SIDC Report57

SIDC
Internship Report
Submitted to:
Project Director SIDC
Submitted by:
Adeel Arif, 2nd
year, BSc. Chemical Engineering
University of Engineering and Technology
Lahore
Supervisors: Engg. Amjad Farooq
Start Date of Internship: 2nd
August, 2015
End Date of Internship: 27th
August, 2015

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SIDC Internship Report
Preface
The report encloses the work done during summer internship program at Sports
Industries Development Center (SIDC). The brief description of all the processes
that are being carried out in SIDC are documented in the report. The report is divided
into sections for ease of study. Moreover each and every machine and apparatus used
here is explicitly explained to encourage the learners towards its study. At last the
safety remedies of each and every section are listed and possible suggestions are
given to improve the quality of work.
I tried my best to keep the report simple yet technical. Hope I succeed in my attempt.
Adeel Arif

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Acknowledgment
This report would not come to an end if I had not gained a lot of help from the whole
staff working in SIDC cheerful environment. SIDC working environment is quiet
motivate. Everyone here tries his best to accomplish the task assigned to him within
time and thus stress never comes in the way.
I would really thank to Engg. Shakeel and Engg. EhsanUllah for their guidance and
delivering some technical knowledge helpful for me in future. Not only guiding me
but listening to my ideas and encouraging me on my work. I am also indebted to my
Supervisor Engg. Amjad Farooq who seemed to have solutions to all my problems
and always enforcing me into the working environment.
Adeel Arif

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Abstract
The report presents the following tasks completed during Summer Internship
program in SIDC
 Manufacturing of football bladder from Raw Rubber batches
 Yarn winding and panel printing techniques
 Quality Control of each step carried in SIDC
All these workings were analyzed great fully and final product either it was Football
or Basketball was according to the FIFA Standards. Quality and Control department
analyzed the final product and minor errors of upto 10% were ignored and more of
it were rejected.
The corporative environment and inter linking of all sections in SIDC helps to make
a furnished and neat product. This environment in SIDC would be helpful for growth
of its reputation in the market in future.
Adeel Arif

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Layout of SIDC
Security
Office
Admin
Block
L.T Panel
Room
Boiler
Room
Compressor
Room
Die and Mold
Workshop
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HOUSE
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Table of Contents
Introduction.................................................................................................................................................9
Project Objectives...................................................................................................................................9
Technological Aspects Of The Project ..................................................................................................9
Estimated Project Cost...........................................................................................................................9
Rubber: An Introduction .........................................................................................................................10
Classification of Rubber.......................................................................................................................10
Rubber Processing ....................................................................................................................................11
Some Basic Terminologies used in Rubber Industries ..........................................................................12
A Brief Description of Chemicals used in SIDC Processing Centre.....................................................13
I. Fillers..............................................................................................................................................13
II. Activator ....................................................................................................................................13
III. Accelerators...............................................................................................................................14
IV. Rubber Sprayed Powder ..........................................................................................................14
V. Glue Paste ......................................................................................................................................14
Boiler Section.............................................................................................................................................15
Boilers used in SIDC.............................................................................................................................15
Types of Boilers.....................................................................................................................................16
Boiler Working......................................................................................................................................19
Safety Remedy for Boiler Use ..............................................................................................................20
Use of Boiler in SIDC............................................................................................................................21
Water Treatment of Boiler Feed Water..................................................................................................22
Hard Water............................................................................................................................................22
Soft Water..............................................................................................................................................22
Effects of using Untreated Hard Water..............................................................................................22
Types of water treatment .....................................................................................................................23
Water Softening Mechanism................................................................................................................23
Resin Bed Regeneration .......................................................................................................................24
Compressor Room ....................................................................................................................................25
Types of Air Compressors....................................................................................................................25
Screw Compressor ................................................................................................................................25
Main Components of Compressed Air Systems.................................................................................26

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Brief Description of Compression System Components....................................................................27
1) Silencers .....................................................................................................................................27
2) Separators..................................................................................................................................27
3) Receivers....................................................................................................................................28
4) Intercoolers and Aftercoolers ..................................................................................................28
5) Dryers.........................................................................................................................................29
Safety Remedy for Use of Air Compression System..........................................................................30
Use of Air Compression System in SIDC............................................................................................30
Bladder Section .........................................................................................................................................31
Process Description Of Bladder Manufacturing................................................................................32
Machinery used in Bladder Section & Mixing Room........................................................................33
1. Raw Rubber Cutter ..................................................................................................................33
2. Dispersion Mixer.......................................................................................................................33
3. Two Roll Mill.............................................................................................................................34
4. Four Roll Rubber Calendar.....................................................................................................36
5. Powder Spray & Cutting Machine..........................................................................................37
6. Valve Hole Punch Machine......................................................................................................37
7. Pneumatic Valve Seat stamp Machine....................................................................................37
8. Bladder Forming Machine.......................................................................................................38
9. Bladder Vulcanizing Machine..................................................................................................38
10. Pin Cutting Machine.............................................................................................................39
11. Pin Inserting Machine ..........................................................................................................39
Yarn Winding Hall ...................................................................................................................................40
Purpose of Yarn Winding ....................................................................................................................40
Yarn Winding Machine........................................................................................................................40
Carcass Bladder ....................................................................................................................................40
Panel Cutting Room..................................................................................................................................41
1) Football Sheet....................................................................................................................................41
2) Panel Printing Machine....................................................................................................................41
3) High Frequency Embossing Machine .............................................................................................41
4) Edge Turning Machine.....................................................................................................................42
5) Auto lamination Machine.................................................................................................................42

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Basket Ball Manufacturing ......................................................................................................................43
Introduction...........................................................................................................................................43
Process Flow Diagram for Basket Ball................................................................................................43
Process Description...............................................................................................................................44
Labouratory Setup....................................................................................................................................45
Introduction...........................................................................................................................................45
List of Machines and Apparatus in Laboratory ................................................................................45
Description and Working of Machines ...............................................................................................46
1. Moving Die Rheometer.............................................................................................................46
2. Plasticity Tester.........................................................................................................................49
3. Demattie Flex Cracking Machine............................................................................................49
4. Scott Volumeter.........................................................................................................................49
5. Sphericity Testing Machine......................................................................................................50
6. Compression Rebound Tester..................................................................................................50
7. Water Absorbtion Unit.............................................................................................................50
8. Air Inflator ................................................................................................................................50
9. Rotational Viscometer ..............................................................................................................51
10. Tensile Testing Machine.......................................................................................................51
11. Programmable Ball Mill.......................................................................................................52
12. Duro Meter (Hardness Testing Machine)...........................................................................52
13. Vaccum Oven ........................................................................................................................53
14. Discloration Meter ................................................................................................................53
15. Nozzle Testing Machine........................................................................................................54
16. Ball Rebounce Tester............................................................................................................54
17. Sample Cutting Press............................................................................................................54
18. Compression Testing Machine.............................................................................................54
19. Shooter Machine ...................................................................................................................54
Recommendations.....................................................................................................................................55
References..................................................................................................................................................56

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Introduction
Sports Industries Development Center (SIDC), Sialkot is a joint initiative of Ministry
of Industries & Production (MoI&P), Small Medium Enterprise Development
Authority (SMEDA) and Sialkot Chamber of Commerce & Industry (SCC&I) to
help sports good sector to adopt new technology of mechanized thermo laminated
balls by providing training, common facilities and technical advisory services along
with mold machinery services.
Project Objectives
The key objective of the Project inter-alia mentioned below is to facilitate local
industry in developing mechanized ball. Actually, mechanized ball is a new
technology in Sialkot and to provide the facilitation to develop Mechanized Thermo
Laminated Balls, this Project is deemed necessary. Pakistan has large manufacturing
units of hand-stitched balls, while technology is being shifted on mechanized thermo
laminated balls. This centre will help developing prototype balls for local industry,
get their staff trained and subsequently local manufacturers will replace their
existing set up of hand stitched ball with mechanized thermo laminated balls.
Technological Aspects Of The Project
• The project will be implemented on Transfer of Technology (ToT) basis including
Plant / Equipment & Machinery, Erection, Installation, Training, Prototype
development and manufacturing of 10,000 mechanized thermo laminated balls by
the supplier through their experts.
• The Thermo-Laminated ball will be developed / manufactured through this
machinery, where Poly Urethane, Rubber, Pigments, Fillers, Yarn and adhesive
compounds will be used as a raw material.
• The center will help produce mechanized thermo laminated balls (Soccer, Volley
and Basket Ball of International Standards). Pakistan has only captured market of
Soccer Ball so far, but SIDC will help local industry to explore the heavy markets
of Volley / Basket Balls, which is yet to be discovered.
Estimated Project Cost
The estimated cost of this project is Rs. 435.637 Million.

