MASTER BATCH COMPOUND MIXING
OFFER FOR SUPPLY OF MASTER BATCHES FOR USE IN RUBBER INDUSTRY.
General purpose rubbers like Natural rubber, Styrene Butadiene rubber, Poly butadiene rubber etc. are versatile elastomers. So also are the speciality rubbers like poly acrylic nitrile rubber [NBR], Poly isobutylene rubber [Butyl rubber], Poly chloroprene rubber [Neoprene rubber] and ethylene propylene diene monomer [EPDM]. However, the versatility of these elastomers both general purpose and special purpose could be manifested only when they are mixed with compounding ingredients known as fillers which are of reinforcing, semi-reinforcing and inert nature. These fillers also can be of carbonaceous origin like Carbon Black or of non-carbonaceous origin i.e. inorganic type like Silicon Dioxide, precipitated Silica, China Clay, Calcium Carbonate etc.
The rubber compound becomes processable for various operations like Shaping, Calendering, extrusion, moulding etc. only with addition of fillers like the above to the extent required as per the exacting requirements.
The main problem in a modern day processing unit is the addition of these fillers into rubber without causing environmental hazards. For example when Carbon Black is mixed with rubber in a Mixing Mill, dust particles emanates from the mix causing serious atmospheric pollution. The Shop floor becomes dirty by the deposition of Carbon Black particles coming out of the Mixing Mill. This is also the case with inorganic fillers. Even when mixing is done on a Kneader Machine, fillers like Carbon Black tend to fly off from the mixing chamber thereby making the shop floor dirty. Whereas in the Intermix mixing, this nuisance of Caron Black particles and other fillers in powder form getting deposited on the shop floor is totally eliminated. This also goes to prove that mixing on Intermixes is an absolutely environment friendly operation.
Mill mixed or Kneader mixed rubber compounds has another major limitation with regard to getting proper dispersion. Proper dispersion of the fillers into the rubber polymer matrix is of utmost importance in the service performance of rubber articles, let it be tyre, cycle tyre, tubes, injection bottle stoppers, door stoppers or any other rubber product.
It has been amply proved that the best dispersion of fillers in rubber can be made possible only by using an Intermix or a Banburry. These equipments being very costly in nature escapes the affordability of small scale and even medium scale manufacturers of rubber goods. Unless one has sufficient volumes to keep the Intermix or Banburry running to achieve viable economical levels it will be difficult for the unit to sustain the huge expenses incurred for the setting up of these machines.
Even after installing these costly equipment, the technical know- how, skill and dexterity required to run these machines are also of prime importance in turning out mixed rubber compounds of optimum properties which should conform to specifications established for such compounds. This means that the entrepreneur of the unit should have adequate technical competency derived not only from theoretical knowledge but also from long term experience.
United rubber has a blemishless record of having undertaken master batch mixing of rubber compounds for major tyre companies in India like Apollo Tyres Ltd, Ceat Limited,Bridgestone India Ltd. J.K. Industries Ltd. Goodyear South Asia Tyres Pvt. Ltd. and Balakrishna Tyres Ltd.
MIXING CAPACITY
CUSTOM DESIGNED TO MEET YOUR NEEDS
UNITED RUBBER PVT LTD, Ankleshwar, India
We are equipped with state of the art Intermixers and have experience of over 40 years to render mixing solution to meet your needs. Custom design and mixing of compounds to meet your specific requirements is our specialty. Our ISO 9001 certified company maintains the best of quality systems to provide you consistent quality mixing/compounds. We have the expertise to mix all type of rubbers, which include Natural, and all Synthetic rubbers.
OUR STRENGTHS
- Experienced team of Rubber Technologists
- R&T and quality control center for design/development and inprocess quality control
- Continuous improvement on quality systems.
- Technical assistance to customers
- 25000 MTA mixing capacity with 3 NOS of K4 and 1 NO. K42A mixer.
- Delivery on schedule
WHAT DO WE OFFER
- Mixing of Customer’s proprietary compounds
- Custom designing your compound and supplying compounds based on end product requirements. Compounds for varied applications like tyres, tread rubber, belting, mats and variety of industrial products.
- Evaluation and testing
- Trouble shooting.
R&T CENTER
United Rubber is backed with an excellent Research and Technology center equipped with test equipments like Rheometer, Mooney viscometer, Hardness tester, Tensile tester, Accelerated ageing oven, Abrasion tester and a host of other equipments. Qualified and skilled technicians man the Center. This is the backbone for rubber mixing and compounding.
BRIEF ON RUBBER PROCESSING
In today’s scenario the performance requirement of rubber component is extremely demanding and critical. The selection of elastomers, design of the compound and proper mixing are of utmost importance to make a product perform.
Rubbers in general are classified into General purpose and Special purpose grades.
Natural Rubber (NR), Styrene Butadiene Rubber (SBR) and Poly butadiene Rubber (PBR) fall under the general purpose category, other synthetic rubbers like Butyl Rubber (IIR/HIIR), Ethylene Propylene Diene Monomer (E.P.D.M), Polychloprene (Neoprene), and Acrylo Nitrile Butadiene Rubber (NBR) etc.come under the Special purpose group.
General purpose rubbers mostly find their applications in Tyres and Tyre related products, in foot wear, in engineering and mechanical products e.g.; bridge bearing pads, antivbration mountings, bushings, rubber rolls, conveyor belts hoses etc. Besides they are also used in the making of adhesives.
Special purpose rubbers are used where end products need resistance to oil, high temperature, chemicals, weatherability etc.
All rubbers need to be compounded to achieve the desired properties. The science of compounding is the key to design best performing products and, United Rubber has the knowledge base to do it.
DESIGN BASE FOR RUBBER COMPOUNDS
In general, a rubber compound will contain a variety of ingredients like fillers (black as well as non black), process aids, accelerators, activators, curing agents like sulfur etc. The proportions in which these are used are generally referred as formulations.
Making a successful compound using the various additives in the base polymer by mixing is a rubber chemist’s job. The performance of the end product depends on the careful selection of these additives in the right proportion and their proper mixing and dispersion in the polymer used.
Mixing of rubber compounds are generally done on Mixing Mills, Kneaders and Internal Mixers. Of these, Internal Mixers/ Banbury Mixers give compounds of consistent quality and the output is much larger compared to Mixing Mills and Kneaders. The mix consistency, dispersion of black and other ingredients are much superior in internal mixing done on Intermixes The process meets the environmental requirements also.
However, quality and consistency of the mixed batches can be ensured only by adopting the most appropriate processes and controls. The expertise acquired in this process and quality control systems makes United Rubber different from others.
For Total Solution to Rubber Mixing
Please Contact United Rubber Pvt. Ltd.
Tel: +91 2646 251549, 252536
Fax: +91 2646 250419
E-mail: [email protected]