM,USA
2 LOW TEMPERATURE BRITTLENESS TESTING
MACHINE
EKTRON-YOUNG CHEM,USA
3 ELECTRO CHEMICAL ANALYZER SWISS ENGINEERS-MUMBAI,INDIA
4 MELTING POINT APPARATUS INDIA
5 GLACIAL OVEN-1 GLACIAL-PUNE,INDIA
6 TEMPO OVEN-1 TEMPO INSTRUMENT & EQUIPMENT-PUNE,INDIA
9 METAL HARDNESS TESTER-1 ARJUN-INDIA
10 METAL HARDNESS TESTER-2 TRS-INDIA
11 COMPRESSION SET APPARATUS PRESTO TESTING INSTRUMENTS-MUMBAI,INDIA
12 DUMB BELL CUTTER PRESTO TESTING INSTRUMENTS-MUMBAI,INDIA
13 GLACIAL OVEN-2 GLACIAL-PUNE,INDIA
14 MUFFLE FURNACE TEMPO INSTRUMENT & EQUIPMENT-PUNE,INDIA
LABORATORY -List of machineries

LABORATORY -List of machineries
16 REFRICCON OVEN REFRICON HVAC SYSTEMS-PUNE,INDIA
17 METAL TESTING UTM FUEL INSTRUMENTS AND ENGINEERS PVT LTD-
YADRAV,MAHARASTRA,INDIA
18 LAB HYDRAULIC PRESS SANTHOSH MACHINERIES PVT LTD-MUMBAI,INDIA
R & D LAB
1 LAB BANBURY FARELL BRIDGE-LEEDS,BRITAIN
2 LAB MILL H.C.LINDER & SONS PVT LTD,BRITAIN
3 LAB COMPRESSOR INDIA
COMPOUND TESTING LAB
1 SALT SPRAY CHAMBER INDIA
2 SPECIFIC GRAVITY BALANCE VIBRA HT-JAPAN
3 MDR-RHEOMETER TECHPRO-USA

OZONE CHAMBER
Test Scope:This test method predicts the ozone
resistance of polymers.Test specimen to be kept inside
ozone Chamber for specified time and check for crack.

LOWTEMPERATURE BRITTLENESS TEMPERATURE
CONTROLLER
Test Scope:This test method predicts the behaviour of
polymers and elastomers at low temperatures.

ELECTROCHEMICAL ANALYZER
TEST SCOPE:Electrochemical Analyser are used for
electrochemical analysis of Copper alloys. It is mostly used for
separation of copper and lead.

MELTING POINT APPARATUS
Test Scope: Melting point of a substance is the
temperature at which the substance changes from
solid state to liquid state.The physical properties of a
compound, such as melting point and boiling point
can provide useful information which can help in the
identification of a sample or to establish its purity.

GLACIAL-1 OVEN
Test Scope:Oven aging is often used to accelerate
the aging process. It is also a way of imitating
conditions the specimen may be exposed to in the
product lifetime. Standard testing can be performed
on the aged samples and comparison can be made
to non-aged samples.What happens in the oven is
that a higher air speed increases the oxidation and
ventilates away softeners and antioxidants and this
changes the ageing conditions.
Moisture/Volatile Content test also conducted inside
oven

TEMPO OVEN-1
oven

TEMPO OVEN-2
oven

TEMPO OVEN-3
oven

METAL HARDNESS TESTER-1
Test Scope:For testing the hardness of hard alloys, quenched and
unquenched steels, using steel ball or diamond penetrators to measure
Rockwell A, B & C units of measurement. Supplied with test block, flat
large, small and V notch anvils, steel ball bearing indentor and diamond
Indentor.
Manufactured in accordance with ISO 6508-2:1999 & ASTME18.

METAL HARDNESS TESTER-2
Test Scope:For testing the hardness of hard alloys, quenched and
unquenched steels, using steel ball or diamond penetrators to measure
Rockwell A, B & C units of measurement. Supplied with test block, flat
large, small and V notch anvils, steel ball bearing indentor and diamond
Indentor.
Manufactured in accordance with ISO 6508-2:1999 & ASTME18.

COMPRESSIONSET APPARATUS
Test Scope:Compression set testing is used to
determine the ability of elastomeric materials to
maintain elastic properties after prolonged
compressive stress. The test measures the
somewhat permanent deformation of the specimen
after it has been exposed to compressive stress for
a set time period. This test is particularly useful for
applications in which elastomers would be in a
constant pressure/release state. They are applicable
particularly to the rubber used in machinery
mountings, vibration dampers, and seals.