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Rubber: An Introduction
Rubber, an elastic substance obtained from the sap of certain tropical plants
(natural rubber) or derived from petroleum and natural gas (synthetic rubber).
Because of its elasticity, resilience, and toughness, rubber is the basic constituent
of the tires used in automotive vehicles, aircraft, and bicycles. More than half of all
rubber produced goes into automobile tires; the rest goes into mechanical parts
such as gaskets, belts, and hoses, as well as consumer products such as shoes,
clothing, furniture, and toys.
Classification of Rubber
There are two main types of rubber
 Natural Rubber
 Synthetic Rubber
Natural Rubber
Natural rubber is a solid product obtained through
coagulating the latex produced by certain plants,
particularly the Brazilian rubber-tree (Hevea
Brasiliensis). This raw material is usually tapped from
the rubber tree, which is native to Amazonia. Although
there a large number of species that exude secretions
similar to latex when the bark is cut, only a few produce
sufficient quantities of a quality adequate for
exploitation on economic bases. Although there are
something like 200 plants in the world that produce
latex, over 99 percent of the world's natural rubber is
made from the latex that comes from a tree species
called Hevea brasiliensis, widely known as the rubber tree. This latex is about one
third water and one third rubber particles held in a form known as a colloidal
suspension. Natural rubber is a polymer of isoprene (also known as 2-methylbuta-
1,3-diene) with the chemical formula (C5H8)n. To put it more simply, it's made of
many thousands of basic C5H8 units (the monomer of isoprene) loosely joined to
make long, tangled chains. These chains of molecules can be pulled apart and
untangled fairly easily, but they spring straight back together if you release them—
and that's what makes rubber elastic.

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Synthetic Rubber
Synthetic rubbers are made in chemical plants
using petrochemicals as their starting point. One
of the first (and still one of the best known) is
neoprene (the brand name for polychloroprene),
made by reacting together acetylene and
hydrochloric acid. Emulsion styrene-butadiene
rubber (E-SBR), another synthetic rubber, is
widely used for making vehicle tires. A wide
variety of synthetic rubbers have been developed
since this product was first discovered.
Rubber Processing
Compounding:
Raw rubbers have few uses in their natural state. To achieve the desired range of
properties, the raw rubber must be combined with a range of additives. These various
ingredients that are incorporated into raw polymer are called as compounding
ingredients. The selection of appropriate additives, and their skilful and consistent
mixing, is known as compounding. The additives in a rubber compound may vary
from 2-3% (in the case of a rubber band) to over 60% by weight and will include
some or all of the following:
1) Curatives: Active chemicals which bring about the cross-linking of the long
chain rubber polymer. Sulphur was the first to be discovered and is still
commonly used.
2) Accelerators: Chemicals which vary the speed and timing of the curing
reaction. Examples are TMTD, DPG, MBT and MBTS.
3) Fillers: Relatively inert chemicals, such as clays, which increase the bulk of
the compound. (Excess use of inert fillers can cheapen materials but often has
an adverse effect on performance.)
4) Reinforcing Fillers: Materials which increase the strength and reduce the
cost of the material. Carbon black and Silicas are the most commonly used
reinforcing fillers.
5) Pigments: Added to produce specified colours. They can only be used with
compounds which do not contain carbon black.
6) Plasticisers: Added to aid process ability or to produce specified properties.
7) Anti-Oxidants/Anti-Ozonants: Chemicals which are added to help the
compound resist surface attack, especially by ozone.

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Some Basic Terminologies used in Rubber Industries
Mastication, mixing, shaping, curing, vulcanizing are commonly heard terms in
rubber processing industries. Following is the detailed information of this terms
1) Mastication
It is the process of breaking down long molecular chains of rubber like polymers to
reduce the viscosity of polymer up to the level where other ingredients may be added
easily. Mastication and softening are usually carried out in batches. The operation is
done either in large enclosed mixing machines or on rubber mills. The prominent
example of an enclosed machine is the Banbury mixer.
2) Mixing
Mixing can be defined as the process of blending various compounding ingredients
of heterogeneous nature and make the combination into homogeneous nature. This
is achieved either by an internal mixer, where the compound is mixed by two
meshing rotors in an enclosed case; or by open mill mixing, adding the ingredients
carefully into the “nip” between two steel rollers. The result of either process is a
batch of uncured rubber compound.
3) Shaping
Shaping of the mixture into the desired form takes place in several ways. Extruders
are used to produce long continuous products such as tubing, tire treads, and wire
coverings. They are also used to produce various profiles that can later be cut to
length. Four roll calendars are used to make sheets of desired thickness as in case of
bladder forming.
4) Curing/Vulcanizing
Curing is carried out in pressurized steel molds, which are heated by steam or
electricity to temperatures at which the interlinking reaction takes place. Typical
cure conditions are several minutes at a temperature of 160 °C and 1 MPa pressure.
Because heat penetrates rubber slowly, thick articles must be allowed longer curing
times, up to several hours, at lower temperatures. Other methods of curing the rubber
mix after it has been shaped include steam heating in autoclaves, microwave
irradiation, and passage through a heated bath of molten metal salts or a fluidized
bed. In these cases curing is carried out at near atmospheric pressure.

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A Brief Description of Chemicals used in SIDC Processing Centre
I. Fillers
 Stearic Acid
It is also called Rubber Grade. It is a solution of 35% stearic, 50% palmitic acid, 9%
oleic acid and 7% miscellaneous saturated compounds. It is used as dispersing agent
and accelerator activator in rubber compounds. It facilitates dispersion of pigments
and fillers and improve processing. It facilitate mold flow and is commonly added
to raw rubber to prevent it from hardness. Its ratio is set to 1% i.e. 100g in 1 kg
rubber batch.
 Carbon Black
It is one of the fillers used in rubber processing
industries. It imparts special strength to rubber
compounds and avoid them from wear and
tear also it give blackish colour to rubber
compounds. It is available in various grades
according to pour size standard but N330 and
N550 are used in SIDC.
 CCR
Calcium Carbonate Refined is also one of the fillers used in rubber processing. It
imparts strength to rubber compounds and provide extra fineness to their surface.
Moreover it also helps in maintaining the weight of rubber compounds and prove to
be economical. That is why it is added in higher percentage i.e. 200%, means 2kg in
1 kg of rubber batch.
II. Activator
 Zinc Oxide
It is used as an activator which bring about the cross-linking of the long chain rubber
polymer and enhances the active site of rubber to take part in reaction effectively. It
is added 0.1% i.e. 1g in I kg rubber batch.

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III. Accelerators
 MBT
Its chemical name is 2-mercapto benzothiazole. It is one of the commonly used
accelerators used in rubber processing and act as Sulphur donors to boost up the
cross linking of long polymer rubber chains. It is added 1g in 1 kg rubber batch.
 MBTS
Chemically called 2,2-Dithiobis(benzothiazole). It helps in aiding vulcanization and
act as Sulphur donor. It is also added 1g in 1kg rubber batch. Generally added to
boost up rubber polymer chain cross linking.
IV. Rubber Sprayed Powder
 Vulkasil
It is a white amorphous powder and is chemically called reinforced precipitated
silica. It does not allow rubber sheets to stick together and imparts strength to rubber
compounds when sparkled.
V. Glue Paste
 Latex Glue
It is a milky exudate from certain plants that coagulates on exposure to air. It act as
a glue and helps in binding rubber panels and sheets together firmly. It is used as a
solution of 50% latex and 50% water.

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Boiler Section
Boilers are pressure vessels designed to heat water or produce steam, which can then
be used to provide space heating or service water heating to a building. In most
commercial building heating applications, the heating source in the boiler is a natural
gas fired burner. Oil fired burners and electric resistance heaters can be used as well.
Steam is preferred over hot water in some applications, including absorption cooling,
kitchens, laundries, sterilizers, and steam driven equipment.
Boilers used in SIDC
Two types of boilers were used in SIDC to meet their requirements of steam used in
rubber making and vulcanizing
 Package type reverse flow fire tube Boiler
 Vertical water tube Boiler
The capacity ranges and their valuable data is lists below
Package type Reverse Flow Fire Tube
Boiler
Vertical Water Tube Boiler
Revomax Fired Boiler Vpomax Packed Steam Machine
Capacity 2000 kg/hr Capacity 600 kg/hr
Thermal Rating 1700 KW Thermal Rating 403 KW
Heated Surface 42 sq. meters Heated Surface 7.44 sq. meters
Empty Weight 7 ton Empty Weight 0.6 ton
Flooded Weight 9.39 ton Flooded Weight 0.65 ton
Design Parameters 12 bar pressure 192°C Design Parameters 12 bar pressure 192°C
Max. Operation 10 bar pressure 184°C Max. Operation 10 bar pressure 184°C
Hydraulic Test 18 bar pressure 30-40°C Hydraulic Test 18 bar pressure 30-40°C
Safety valve Operation 11.5 pressure 190°C Safety valve Operation 11.5 pressure 190°C

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Types of Boilers
The main types of boiler commercially used and also in this sector are
 Fire Tube Boiler
A fire tube boiler is a cylindrical chamber
with flame in the furnace and combustion
gases inside the tubes. Fire tube boilers are
used for applications ranging from 15-1500
horsepower. The furnace and tubes are in a
large vessel which contain water and steam.
Fire tube boilers are generally built in same
sense of shell and tube heat exchangers. A
large quantity of tubes result in more heating
surface per boiler horsepower, which generally improves the heat transfer and
efficiency.
Steam pressure in fire tube boiler is generally in range of 350 psig. Fire tube boilers
are generally rated in Boiler Horsepower.
The furnace and bank of tubes is generally used to transfer heat to water in
cylindrical vessel. Combustion occurs within the furnace and flue gases are routed
out via tubes providing heat to water and then to the outlet stack.
 Water Tube Boiler
When the steam pressure exceed 350 psig fire tube boilers
may cause alarming situations thus water tube boilers are
used in replacement. This is because they have strengthened
structure and compactness. In water tube Boilers the water
flows through the tubes and combustion occur in shell.
Industrial water tube boilers are noted for their fast steaming
capability this is because of the low water content. This
allows them to respond quickly to changing load demands.
They are also capable of generating saturated and
supersaturated steam due to high pressure steam handling capability.

