Rubber compounding- the “classic” way
Rubber is normally made in large batches, because that is the most efficient way of doing it. Compounds are produced in central mixers as large batches, which are shaped into sheets and cooled in a batch-off before moving onto the next stage of the process. Each compound is produced to a recipe, which defines the materials going into the mixer and the machine settings needed to produce a certain type and quality of rubber compound.
While this sounds simple and straightforward, in real life there are many factors that complicate the compounding process, including:
Rubber production- the VMI way
We can’t change the chemistry of rubber compounding- there will always need to be heating, mixing and shaping. Instead, what VMI does is simplify the process, while cutting down on waste and also providing personalized, integrated solutions for every customer.
VMI’s COMBEXX extruder gear pump and Batch-Off systems can be used as versatile individual solutions, but are most effective as a single, integrated solution in the mixing line. Here are the key benefits offered by the VMI approach:
Managing variations. Batches are not all completely uniform, especially where the first batch is concerned- as the mixer may not be at production temperature when mixing starts. VMI’s smart extruder technology makes it easy to blend batches to meet the right tolerances and avoid wastage.
Reclaiming waste. The need to cut batches into different shapes and sizes leads to left-over material. VMI’s handling techniques make it easy to reclaim these off cuts, then feed them back into the process to be blended for reuse.
Final Mixing. Most compounds are produced in 2 or more mixing steps, with the final stage always being to add the vulcanization chemicals. Mixing the chemicals can also be carried out more efficiently as part of an integrated solution, using a VMI COMBEXX in combination with a Batch-Off. This uniquely efficient process is known as iCOM.
The importance of straining. All compounds are likely to include some contaminants, which is why VMI’s strainer technology is so important in cleaning the materials, especially when reclaimed compound is being used. As VMI COMBEXX machines come with a gear pump, straining is already a standard, integral component of the equipment. VMI strainers are available both in a hot feed (in-line) and also in a cold feed (off-line) configuration.
Use of filler materials. Vulcanized rubber is sourced both from end-of-life products or materials that are left-over at the end of the production process. These materials are ground into powder to be used as filler. VMI’s integrated system has an option to dose this filler material into the extruder to mix it with the fresh compound.
The flexible approach. Whatever the similarities between companies and their processes, each producer has unique requirements, which usually means their production lines must be fine-tuned for most efficient use. VMI’s modular design makes it easy to put components together exactly as needed to deliver a solution that is highly efficient, delivers output to the highest achievable standards- and is precisely customized to the needs of an individual enterprise.
The turnkey approach. Both the COMBEXX extruder (for blending or mixing, straining and shaping) and the Batch-Off are designed to work together, so they operate as a perfectly tuned and fully integrated system, taking into account topics like simple operation, high output and minimal floorspace.
Rethinking rubber production
It really doesn’t matter what area of manufacturing you operate in- you probably need to use rubber components in some form, at some stage in your processes. Every industry is facing the same kind of challenges: high energy costs, the need to be more responsive and faster to market than competition, automating more effectively and cutting wastage.
VMI helped to create the modern rubber processes, and we are continuously redefining them through innovation based on deep experience. Helping our clients to achieve the right combination of speed, agility, operational efficiency and quality is what we do. Call us to find out how we can transform your competitive position, too.
To find out more, fill in the form below for a detailed online briefing or face to face meeting.
