Rubber & Tyre Machinery World

Info on Equipment And Suppliers


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The Biggest Problem with Heat Transfer Efficiency in Rubber Machinery (And How You Can Fix It)

Rubber processing has a bizarre energy pattern, when seen from a layman’s perspective. Because you add heat into your process and then you cool down!

Heat addition and removal is repeated in each of your subsequent stages as well.

When you process rubber, energy is consumed across the value chain – right from transport of raw rubber, to the various processing operations (be it rubber mixing, rubber extrusion, rubber calendering, moulding etc) to convert into your suitable product and then transportation of your product.

Energy Uses in Rubber Processing

Source: Tangram

This implies that you need to cool down your rubber processing machinery regularly, which simultaneously involves heat exchange from a hot medium to a cooler medium.

And the most common medium to cool is water.

But where there’s water, you will face water-related problems caused by its mineral deposits. These deposits could give you varying degrees of water-related problems that affect your operating efficiencies and/or even leading to more costly equipment downtime issues.

This could be in your Rubber Machinery like Mixer, Mixing Mill Rolls, Calender Rolls, Press, Extruder, Heat Exchangers, Moulds, and factory equipment like Boilers, Chillers, Compressors, and TCU‘s or other Ancillary Units, etc.

You would notice that the mineral deposits accumulate quickly regardless of screens or treatment actions adopted. Even a thin coating of water scale will act to insulate the water system’s surface and retard the transfer of heat.

Hence, scaling is the biggest problem affecting the heat transfer efficiency in rubber machinery.

To increase heat transfer efficiency, lower maintenance cost, conserve overall energy consumption and thus enhance the usable life of your machinery, removing scales in all your water-cooled or water-heated rubber and tyre equipment is very important.

In a simple rubber machinery like the mixing mill, the presence of scales on rolls leads to localized hot spots affecting your mixing quality. In the case of boilers, scales can be very damaging leading to even boiler rupture. When water scale, lime and rust deposits accumulate on the water side of chambers, rotors and the drop door of the Mixer, it causes temperature of your rubber stock to rise and gradually lead to a loss in production.

Different machinery has different safe and effective method to remove scales. Recently, I was shown an instruction sheet, from one of the descalers (RYDLYME), on the process to descale a rubber mixer that I found interesting.

Here’s the process reproduced. I hope you too find it informative.

How To Clean Your Rubber Mixer

Image From RYDLYME

  1. Take mixer out of service.
  2. Close water supply valve at header as shown in the sketch above.
  3. Drain all water from all sections of mixer.
  4. Connect Descaling Solution pump discharge hose to water header. Header usually supplies all circuits.
  5. Connect return hoses to drain lines from all circuits and place into the Descaling Solution receiver.
  6. Close water supply valves to gate and jacket circuits.
  7. Start pump and pump the descaling solution into rotors to purge the water from this circuit to sewer. When the descaling solution begins to discharge from this hose, return to the receiver.
  8. Open water supply valve to gate and maintain Descaling Solution circulation through this circuit.
  9. Open water supply valve to jacket and maintain Descaling Solution circulation through this circuit.
  10. If any circuit is NOT flowing properly, restrict Descaling Solution flow in other circuits until flow returns to normal in this circuit.
  11. Circulate a total of 120 Litres of Descaling Solution through all circuits of mixer until clean. This will require approximately four (4) hours pumping time.
  12. It is suggested to periodically rotate the rotors during Descaling Solution cleaning to assure that the Descaling Solution is in contact with all of the lobes of the rotor.
  13. Upon completion of cleaning, flush all Descaling Solution from all circuits with fresh water.
  14. Disconnect the Descaling Solution pump and all hoses. The mixer is now ready to be returned to service.
  15. Periodic descaling will keep the temperatures of the mixer within acceptable limits, assuring you a better product and minimize burnt or improperly mixed stock.
  16. Clean out the Descaling Solution System and store for future use.

Summarizing, scaling is the biggest problem with heat transfer efficiency in your rubber machinery. Descaling or cleaning the scales helps you fix this issue. Hence incorporating descaling solutions into your preventive maintenance program is recommended to keep your equipment running effectively and economically.

Do you agree?


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A Starter’s Guide – Special Edition

This edition of Knowledge On-The-Go Special Supplement features two key machinery used in the rubber industry viz. Autoclave and Compression Moulding.