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Components of Boiler
The basic components of boiler are listed below
I. Feed Water Heaters:
Feedwater heaters are energy recovery devices generally found only in large steam
generating plants where all of the steam generated is not reduced to condensate by
the steam user. This "waste steam" is reduced to condensate for return to the boiler
in the feedwater heater. The boiler feedwater is used as a cooling medium to reduce
the steam to condensate, which increases the temperature of the feedwater and,
thereby, increases the thermal efficiency of the boiler.
II. Fuel Heater:
Many boilers firing heavy fuel oil require fuel heaters to reduce the fuel viscosity,
so the fuel can be atomized by the burner system for complete combustion.
III. Deaerators:
A deaerator is a special case of feed water heater that is designed to promote the
removal of non-condensable gases from the boiler feed water. The principal gases
of concern are oxygen, carbon dioxide, and ammonia, which are major contributors

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to boilers, and steam and condensate piping corrosion problems. In small steam
plants, a portion of the steam generated by the boiler is used to operate the deaerator
if "waste steam" is not available. Failure to maintain and properly operate the
deaerator can lead to early failure of the boiler, steam using equipment, and the steam
and condensate piping.
IV. Pumps:
In most hot water systems, the system circulating pumps are electric motor-driven,
end suction centrifugal pumps. In steam systems, the condensate return pumps are
typically electric motor-driven, end suction, centrifugal or turbine-type pumps. Feed
water pumps are generally electric motor-driven, multiple-stage, end suction
centrifugal pumps. The shutoff head of the pump must be greater than the steam or
hot water system operating pressure.
V. Combustion Air Blowers:
In many packaged boiler installations, the combustion air fan is designed and
provided by the boiler manufacturer and is integral with the boiler housing. In
installations where a stand-alone fan is provided, low-pressure centrifugal blowers
are commonly used. An important characteristic of the blower is the ability to
maintain a relatively constant air pressure over a wide range of airflows.
VI. Flue:
Flues (boiler firebox exhaust duct or boiler discharge stack) must be large enough to
conduct the products of combustion away from the boiler with a minimum of duct
friction loss. Flues may be fabricated from any material suitable for the operating
temperature and pressure. Common materials of construction associated with
packaged boiler installations are carbon steel and stainless steel.
VII. Boiler Economizer
Flue gas economizers offer the best opportunity
for heat recovery. These are essentially heat
exchangers in the boiler exhaust which transfer
heat from the flue gas to either the boiler feed
water or combustion air. Even with efficient
boilers that operate with a relatively low flue gas
temperature, there is ample room to recover
some of the flue gas heat that would otherwise
go up the stack. Economizers typically increase
overall boiler efficiency by three to four percent.

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Condensing economizers use the same principle, but further reduce the flue-gas
temperature, which improves the boiler system efficiency further.
VIII. Steam Traps:
Steam traps are installed throughout steam systems to remove condensate (spent
steam), air, and non-condensable gases from the steam system. There are five types
of steam traps in general use now a days.
IX. Boiler Blowdown:
Blowdown of steam boilers is very often a highly neglected or abused aspect of
routine boiler room maintenance. The purpose of boiler blowdown is to control
solids in the boiler water. Blowdown protects boiler surfaces from severe scaling or
corrosion problems that can result otherwise.
There are two types of boiler blowdowns: ''continuous'' and ''manual''.
a) Continuous blowdown uses a calibrated valve and a blowdown tap near the
boiler water surface. As the name implies, it continuously takes water from
the top of the boiler at a predetermined rate. A continuous blowdown is an
optional feature and may not be included on your steam boiler; however, all
steam boilers should include a means for manual blowdown as standard
equipment.
b) Manual blowdowns are accomplished through tapings at the bottom of the
boiler. These openings allow for the removal of solids that settle at the bottom
of the boiler. Manual blowdown is also used to keep water level control
devices and cutoffs clean of any solids that would interfere with their
operation. All steam boilers require manual blowdown whether or not they
are supplied with continuous blowdowns.
Boiler Working
Both gas and oil fired boilers use controlled combustion of the fuel to heat water.
The burner mixes the fuel and oxygen together and, with the assistance of an ignition
device, provides a platform for combustion. This combustion takes place in the
combustion chamber, and the heat that it generates is transferred to the water through
the heat exchanger. Controls regulate the ignition, burner firing rate, fuel supply, air
supply, exhaust draft, water temperature, steam pressure, and boiler pressure. Hot
water produced by a boiler is pumped through pipes and delivered to equipment
throughout the building, which can include hot water coils in air handling units,
service hot water heating equipment, and terminal units. Steam boilers produce

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steam that flows through pipes from areas of high pressure to areas of low pressure,
unaided by an external energy source such as a pump. Steam utilized for heating can
be directly utilized by steam using equipment or can provide heat through a heat
exchanger that supplies hot water to the equipment.
Safety Remedy for Boiler Use
Boiler is one of the critical equipment of process industries so its maintenance and
safety must be the first priority to avoid any technical and human loss.
 Monitor the Boiler Gauges
It is possible that a leak will develop in the hot water distribution loop. Such leaks
will increase the system’s energy and water consumption, and may also result in
water damage. Hot water and steam distribution systems should be provided with
make-up water to replace any steam or water that is lost through a leak in the system.
This will provide an easy way to ensure the system is fully charged with water at all
times. It is best practice to install a meter on the make-up line to the system. The
meter should be read weekly to check for unexpected losses of water from the
system. In steam systems, it is a best practice to monitor make-up water volume
daily. As steam leaks from the system, additional make-up water is required to
replace the loss. Monitoring the make-up water will ensure that you are maximizing
the return of condensate, thereby reducing the need for make-up water.
 Seasonal Operation
If a steam or hot water system is not used for a portion of the year, shutting the
system down can result in significant savings. Maintaining a boiler at its operating
temperature consumes energy equivalent to its standby losses. In the case of a hot
water system, energy use may also include pump operation.
 Keep the Boiler clean
Any residue, such as soot or scale that coats the heat transfer surfaces of the boiler
will reduce its efficiency and also increase the likelihood of equipment failure.
Cleaning this surface according to manufacturer’s recommendations is important to
maintaining optimum boiler performance and equipment life. Residue that coats the
tubes of a boiler will interfere with heat transfer and elevate the flue gas temperature.
If incomplete combustion occurs, the resulting soot accumulates on the combustion
side of the tubes. Similarly, poor water treatment practices can result in scale
accumulation on the water side of the tubes. A layer of soot or scale only 0.03 inches
thick can reduce heat transfer by 9.5%. A layer 0.18 inches thick can reduce heat
transfer by 69%.

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 Minimize boiler Blowdown
Having too many total dissolved solids (TDS’s) in the boiler water can cause scale
and reduce boiler efficiency. Therefore, it is necessary to maintain the solids below
certain limits. As TDS concentration increases, it becomes more likely that the
dissolved solids will precipitate out of the water and form scale. Draining of the
water, called boiler blowdown, is required to remove some of those dissolved solids
and keep the TDS concentration below the level where they will precipitate.
Consistent and frequent small volume blowdowns is a better practice than infrequent
high volume blowdowns, because it conserves energy, water, and chemicals.
 Inspect and Repair Insulation
Insulation is critical for steam and condensate piping. Un-insulated pipes, valves, or
fittings carry a heavy energy penalty Steam, condensate, and hot water pipes in air
conditioned spaces produce a double penalty if un-insulated because the heat loss
from the pipes must be removed by additional air conditioning.
Use of Boiler in SIDC
Steam produced by boilers used in SIDC is saturated steam which is used in various
steps of rubber to football making process.
 Steam is used to heat up the rolls of two roll mixer, 4 roll calendar and kneader
mixer to soften the batch of rubber so that it can easily be processed. The set
temperature of rolls in two roll mixer is 4.-50°C whereas in four roll calendar
and kneader mixer is between 80-90°C.
 In rubber curing section steam is used to heat the curing machine to 160°C to
make neat joints of rubber pieces together.
 In die cut bladder machine the steam generated is used to heat up the die that
will afterwards make the mold of rubber. Temperature set to this machine is
60-70°C.
 In auto laminated machine where two halves of football are joint together with
bladder inside and football attains its complete shape, steam is used to heat up
the die to 160°C so that strong joints may be formed between two halves.