DUMBBELLCUTTER
Test Scope:The machine useful for punching
standard specimen research units of Tensile and
Elongation testing.

GLACIAL-2 OVEN
oven

MUFFLE FURNACE
Test Scope: To assess the quality of the materials,
it is very important to understand the properties.
Temperature plays an important role in deciding the
properties of rubber. A rubber becomes stiff in cold
weather and becomes flexible in hot weather. And, if
we talk about the properties of rubber, ash is an
important factor. It is deliberately added to it during
manufacturing. A certain amount of ash is required
to make it fit for the application.On the other
hand,excessive ash may lead to volatile behaviour
of the Rubber. A manufacturer who is procuring
rubber as raw material knows what percentage does
he wants in his sample. But he cannot blindly trust
the supplier. Thus, rubber is burnt down into fumes
to check the residual ash content, that remains left
over after the heat treatment. This all is done in a
controlled environment using Muffle Furnace.

DESICCATORS
Test Scope:After Heating in Muffle Furnace it is
necessary for silica crucible to get cool for some
time.
Desiccators are sealable enclosures containing
desiccants used for preserving moisture-sensitive
items such as cobalt chloride paper for another use.
A common use for desiccators is to protect
chemicals which are hygroscopic or which react with
water from humidity.

REFRICONOVEN
oven

METAL TESTING UTM
Test Scope:Universal Testing Machine is designed
for testing metals and other materials under tension,
compression, bending, transverse and shear loads.
Hardness test on metals can also be conducted.
The available capacity is 10 ton to 100 ton.

LAB HYDRAULICPRESS
Test Scope:For Making Cured Button after
compound preparation to check basic properties like
Hardness,sp-gravity

SPECIFIC GRAVITY BALANCE
Test Scope:This test method determines the density of a vulcanized
specimen, know
as ‘Specific Gravity’. It is useful for determining the quality of rubber
compound and in calculation of mass of rubber require to produce given
volume of vulcanicate.

SALT SPRAY TESTING CHAMBER
Test Scope:Salt Spray Chamber is a consistent tool
useful for checking the corrosion resistance of
surface coatings when exposed to salt laden
environment. This instrument provides simulation of
real time weathering conditions. The salt spray test
is an accelerated corrosion test used to measure the
comparative corrosion resistance of materials
exposed to a salt spray or salt fog at specified
temperature.

MDR-RHEOMETER WITHPC
Test Scope:The MDR is designed for measuring the
viscoelastic properties of polymers
and elastomeric compounds before, during and after
cure.
The acquired data gives exact information about
advanced
material properties, processability, cure
characteristics, cure
speed, and the behavior of the compound at the
after-cure,
as well as final compound dynamic mechanical
properties.

DAK TENSILE TESTING MACHINE
Test Scope:ASTM D412 (D 412) covers the tensile
properties of thermoset rubbers and thermoplastic
elastomers. The specification describes two test
methods, A and B. Method A is common
This Machine is useful for testing of Tensile and
Elongation of Cured test specimen.

KMI TENSILE TESTING MACHINE
Test Scope:ASTM D412 (D 412) covers the tensile
properties of thermoset rubbers and thermoplastic
elastomers. The specification describes two test methods,
A and B. Method A is common
This Machine is useful for testing of Tensile and Elongation
of Cured test specimen.

FLEX-ENDURANCE TESTING MACHINE
Test Scope:The characteristics of flexibility and
flex fatigue resistance frequently represent the key
reasons that polymers are selected to comprise
certain products. Cut-growth resistance represents
an added dimension to flex fatigue and is
frequently investigated under bending strain or
high extension strain circumstances.

LAB BANBURY
Application Scope of Lab Banbury Mixer:
* Mixing and plasticizing of common rubber
materials
* Filling, mixing and dispersing of rubber
materials
* Rubber formula design
* Common thermal pretreatment of rubber
materials

LAB MILL
Application:This machine is suitable for mixing Natural
rubber, synthetic rubber, special compounds with small
quantity.
Development of Formulation trials done here.

LAB COMPRESSOR
Application:For Air Supply to Laboratory

Sepl mixing plant presentation

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