Autoclave is a vulcanizing equipment, and the other is the equipment used in your most common rubber moulding technique – compression moulding.

Our previous issue on Mixing Mills tracked the advancements of a very popular rubber machinery. This edition is aimed at fulfilling the curiosity of the new generation of business leaders in rubber goods manufacturing – who are either taking over from their parents or those young entrepreneurs setting up their own venture.

Hence, the theme – ‘A Starter’s Guide’.

Download Your PDF Here

I hope you find this special supplement different and informative.

(Disclaimer: Any pictures and quoted statements in our special supplements including Know Your Supplier editions are shared with us by the respective companies and/or sources are mentioned appropriately. Rubber Machinery World does not independently verify them nor will vouch for their actions, hence will not be liable for any misrepresented data)


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If you are an equipment supplier and would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at rubbermachineryworld@gmail.com for your customized offering.


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Tire Production Simplified In A Flow Chart

My earlier post on Tyre Building Machine – 5 Amazing Videos You Must See was well received by the readers and they found it informative.

I have in earlier posts covered rubber machinery like Bale Cutter, Mixer, Mixing Mill, Batch-Off, Extruder, Tire Buffer, etc. However, its intriguing to see where all these equipment (along with the other machinery) goes into tire production.

This flow chart simplifies tire production overview and helps you visualize the various equipment that we discuss on this portal Rubber Machinery World in the right perspective.

Tire-Production-Flow-Chart

The source of above flow chart is from Nell Achieve Website.

And just in case, you thought even for a microsecond ‘Is this all to tyre manufacturing?’, I correct you here.

The tire production process is a very meticulous and complex  affair. Click here to download the infographic from Giti that explains their tire production concisely.

I hope you found this post informative. Let me know.


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How To Select Your Rubber And Tyre Machinery? Insightful Advices From 6 CEO’s

“How To Select Your Rubber And Tyre Machinery?”

This subject question could have volumes written in theory. But today we focus on what the CEO’s advise, distilled down from their experience, expertise, and wisdom.

Your equipment supplier ecosystem includes New Manufacturers, Rebuilders, OEM Suppliers, Pre-Owned Machinery Suppliers and Agent representatives.

So I asked all the CEO’s the same question to give you a true perspective.

“What would you advice on machinery selection to buyers and users of rubber and tire equipment?”

The different views they offered here are not only insightful, they are pertinent, prudent and practical.

Read on in our Special Supplement here….

This special supplement is one of our efforts to give you useful knowledge on-the-go in a concise and timely manner. This topic based micro-editions is in addition to our other initiatives like ‘Know Your Supplier’ that provides you information on the machinery supplier ecosystem.

Watch Video Version of this supplement on YouTube or Download Full PDF Here.


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If you are an equipment supplier and would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at rubbermachineryworld@gmail.com for your customized offering.


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Practical Solutions On Equipment Simplified – A Know Your Supplier Special

At Rubber Machinery World, we understand your information requirements. Our effort on this portal to share authentic information to help you source your machinery wisely remains incomplete without notes on equipment suppliers from whom you source your rubber and tire equipment.

Hence, ‘Know Your Supplierseries is one of our advertorial initiatives to bring to you information on the machinery supplier ecosystem – Manufacturers, OEM Suppliers, Machine Rebuilders, Used and Pre-Owned Equipment Buyers & Suppliers, and Agents.

In Know Your Supplier editions, we cover an equipment supplier’s Competency, Capacity, Commitment, Culture, Communication, Market Presence, Technology, Solutions, amongst other details that you seek; so you know these organizations better and reach them quicker.

In this post, I introduce you to an equipment supplier based in India but wired globally. Read on to know why.


Pracsol Chemicals & Machinery is into trading of Machinery, Raw Materials and Chemicals since 2007 and is growing in reputation in machinery business. We understand from our conversation with Harish Nene, Chief Executive, that in the last 4 years they have secured landmark orders for Used Machinery from Indian Rubber and Tyre industry.

Pracsol is now fast building on this rising confidence and customer trust to extend practical equipment solutions to the industry in new machinery as well.

Flip through this Special Edition using the link – http://is.gd/UHPT5U

In this conversation, Harish Nene outlines on a wide array of his business aspects right from the genesis of his company name to his experiences in rubber and tyre industry, partnership with JM Machinery USA, recent successes and new products on the anvil. Harish also informs us the unique service proposition Pracsol offers to their customers, their competence and comprehensive range of machinery offered to buyers.