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Water Treatment of Boiler Feed Water
Water is an excellent solvent in which many compounds readily dissolve. It is also
an excellent medium for transporting suspended and colloidal material. However,
the presence of these impurities and contaminants makes appropriate water treatment
and conditioning regimes essential to provide water of a suitable quality for the
effective operation of steam boiler plant and systems.
The water used in steam boilers can be supplied from many different sources and
will contain various contaminants and impurities. If water is used directly in steam
boilers without treatment, then these contaminants and impurities can cause fouling
of heat-transfer surfaces and corrosion, leading ultimately to plant failure.
Hard Water
Hard water is water that contains more dissolved minerals than ordinary water. Hard
water contains mainly calcium and magnesium salts and these result in scale
formation.
Soft Water
Soft water is preferable for use in boiler plant because it has fewer dissolved solids,
so it needs less treatment.
Effects of using Untreated Hard Water
Foaming, due to high levels of total dissolved solids (TDS) and alkalinity in the
boiler water, can also cause operational problems, such as salt deposits and pipework
corrosion.
Poor water treatment and boiler-water conditioning can:
• Reduce the steam-generating efficiency of boiler plant through fouling of
water-side, heat-transfer surfaces and increased blowdown.
• Increase the cost of routine boiler cleaning operations (chemical and
mechanical) and the need to repair/replace corroded parts.
• Result in carry over and reduced heat delivered to components using the
steam system.
• Result in catastrophic plant failure if sustained over a significant period

Page | 23
Types of water treatment
Water treatment is generally divided into two forms:
• External treatment – applied before the water enters the boiler to remove or
modify problem mineral salts. SP 502 (a neutralizer) was used in SIDC boiler feed
water tank which donot allow scale to build up, moreover tri sodium phosphate and
tactic acid were used which remove scaling and donot allow scale to stick to the
tubes respectively.
• Internal treatment (sometimes referred to as boiler water conditioning) –
chemicals are added directly to the feed or boiler water to prevent scale formation
and corrosion.
Water Softening Mechanism
A water softener is a mechanical appliance that includes a resin tank filed with a
softening bed of resin beads and a brine tank that holds a salt solution. Water
softeners are available in side-by-side and cabinet styles.
Working
In a process known as an ion (or cation)
exchange, the positively charged calcium
and magnesium ions in the hard water
pass through the resin bed and exchange
places with positively charged sodium
ions that are attached to the active sites
on the beads. The result is that the water
is now softened.
As the resins attract more and more
calcium and magnesium minerals, the
active sites decrease and their ability to
soften the water is lessened. At this point,
the softener needs to be regenerated. This
means that the calcium and magnesium
minerals need to be flashed from the resin
tank and the beads active sites need to be
replenished with new sodium or
potassium ions from the brine tank.

Page | 24
Resin Bed Regeneration
The resin bed regeneration process takes place in 3 catagorized steps called 3- phase
regenerating cycle.
 Back wash
First step to regenerate resine bed is water is allowed to enter dip tube from inlet and
moved from resine bed to expand the bed, it is called startification.
 Brining
Water enter free board from inlet and after passing resine move up to dip tube also
brine moves from brine tank thus a siphone is created on free tube. It takes 49-84
min to brining.
 Rinse
The resine bed is still expanded, we need it to compress down. Water enters from
inlet and pass through resine bed and allow it to compress simultaneously. Water is
also allowed to enter brine tank to regenerate it.

Page | 25
Compressor Room
Compressed air is a form of power that has many important uses in industrial
activities. Air compressor plants are used to provide an adequate quantity of
compressed air at sufficient pressure to various points of application. Industrial
plants use compressed air throughout their production operations, which is produced
by compressed air units ranging from 5 horsepower (hp) to over 50,000 hp.
Types of Air Compressors
There are various types of air compressors as tabulaed in the figure below.
Screw Compressor
A screw compressor consists of male and
female rotors mounted on bearings to fix their
position in a rotor housing which holds the
rotors in closely toleranced intersecting
cylindrical bores. The rotors basic shape is a
screw thread, with varying numbers of lobes on
the male and female rotors. The driving device
is generally connected to the male rotor with the
male driving the female through an oil film. In
refrigeration, four or five lobed male rotors generally drive six or seven lobe female
rotors to give a female rotor speed that is somewhat less than the male speed. Some
designs connect the drive to the female rotor in order to produce higher rotor speeds
thus increasing displacement. However, this increases loading on the rotors in the
area of torque transfer and can reduce rotor life.

Page | 26
Main Components of Compressed Air Systems
Compressed air systems consist of following major components: Intake air filters,
inter-stage coolers, after-coolers, air-dryers, moisture drain traps, receivers, piping
network, filters, regulators and lubricators.
1) Intake Air Filters : Prevent dust from entering a compressor; Dust causes
sticking valves, scoured cylinders, excessive wear etc.
2) Inter-stage Coolers : Reduce the temperature of the air before it enters the
next stage to reduce the work of compression and increase efficiency. They
are normally water-cooled.
3) After-Coolers: The objective is to remove the moisture in the air by reducing
the temperature in a water-cooled heat exchanger.
4) Air-dryers : The remaining traces of moisture after after-cooler are removed
using air dryers, as air for instrument and pneumatic equipment has to be
relatively free of any moisture. The moisture is removed by using adsorbents
like silica gel /activated carbon, or refrigerant dryers, or heat of compression
dryers.
5) Moisture Drain Traps: Moisture drain traps are used for removal of moisture
in the compressed air. These traps resemble steam traps. Various types of traps
used are manual drain cocks, timer based / automatic drain valves etc.
6) Receivers : Air receivers are provided as storage and smoothening pulsating
air output reducing pressure variations from the compressor.

Page | 27
Brief Description of Compression System Components
1) Silencers
Compressor system silencers are sound-
absorbing accessories attached to the system
at the intake and output of the compressor.
The silencers absorb noise produced by the
compressor in order to reduce the noise output
to an acceptable level. In general, air noise
silencers are cylindrical housings containing
acoustically tuned baffles and sound-
absorbing material.
2) Separators
Separators are used on compressor installations to remove entrained water and oil
from the compressed air.
There are two types of separators
 Centrifugal Separator
 Baffle Separator
In centrifugal separators, Centrifugal action forces the moisture particles against
the wall of the separator where they drain to the bottom. In the baffle type separator
the air is subjected to a series of sudden changes in direction. The heavier moisture
particles strike the baffles and walls of the separator and drain to the bottom of the
unit.

Page | 28
3) Receivers
Air receivers serve as reservoirs for the storage of compressed air so that air is
available to meet peak demands in excess of the compressor capacity. They also
function as pulsation dampers on reciprocating compressor installations. Air
receivers are usually vertically mounted, but may be horizontal in the smaller sizes.
Receivers are furnished with a relief valve, pressure gauge, drain valve, and
inspection openings.
4) Intercoolers and Aftercoolers
Intercoolers and aftercoolers are heat exchangers employed to dissipate the heat
generated in compression. There are two types of heat exchangers used on air
compressors
 air-cooled
 water-cooled
The inter cooler is located between the discharge of one cylinder and the intake of
the next cylinder of multistage compressors. The intercooler reduces the temperature
and the volume of the compressed air for delivery to the next compression stage.
The after cooler is located at the discharge of the last cylinder to cool the air,
reduce its volume, and to liquefy any condensable vapors.

Page | 29
Air-cooled heat exchangers are most often used on small compressors. The air-
cooled heat exchanger is a finned, tubular radiator. The most common design of
Water-cooled heat exchangers, shell and tube type, consists of a single bundle of
tubes enclosed inside a cylindrical shell The air to be cooled passes through the tubes
while the water passes over the tubes. Baffles are often provided in the tube bundle
to direct the waterflow across the heat exchanger tubes in the most efficient manner.
5) Dryers
Compressed air dryers remove moisture that might otherwise condense in airlines,
air tools, and pneumatic instruments. This condensate can cause damage to
equipment from corrosion, freezing, and water hammer, and can cause
malfunctioning of instruments and controls.
Dryer is a pressure vessel in which a bed of
crystalline solids is placed on top of a
screen which is located close to the bottom
of the vessel. Wet air from the after cooler
and separator enters the bottom of the
vessel and flows upward through the bed.
As it passes through the bed, the liquid
water and vapor present in the air, dissolve
the drying medium in what is termed a
deliquescent effect. The resulting solution
trickles to the bottom of the dryer where it
is removed by a trap. The frequency with
which the crystalline absorbent material
must be replaced is a function of the design thickness of the bed and the amount of
water and vapor present in the air entering the dryer.

Page | 30
Safety Remedy for Use of Air Compression System
Good and proper maintenance practices will dramatically improve the performance
efficiency of a compressor system. Following are a few tips for efficient operation
and maintenance of industrial compressed air systems:
1. Lubrication: Compressor oil pressure should be visually checked daily, and
the oil filter changed monthly.
2. Air Filters: The inlet air filter can easily become clogged, particularly in
dusty environments. Filters should be checked and replaced regularly.
3. Condensate Traps: Many systems have condensate traps togather and (for
those traps fitted with a float operated valve) flush condensate from the
system. Manual traps should be periodically opened and re-closed to drain any
accumulated fluid; automatic traps should be checked to verify they are not
leaking compressed air.
4. Air Dryers: Drying air is energy-intensive. For dryers, inspect and replace
pre filters regularly as these dryers often have small internal passages that can
become plugged with contaminants. Dryers require an effective oil-removal
filter on their inlets, as they will not function well if lubricating oil from the
compressor coats the desiccant. The temperature of deliquescent dryers
should be kept below 100°F to avoid increased consumption of the desiccant
material, which should be replenished every 3-4 months depending on the rate
of depletion.
Use of Air Compression System in SIDC
The use of compressed air in SIDC can be analyzed by following facts
 The bladder and football are inflated using compressed air.
 Much of the machinery is pneumatic i.e. panel cutting machine, hole punching
machine, tikra press etc.
 Almost all machines have pistons and plungers i.e. curing machine,
vulcanizing machine, kneader mixer etc. that are either pneumatic or
hydraulic.

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Bladder Section
The bladder section of SIDC comprises of various pneumatic, hydraulic, electro
pneumatic, steam and electric heater machines which take part somewhere in
rubber to bladder production process and are listed below
 Raw Rubber Cutter
 Kneader Machine/Dispersion Mixer
 Two Roll Mill
 Four Roller Calendar
 Powder Spray & Rubber Slice Cutting Machine
 Valve Hole Punching Machine
 Pneumatic Valve Seat Stamp Machine
 Hydraulic Bladder Forming Machine
 Bladder Vulcanizing Machine
 Pin Cutting Machine
 Pin Inserting Machine
Process Flow Diagram of Bladder Section

Page | 32
Process Description of Bladder Manufacturing
The Raw rubber is available in the packing of bales so it is necessary to cut the bales;
this is done by using Raw Rubber cutter. After the cutting of rubber into pieces the
Rubber & the other chemicals are weighed as per the formulation.
Working in Mixing Room
The dispersion mixer is used for mixing after achieving the required temperature by
using steam the weighed chemicals are fed to the dispersion mixer the amount of
feeding material begin from half load to full load. According to the material and craft
requirement of consumer the mixing time is adjusted.
If the temperature increased beyond the set value an alarm starts indicating & needs
the circulation of cooling water. After completing the mixing the mixing chamber
tilt at an angle of 140° & the master batch is discharged from the chamber.
The master batch from the dispersion mixer is fed to the two roll mill for further
mixing of accelerators etc. The two roll mill is also used for plastication prior to
mixing in the dispersion mixer.
Working in Bladder Section
The final batch prepared at two roll mill is fed to the four roller calendar for sheeting
purpose. The gap of the rollers is adjusted as per the thickness of sheet required.
The sheet is rolled to the powder spray & cutting machine it’s a triple action machine
i.e. Cooling, powder spray & Cutting, the speed of this machine is synchronized with
the calendar speed.
The sheet is cooled via cooling water through cooling roller. The powder is sprayed
through the powder box & spare powder is cleaned through powder brush. Finally
the desired length of sheet is cut through heated knife cutter.
The sheet is transported to the next stage of hole punching. The hole punch machine
is used to produce the hole in bladder rubber sheet.
After the hole punching the sheet transported to valve seat stamp machine, this
machine is used to stamp-paste a valve onto the bladder sheet. The valve inserted
sheet is cut into bladder on bladder forming machine as per the required size.
The vulcanization of bladder is done on bladder vulcanization machine. This
machine adopts steam heating and water cooling. After vulcanization the pin is
inserted in the bladder through which the football is inflated.

Page | 33
Machinery used in Bladder Section & Mixing Room
1. Raw Rubber Cutter
The machine is used to cut the blocky materials (such as
natural rubber, synthetic rubber and reclaimed rubber). The
temperature of the natural rubber must be more than 35 C°.
The main engine of the machine is frame welded structure.
The cylinder is fixed on the upper part of the top crossbeam
in the frame by a connection board. The cylinder is made of
welded seamless steel pipe. In order to reduce the intensity
of labor, an apparatus for pushing rubber is installed in this
machine.
The hydraulic system is designed separately so as to easier
operation and maintenance for the hydraulic system.
The movement of the cutter is from upper to down. During
the movement, it will stop at any position as you like if you
push the button.
Technical Specification:
 Model XQ-8
 Cutting Width 660 mm
 Rated cut-off force 80 KN
 Rated operating pressure of the cylinder 4.5 MPa
 The distance of the cutter 680 mm
 The round trip time of the cutter 20-30s
2. Dispersion Mixer
The machine is mainly used for plasticating and mixing of rubber and plastics. This
machine is widely used in rubber and its products industry. The machine furnished
with mixing chamber mechanism, tilting mechanism, pressure lid device, main
transmission system, cooling (heating) system, air pressure control system and
electrical control system, etc.

Page | 34
The mixing chamber is mainly working part of the machine, Material of formulation
calculate is fed to closeness mixing chamber from feeding mouth behind the
machine, in the case of pressure and limited temperature, through these actives of
mix blend, mixing , squeeze, slice, etc. Motive of rotor comes from main driving
system, The top ram moves up or down rectangular slide way which it is fixed upper
the mixing chamber through the piston rod stretch and contract, it is controlled by
pneumatic system. The inner of mixing chamber, rotor and top ram are hollow
structure. The cooling & heating water could pass through them, so rubber material
will be mixed and plasticed under the fit temperature through cooling & heating
water controlled, so quality of products should be assured. Mixing chamber can tilt
140° under the tilting motor driving; it is convenient to automatic discharge and
recharge color.
 Total capacity of mixing chamber 125L
 Effective capacity of mixing 55 L
 Rotor speed(Front/Rear) 30/24.5r/min
 Main motor rate power 75KW
 Tilting motor rate power 2.2 KW
 Mixing chamber tilting angle 140°
 Pressure of compressed air 0.6-0.8MPa
 Pressure of cooling water 0.2-0.4MPa
 Pressure of steam 0.5-0.8 MPa
 Overall dimensions ( L×W×H) 3280×1930×3070mm
 Weight 7800 Kg
3. Two Roll Mill
The machine is to be used for Raw rubber plasticating and mixing, warm-up or
sheeting of rubber. It is general equipment in rubber industry.
This is a double roll rubber-mixing machine. It consists of motor, reducer, speed-
ratio gears, front and rear rolls, bearings, frame, cover, bed plate, roller gap adjusting
device, emergency stop device, roll temperature adjust device, lubricating device
and material tray, etc.
Front and rear rolls are parallel mounted into the bearing of the machine frame. By
driven of the motor, via the reducer, speed ratio gears, the front and rear rolls rotate
toward each other so that rubber-mixing is start. The rolls are made from chilled cast
alloy iron, the structure of the roll is hollowed, can go through steam and cooling
water, to adjust the roller surface temperature. Its surface possesses the higher
hardness and fineness. Roll spacing adjusting is carried out by means of the reverse
of hand wheel makes the thread rod drive front bearing base movement. The roll pin

Page | 35
reduces when the hand wheel rotates clockwise, otherwise it will increase. The
emergency stopping device is mounted in the upper part of cover. In abnormal
situation, pulling the rod, via dynamic, the machine is stopped immediately. The roll
surface adjust device is, a two spray pipes with numeral rows of holes, and extend
(the two pipes) into the hollowed roll (inside), the holes are in the position of
working section of the roll. The position of holes slants to 45 degree inner direction
so that the spraying water or steam is directed at the contacting angle of sizing
material; this can control the surface temperature of roll in good condition.
In order to lubricate the roll bearing perfectly, we use mechanical oil or grease to
lubricate the bearing. The oil is supported by gear pump and pipeline, grease is fed
by grease pump. The gear oil is filled into the covers of driving gear and speed-ratio
gear, the height of oil should less than (or equal) the half of the height (of the small
gear).
Material tray is put under two rolls, it is used for feeding and receiving the drop
material.
 Roll diameter 450 mm
 Roll working length 1200 mm
 Max. roll spacing 12 mm
 Rolls speed-ratio 1:1.2727
 Linear speed of front roll 21.8 m/min
 Linear speed of rear roll 27.7 m/min
 One-batch rubber capacity 50 Kg
Main motor:
 Model Y280M-6
 Power 55 KW
 Speed 980 r/min
 Voltage 380 V/50HZ
 Service temperature 800C
 2.11 Method of lubrication Oil pump or grease

Page | 36
 2.12 Overall dimension(L×W×H) 5405×1740×1790mm
 2.13 Weight 11400 Kg
4. Four Roll Rubber Calendar
This machine is used mainly in rubber calendaring,
rubber coating of fabric, rubber friction and wire
cord fabric rubber coating.
It consists of frame, bearings, electrical nip
adjustment device, connecting gears, lubrication
device, roll temperature adjustment device,
reducer, motor, bedplate, coupling etc.
The lubrication oil goes through each part via gear
pump. There are stop valves for adjusting the oil
range. Also the pressure dial is on the pipes, the
pressure is no more than 0.1-0.2MP. All of the
lubrication oil goes back the oil box via back pipes.
Roll temperature adjustment device: Open the stop
valve, the steam or cold water go through rotating joint, heating or cooling the roll,
the steam or water go out via outlets.
 Roll diameter 230 mm
 Roll working length 630 mm
 Middle roll linear speed 1-11 m/min
 Roll speed ratio 1:1:1:1
 Max. Nip 0-10 mm
 Min. product thickness 0.2 mm
 Max. product width 500 mm
Main Motor:
 Code YVP180L-6
 Voltage 380V
 Power 15 KW
 Speed 980 r/min
 Lubrication motor power 0.25kW
 Working oil pressure 0.1-0.2MPa
 Dimension 3800×1400×1900 mm
 Weight 5000 kg

Page | 37
5. Powder Spray & Cutting Machine
The final sheet from the calendar is transported to the powder spray & cutting unit.
This machine has three functions i.e. cooling, powder spray & cutting. The rubber
sheet is cooled down via cooling water and after that powder is sprayed on the sheet
by passing the sheet through a powder box, the extra powder is wiped through the
brushes. At the end, the sheet is cut as per the required length through the blade, the
blade has auxiliary heating for easy & convenient operation.
 Motor Power 1.65 KW
 Heating Power 700 W
 Dimension 3650x1200x1300 mm
6. Valve Hole Punch Machine
The machine is used to produce hole in bladder rubber sheet (Natural Rubber,
Synthetic Rubber & reclaimed Rubber). The hole then accommodates valve seat in
them. The temperature of the natural rubber based bladder sheet must be at ambient
temperature.
The operation of this machine is fully pneumatic. In order to operate the machine
first of all open the instrument air to energize the machine & check the pressure of
instrument air is between 0.15 to 0.8 MPa. Put the bladder rubber sheets beneath the
plunger and press the push button, keep the button pressed until the plunger is
through the sheet, duration of pressing the button depends on the number of sheets.
More sheets more will be the duration.
 Type WX-2
 Serial No. 0138103
 Contour dimension 1500X500X800 mm
 Plunger hole punch dia. 15 mm
 Operating pressure of plunger 0.15~08 MPa
 Weight 180 kg
7. Pneumatic Valve Seat stamp Machine
This machine is used to stamp-paste a valve into the bladder sheet that has already
been through from the valve hole punch machine concentrically. The seat then
accommodates the nozzle through which the football is inflated. The machine is
welded to a bed/table. There are six working stations on a bed. The operation of
machine is electro-pneumatic.
First of all instrument air is opened to energize the machine, the pressure should be
in between 0.15 to 0.80 MPa. The bladder sheets that are through from the hole

Page | 38
punch machine are placed concentrically beneath the plunger and then put valve onto
the bladder sheet. Put both hands on the push buttons and press them simultaneously.
Keep the button pressed until the plunger stamps the seats well on the sheets.
Duration of pressing the button will depend upon the quality of stamping if
unsatisfied; repeat the procedure with a longer duration.
 Contour dimension 2500x453x855 mm
 Plunger valve seat stem diameter 18 mm
 Operating pressure of plunger 0.15~0.8 MPa
 Weight 310 kg
 Electrical consumption 0.1 KW
8. Bladder Forming Machine
This machine is used to cut the raw bladder from the rubber sheet. The machine
adopts hydraulic transmission, and four column structure, good guidance, oil
cylinder installed on the platform, hydraulic pump adopts double pump structure.
Uses the low pressure large flow and high pressure small flow pump, combining
action quickly. Hot plate temperature is controlled by electric heating. The sheet is
folded as per the folding method of the knife mold, press the start button. The sheet
will be cut into hollow rubber bladder.
 Oil pump pressure 8-12 Mpa
 Heating power 2KW
 Weight 1050 Kg
9. Bladder Vulcanizing Machine
Pneumatic carcass vulcanization machine is used for vulcanization of rubber ball
and carcass.
This machine adopts steam heating and water cooling, heating process is soft,
uniform temperature distribution, good curing effect. The mechanical transmission,
simple structure, reliable operation, high degree of automation.
Put bladder into the mold ( molds are opening, press the clamping button on the
station, so the electric solenoid valve, compressed air into the main the upper end of
the cylinder, the piston descends, driven by the upper mold clamping immediately.
Compressed air goes to front of the locking cylinder. A lever is driven to motivate
the rotation of locking pin to lock up the cylinder. In the mean time travelling switch
is motivated, vulcanization timing is recorded. Bladder starts to exhaust and

Page | 39
countdown exhausting time. Unlock the locking pin, the main cylinder goes up when
time is up, opening the molds. Each position repeats the same procedure.
 Air Pressure 0.5-1.6 MPa
 Steam Pressure 0.4-0.8 MPa
 Weight 1350 Kg
10.Pin Cutting Machine
The operation process of this machine is as follow;
Greater than or equal 0.4 MPa pressure turned the gas source, and make sure that
there is compressed air in the pipe. Make sure the power indicator is displayed
correctly. Depress the foot switch, observe the positioning cylinder and cylinder bore
stab whether to return in situ. When the two cylinder return in situ, adjust the air
nozzle which in side of the throttle valve, the air nozzle there is adequate airflow.
Depress the foot switch, the machine start working. Work is completed lift the foot
switch. Off the air and power supply.
11.Pin Inserting Machine
Pin inserting machine is used for opening a hole on the air pin for inflation. The
cylinder installed on the bracket, cylinder on the piston rod is equipped with a blunt
needle, needle punching on three sides into edge. Valve core to be included in the
lower die, the foot pedal switch, cylinder piston rod drives the blunt needle drop, a
cut blunt needle to the valve core.
 Air Pressure 0.3-0.6 MPa

Page | 40
Yarn Winding Hall
The standard weight of bladder which come from bladder section is 210-240g and
it also depends upon the consumer.
After bladder is vulcanized, it is sent to yarn winding section where yarn is warn
on the bladder.
Purpose of Yarn Winding
The sole purpose of yarn winding is
 Not to allow bladder to become DE shaped when inflated
 To control the size of bladder
 To impart extra strength to bladder
Yarn Winding Machine
PVA 38 yarn is used in SIDC which is winded on bladders to enhance their strength
and sphericity. An electronic machine with gear system is used to wind yarn on
bladder. WX-D Coiling machine is used to wind yarn on bladder. Bladder is held in
a cup shaped chamber and various rolls rotate the bladder along with winding yarn
on it. The set weight of yarn is 30g which is to be winded on bladder.
A latex glue is used from which yarn after passing is winded on ball. Latex used in
yarn winding hall is a solution of 50% latex and 50% water. This glue help in sticking
of yarn together and do not allow the threads to be loosen. The weight of latex is
again set to be 10g to meet the weight standards of ball.
Heating conveyors are used to firmly stick glue on bladder winding. Temperature of
these conveyors is 60-70°C.
Carcass Bladder
The completely finished yarn winded bladder is called carcass bladder. It is free from
DE shaping and has improved sphericity and strength.
Now this carcass bladder can be inflated to 0.6 bar air pressure and send to panel
cutting room where panels would be sticking on it.

Page | 41
Panel Cutting Room
The outer look of football i.e. patches of rexin are made and printed in this section
or we may say that the finished shape of football take place in this section.
1) Football Sheet
Football sheet is made from three basic ingredients
 Rexin
 Cloth
 Eva Foam
Rexin is at the top, eva foam at bottom and cloth is sandwich between the two. These
three ingredients are stick together by a strong glue solution i.e. 50% latex glue soln.
One meter length sheets are made from which patches of 6 footballs would be cut
out. The thickness of sheet is maintained at 4.3mm. Eva 3mm, rexin 1mm and cloth
is 0.3mm.
The Eva foam provides shock absorption effect to ball when shooted. Rexin is used
to add charming appearance to ball. The purpose of using cloth in between eva and
rexin is that
 It provides strength to ball
 Do not allow ball to wear out
 Protects Eva foam from damage.
2) Panel Printing Machine
After sheet is made it is sent for printing various designs on it. A positive is made of
a printed sketch and by using auto screen printer machine or by manual printing,
sketches are drawn on ball.
3) High Frequency Embossing Machine
A high frequency embossing machine is also available here which is designed to
emboss various patterns or tags on the panels. It works on simple principle, a plunger
is at the top, the design to be embossed is fed to it, the plunger simply punch the
panel and pattern is embossed on it.
Panels are cut in two basic patterns
 Pentagonal
 Hexagonal

Page | 42
Hexa or Penta shaped dies are provided and by using hydraulic cutting press panels
are taken out of the sheet. The ball is designed such that in between 5 hexagonal
panels a pentagonal panel is adjusted. It helps in providing
 Roundness to ball
 Strength to ball
4) Edge Turning Machine
After the panels are cut out they are flat and cannot be put in operation until and
unless they are made curved and their edges are turned. This is done via Panel
turning machine. The angle of turned edges is set to be 80-90°. A panel shaped die
is provided in machine and a high pressure plunger presses panel down so the desired
shape is achieved.
5) Auto lamination Machine
The panels of ball are stick together using latex glue. Two halves of football are
made from panel. These two halves are placed in auto laminated machine with
carcass bladder inside them. It is then baked at 160°C for 2-3 min, suction is provided
inside the die which allow the two halves to stick together firmly and at last final
football is made.
The final football must have the weight of 420-440 g.

Page | 43
Basket Ball Manufacturing
Introduction
The ball is spherical in shape and is inflated. Basket-balls range in size from 28.5-
30 in (72-76 cm) in circumference, and in weight from 18-22 oz (510-624 g). For
players below the high school level, a smaller ball is used, but the ball in men's games
measures 29.5-30 in (75-76 cm) in circumference, and a women's ball is 28.5-29 in
(72-74 cm) in circumference. The covering of the ball is leather, rubber,
composition, or synthetic, although leather covers only are dictated by rules for
college play, unless the teams agree otherwise. Orange is the regulation color. At all
levels of play, the home team provides the ball. Inflation of the ball is based on the
height of the ball's bounce. Inside the covering or casing, a rubber bladder holds air.
The ball must be inflated to a pressure sufficient to make it rebound to a height
(measured to the top of the ball) of 49-54 in (1.2-1.4 m) when it is dropped on a solid
wooden floor from a starting height of 6 ft (1.80 m) measured from the bottom of
the ball.
Process Flow Diagram for Basket Ball

Page | 44
Process Description
In the manufacturing of a basketball, all balls contain a bladder with an inflation
valve, a carcass, and a cover material. The following lists the procedure in producing
a basketball:
1. Sheets of butyl rubber are cut into shapes, and bonded together with an
inflation valve in a mold under high temperature and pressure. Butyl
rubber is used instead of other rubber materials because of its superior
ability to hold air.
2. The inflated bladder is coated with a heat-curing adhesive and wound with
a nylon or polyester thread like a ball of string. Nylon is more durable, yet
more expensive, material than polyester. Generally, a "nylon wound"
basketball is a better quality basketball than one which is "nylon/polyester
wound" or "polyester wound."
3. In forming the carcass, two bowl-like pieces -- called "half shells" -- of
partially-cured natural rubber are molded. These half shells are placed over
each half of the wound bladder, placed in a hot mold, and cured under
pressure. For a rubber basketball, a special mold with a textured surface
forms the pebbles in the rubber during the molding operation. This
operation produces the finished rubber basketball. For leather and
synthetic leather balls, the finished carcass is black, round, and smooth
except for raised ridges for the channels.
4. For leather and synthetic leather basketballs, pieces of material -- called
panels -- are die cut. The panels are shaved down in thickness in an
operation called "splitting," which brings the material in at the proper
weight for game play. After splitting, the edge of the panels are tapered in
a shaving operation called "skiving", so that the panels lay down next to
the channel and provide a place for gripping the ball. Finally, the panels
are hot stamped with the desired logos.
5. For leather and synthetic leather basketballs, adhesive is applied to the
carcass and the back of the skived panels. The panels are then applied by
hand -- eight panels in all. The assembled ball is then put into a mold and
inflated to 80-100 lb. of pressure for a short period of time, and then the
air pressure is reduced to the specified pressure of 7-9 lb. This operation -
- called "molding" -- presses all of the parts together to provide a tight bond

Page | 45
Labouratory Setup
Introduction
SIDC as its name indicates is not only a production center but also a Research and
Development Center which make aware its clients of the new researches and
technologies. The sole purpose of this laboratory section is to experiment new
techniques and improve the older one. Laboratory is decorated with all kind of
rubber related testing and modern computerized automated machines which serve
the key role in quality inspection and innovating new techniques.
List of Machines and Apparatus in Laboratory
Following is the list of machines and apparatus available in SIDC laboratory section
1. Moving Die Rheometer
2. Plasticity Tester
3. Demattie Flex Cracking Machine
4. Scott Volumeter
5. Sphericity Testing Machine
6. Compression Rebound Tester
7. Water Absobtion Unit
8. Air Inflator
9. Rotational Viscometer
10.Tensile Testing Machine
11.Programmable Ball Mill
12.Duro Meter
13.Vacuum Oven
14.Discoloration Meter
15. Nozzle Testing Machine
16. Ball Rebounce Tester
17. Sample Cutting Press
18. Compression Testing Machine
19. Shooter Machine

Page | 46
Description and Working of Machines
The basic description and working of each machine is given with respect to the
machines mentioned above.
1. Moving Die Rheometer
In the Rubber Industry the effects of compound
variations on curing characteristics are important in
compound development studies or production
control. In compound development, the composition
of the ingredients can be varied until the desired
vulcanization characteristics are achieved. For all
this, the Computerized Rheometer with Micro-
processor temperature controls is an equipment of
vital importance.
The moving die Rheometer is an efficient, simple and
reliable testing equipment. It is quite easy to operate.
The Rheometer describes precisely and quickly
curing & processing characteristics of vulcanizable rubber compounds. It works on
a very simple principle.
Working
A test piece of rubber compound is contained in a sealed test cavity under positive
pressure and maintained at a specified elevated temperature of about 160°C. A Rotor
(rotating disc) is embedded in the test piece and is oscillated through a small
specified rotary amplitude of about 0.5°. This action exerts a shear strain on the test
piece and the torque (force) required to oscillate the disc depends upon stiffness
(Shear Modulus) of the rubber compound. The stiffness of the specimen compound
increases when crosslinks are formed during cure.
The cross linking isotherm is thus the function of time, of the oscillating shear force
F, or of the Rheometer indication proportional to it, occurring at a given temperature
as a result of vulcanization and expressed as
F = f (t)
Where‘t’ is vulcanization time.
A complete “Cure Curve” is obtained when the recorded torque value either
increases to an equilibrium value or a maximum value. The time required to obtain
a “Cure Curve” is a function of the test temperature and the vulcanization
characteristics of the Rubber compound specimen.

Page | 47
Main Technical Data:
 Torque range S*, 1~200 lb-in/ S**, 0.3~200lb-in
 Torque precision 0.5%
 Min torque value 0.001
 Torque unit kg-cm, lb-in, N-m, dN-m
 Oscillating frequency 100 cycles/min
 Oscillating angle ±0.5˚,±1˚,±2˚,±3˚
 Cavity temperature 25 to 230 ˚C
 Temperature Control precision ±0.3˚C
 Min temperature Value 0.1 ˚C
 Test Time no limit
Torque values
The rotaional tourque applied to sample by moving die is characterized as
i. MI (Initial Torque): It is the torque recorded at the start of the test i.e. t=0.
ii. ML (Minimum Torque): As the compound gets heated under pressure, the
viscosity decreases and the torque falls. The lowest value of Torque recorded
is called ML. Basically, it is a measure of the stiffness and viscosity of
unvulcanized compound.
iii. MH (Maximum Torque): As the curing starts, the torque increases
proportionately. After a while the torque typically attains maximum value and
it plateaus out. It is called “Plateau Curve”. MH (Max. torque) is the highest
torque recorded in plateau curve.
Time values
Time vallues are also characterized as
i. Scorch time: Scorch is premature vulcanization in which the stock becomes
partly vulcanized before the product is in its final form and ready for
vulcanization. It reduces the plastic properties of the compound so that it can
no longer be processed. Scorching is the result of both the temperatures
reached during processing and the amount of time the compound is exposed
to elevated temperatures. This period before vulcanization starts is generally
referred to as “Scorch time”.
ii. Cure Time: it is the time at which the sample is 100% cured and valcunized.
Infact it is the time at which final product is attained.

Page | 48
The graphical data of rheometer gives value of scorch and cure time as
a) ts2 (Induction time). After attaining minimum torque, during cure phase, as
the torque rises, ts2 is scorch time for viscosity to rise 2 units above ML.
b) ts5 (Scorch time). It is the time for viscosity (torque) to rise 5 units above
ML. Both ts2 are ts5 are measures of processing safety
c) tc50 (Optimum cure time). It is the time at which 50% of cure has taken
place.
d) tc90 (Optimum Cure time). It is the time at which 90% of cure has taken
place.
The graphical representation of results from rheograph is as below:

Page | 49
2. Plasticity Tester
This apparatus is used to measure the plasticity and
reexpansion ability of given rubber sample. The sample is
placed in a closed chamber at 70°C for 3 minutes and force
is applied on it via movable piston. The initial thickness
‘h0’ of material is noted before placing it in tester and final
thickness ‘h1’ is noted via gauge inserted on tester. The
sample is then allowed to expand at atmospheric
conditions to height ‘h2’. Thus the percent expansion of
material is found by
H=(h2-h1)×100
This test is applied to only non cured rubber sample.
 Loading force on sample 49±0.05N
 Temperature 70±1 °C
 Dial gauge capacity 0~30 mm, accuracy 0.01 mm
 Heating power 220V±10%, 70W, 50Hz
 Net weight 30 kg
3. Demattie Flex Cracking Machine
This machine measures the cracking growth of given
rubber sample. A curve with a hole is made at center of
the sample and held between the claws of machine which
gives 1000 strokes to sample by squeezing it up and
down. After the test is completed, analysis of sample
show how much cracks have occurred and grown.
 Distance between two grips 19~75 mm
 Travel 57±.05 mm
 Test speed 300±10 r/min
 Counter LCD, 0~99,999,999
 Dimension (55x44x69) cm
 Weight 78 kg
4. Scott Volumeter
It is designed to measure the density of given powdered
sample. a cup of known volume is allowed to fill with a pre-
weighed sample compound. Thus by using simple

Page | 50
calculation the density of sample can be found. For accurate rresults, the test is
repeated 3-5 times.
Formula
= ⁄
5. Sphericity Testing Machine
Its procedure is simple using an inch tape or a vernier stand
the sphericity of ball is measured at about 16 different
positions to ensure complete sphericity. An unsphered ball is
claimed as D-shape and is rejected as it does not give accurate
rebounce.
6. Compression Rebound Tester
It measures the compression strength of given rubber sample.
The sample is placed on a patform and compression force is
applied bymoving the upper rotational wheel that allows the
piston to move down and compressthe sample. The value of
thickness of final sample is calculated via gauge inserted under
the platform.
 Maximum capacity 500 kgf
 Dial indicator 50 mm
 Volume 25 cm x 23 cm x76 cm
 Weight 45 kg
7. Water Absorbtion Unit
The amount of water absorbed by football is calculated using water absorbtion unit.
Initially ball is weighed and imersedin a tub comtaining 2 cm of water in it. Then
the piston from top at 0.6 MPa pressure is allowed to compress the ball upto one
fourth while rotating it for 6 minutes. Total 250 strokes are applied to ball. The final
weight of ball is noted and the difference between initiall and final weight give
information about amountt of water absorbed by ball. The water absorbed must not
exceed 10% of its total weight.
8. Air Inflator
It is used to inflate air in to the bladder and football. The set pressure of this machine
to inflate ball is 0.5 bar. Pin is inserted into ball and after pressing level air is filled.

Page | 51
9. Rotational Viscometer
Rotary viscometer is a new instrument used for determining the
liquid viscose capacity and the absolute viscosity. It has been
widely used to determine and measure the liquid viscosity in
many applications such as grease, painting, plastic, pharmacy
and adhesives. It is a precision instrument to monitor and
control the stable quality of products in the manufacturing. At
last the reading must be multiplied to the specific coefficient in
the coefficient table in order to get the absolute viscosity.
That is:
= .
Where;
η is absolute viscosity
k is coefficient
α is reading ( deflection angle)
Its rpm are variable and the rotor designes according to the type of fluid are provided.
10.Tensile Testing Machine
This machine is widely used in rubber, footwear,
leather, apparel and fabric for tensile tear and shear
tests.
This machine adopts the electronic tensile meter, use the
motor to make displacement of the fixture. Place the
fixture with sample between the upper and lower
fixture, use a given speed to pull the upper fixture
upward, and the upper load cell with sensor the tensile
strength, and convert the strength into voltage sign and
output to the display screen. And the strength value will
be displayed automatically.

Page | 52
11.Programmable Ball Mill
A ball mill is a type of grinder used to grind materials
into extremely fine powder. A ball mill works on the
principle of impact: size reduction is done by impact as
the balls drop from near the top of the shell. A ball mill
consists of a hollow cylindrical shell rotating about its
axis. The axis of the shell may be either horizontal or at
a small angle to the horizontal. It is partially filled with
balls. The grinding media is the balls, which may be
made of steel (chrome steel), stainless steel or rubber.
The inner surface of the cylindrical shell is usually lined
with an abrasion-resistant material such as manganese
steel or rubber.
 Dimension Roller 50x300 mm
 External (wxdxh) 1570x850x1640 mm
 Capacity up to 2 pots
 Speed (rpm) Max.600
 Speed accuracy (rpm) ±5
 Display Digital LCD Display
12.Duro Meter (Hardness Testing Machine)
It is designed to determine the indentation hardness of
materials ranging from cellular products to rigid plastics.
Each durometer type is made to a specific scale (i.e. A, C,
D) and is capable of producing a value between 0 and 100.
Shore A is designed to measure the penetration hardness
of rubber, elastomers and other rubber like substances such
as neoprene, silicone and vinyl. It can also be used for soft
plastics, felt, leather and similar materials.
Shore C is designed for various foam and sponge.
Shore D is designed for plastics, Formica, epoxies and
Plexiglass.
Measuring Procedure:
Test specimen
Shore A: 6mm thick minimum
Shore D: 3mm thick minimum

Page | 53
Specimen should allow measurement to be taken at least 12 mm from any edge.
Specimen surface should be flat and parallel to allow the presser face to contact to
the specimen over an area which has a minimum radius of 6mm from the durometer
probe.
The specimen may be constructed with layered pieces to achieve the necessary
thickness requirements, however measurements taken on these specimens may not
agree with those made on solid specimens, due to the surface faces between layers
not being in complete contact.
Depress and release the key to power the tester on.
Depress the 'MAX' key till the mark MAX shows on the display.
Hold the durometer vertically with the point of the indenter at least 12 mm from any
edge. Apply the presser foot to the specimen as rapidly as possible, without shock,
keeping the foot parallel to the surface of the specimen. Apply just sufficient force
to obtain firm contact between the presser foot and the specimen. Hold for 1 or 2
seconds, the maximum reading can be obtained automatically.
 Display 4 digits, 10 mm LCD
 Range 10~90 H(A, C, D)
 Resolution 0.1
 Measurement deviation: error 1
 Power supply: 4x1.5v AA (UM-3) battery
 Operating condition: Temp. 0~50
 Humidity <80%
 Size 162x65x28mm (6.4x2.6x1.1inch)
 Weight about 170g
13.Vaccum Oven
The purpose of this oven is to find the purity of liquid
sample. A solution is provided and is heated in oven at
temperature on which solvent may evaporate and solute
is left behind. Hence by noting amount of solute, purity
of sample can be found.
14.Discloration Meter
It is designed for testing the surface discoloration of white
or light colored top pieces or soling materials, which are
exposed to ultraviolet radiation. Based on the principle that
white or light colored articles are easy to cause color change
under long term ultraviolet radiation, the specimen is

Page | 54
exposed to radiation from the UV lamp for 3 hours so that the degree of discoloration
is rated against the reference standard or the original specimen, or both.
 Light source two tubes of UV lamp 15W
 Wavelength 280 to 400nm
 Wire screen 43cm x30 cm
 Timer 0 to 999h
 Interior 50 cm x 30 cm x 35 cm
 Dimension 60 cm x 35 cm x 37 cm
 Weight 12 kg
15.Nozzle Testing Machine
This machine is used to find life of the nozzel. A pin is inserted in and out of the ball
nozzle for about 500 times and leakage around nozzel is analysed after every 50
turns. Thus it is useful to predict nozzel life before it wear out.
16.Ball Rebounce Tester
It is used to measure the rebiunce of the ball. The ball is fallen from 2m height on a
solid platform and its rebounce is predicted via camera inserted at suitable distance.
The standard rebounce must be 150-160 cm.
17.Sample Cutting Press
It is used to cut out samples of various machines like plastometer, flex cracking,
tensile tester etc. it cut out the sample according to the required desire of length and
width.
18.Compression Testing Machine
It is used to check the shear limit of material after which it
break down. Shear force is applied on material and its data
is displayed on digital scrreen. It is usefull to measure the
stress that material can bear before it breakup.
19.Shooter Machine
This machine is used to ensure that the ball’s shape, pressure
and circumference remain constant. The ball is fired against a steel plate at 50
kilometers per hour – 2,000 times. The seams and air valves must remain intact and
undamaged. Only minimal pressure loss and minimal changes in roundness and
(pointer) circumference are permitted.

Page | 55
Recommendations
 The bladder sections muust be properly vantilated to avoid andy suffocation
of worker working there.
 Some machines in bladder hall are temperature sensitive, so proper
conditioning must be provided to make quality standards product.
 Each curing machines must have its own exaust fan so that the machine may
not heat up beyond limits and worker operating it may not suffocate.
 The complete bladder section must be made duust proof because tiny dust
particles can alter the quality of product .
 Labouratory section must have air sealed enviornment to carry out sensitive
reeadings greatfully.
 Boiler section and compressor section must be made far away from working
area to limit the hazards of danger.
 A complete boiler understander must be hired so that he may tackle the
alarming situation effectively.
 The workers must be trained properly with regular intervals with the latest
techniques of bladder and football making. For this purpose an engineer or
football related person must be hired whose sole purpose must be to be aware
of lateest technology and teach them to the workers.

Page | 56
References
1. https://www.wbdg.org/ccb/NAVFAC/OPER/mo206.pdf
2. https://www.americantrainco.com/pdfs/studyguide-bo.pdf
3. http://www.moeschle.de/files/upload/S350_engl.pdf
4. http://www.iisrp.com/WebPolymers/00Rubber_Intro.pdf
5. http://wwwme.nchu.edu.tw/~CIM/courses/Manufacturing%20Processes/Ch1
4-Rubber-Wiley.pdf
6. http://www.uotechnology.edu.iq/dep
materials/lecture/thirdclass/RubberTechnology3.pdf
7. http://www.brcil.com/common/downloads/technical/Rolling_Mill_Rolls.pdf
8. http://www.chemfilt.com/PDF%20Files/SIGMA%20KNEADER.pdf
9. http://ir.library.oregonstate.edu/xmlui/bitstream/handle/1957/5199/Basic_W
ater_ocr.pdf
10.http://www.gibitre.it/Eng/Pdf/MoreRheoMd.pdf
11.http://researchcommons.waikato.ac.nz/bitstream/handle/10289/8094/A%20n
ew%20method.pdf?sequence=1
12.http://4tsi.com/wp-content/uploads/2012/10/What-is-Durometer.pdf
13.http://www.akrochem.com/pdf/product/rubber_chemicals/accelerator_mbt.p
df
14.http://www.akrochem.com/pdf/product/rubber_chemicals/accelerator_mbts.
pdf

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