I reproduce for you a few snapshots of our conversation here. (For full story, please do read and download here, this special edition of Know Your Supplier)

  • Pracsol is a strange name. What is the story behind this name?

Pracsol is derived from the words ‘Practical Solutions’. Through my experience of last 20 years in International Business, I would state that solution for a problem is possible if looked at it practically not by just following procedures.

Pracsol Logo

  • Having started in 2007 how has been your experience so far in this industry?

Business Ethics, Honesty, Transparency and Hard work is important. Customers who do business with me recognize that they can expect these from me and have helped me succeed in the rubber and tyre industry. I also have good support from my principal company. This makes things simple and gives me time to focus on delivering value to customers. From my last 7 years experience, I would opine that doing business with Private Companies is easier than doing business with Public Limited Companies.

  • Purchasing machinery is a major investment for most buyers and they would need technical inputs and customization. What level of pre-sales support do you offer?

We provide all the important technical details about the machinery with photographs. Through JM Machinery, we can aid in design and engineering from concept thru completion of the desired machine. If the customer insists on Physical Verification Report then physical verification is carried out by our principals’ engineers and a report is provided. The client has the liberty to visit for physical verification if the machines are available at our warehouse in USA.

  • Are you launching any new products?

We are targeting the rubber industry in Europe & USA to export our range of new machinery from India. We have recently bagged an order to design, manufacture and supply a NEW BATCH OFF for Europe. This is expected to be despatched by end of September 2015.

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For full conversation and other details of Pracsol, access this special edition of Know Your Supplier in PDF here.

Meanwhile, here is a quick overview of industries covered by Pracsol and Harish Nene’s contacts if you would like to reach him quickly.

Pracsol-Small-Ad


Know Your Supplier is an advertorial initiative of Rubber Machinery World and all information are as provided by the supplier. If you desire to know more, kindly reach out on the contact details provided or write to me stating the additional details you seek on this supplier.

And if you would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at rubbermachineryworld@gmail.com for your customized offering.


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Tyre Machinery Industry: What to Expect?

At a recent event organized by a major automation brand, I had the opportunity to sit through a customer presentation (a leading tyre brand). A well articulated presentation, the speaker outlined the challenges that the tyre producers are facing in business today – increased competition on price, quality and delivery, pressure to reduce the tire development life cycle, enforcement of modular processes, perform with fewer employees and frequently changing product demands.

I bet that a tire producer three or five-year back would have presented these same set of challenges as the major concerns for their business. So what’s new and why are these concerns still valid?

It’s the fast pace of change!

Tug-of-War

Image from Web

Competition Galore

Tire manufacturing is a highly competitive field and faces volatile changes. The whole ecosystem of tire manufacturers, raw material suppliers, and machinery manufacturers are affected by industry consolidation, innovations in technology, labeling and safety requirements, increasing government regulations, shifting customer demands, and the pressure for lower customer prices.

For example, car manufacturers are focusing on energy-saving technologies. Translated to tyre, machinery experts feel energy-saving tyres will be a major focus area on the tyre equipment sector over next few years. As a machinery manufacturer, you must ensure the tires produced using your machinery has the highest manufacturing accuracy to meet the customers’ specifications in their local markets and overall quality standards.

Tyre manufacturing is a complex process. A fault or improper procedure at any of these stages threatens the structural integrity of the tire. And, tyre manufacturers demand the highest productivity from every stage of their manufacturing process. This means as a machinery manufacturer, you must cater to their demands of machines that offer high production output, manufacturing accuracy, reliability and product quality with low processing and maintenance costs and lowest possible manpower.

Over the next few years in tire machinery sector, you will have just two segments – “Chinese” & “Non-Chinese”. This thought first occurred to me a few years back. But in the recent times, I have heard this statement echoing strongly from peers in the industry. There is a handful of technologically strong tyre machinery manufacturers in China and some others are fast growing. I would not get into the industry perceptions because then I could digress.

However, this means that every tyre machinery manufacturer is continuously challenged to evolve rapidly in technology offered and differentiate globally. Also, the machines that you manufacture should possess the flexibility to adapt to changing trends in tire dimensions and complex designs.

Tyre Building Machines (TBM’s) and Curing Presses will be under intense scrutiny by tyre manufacturers for various reasons.

Tyre Building Machines

In TBM, it would be more to do with design and automation. A TBM assembles all components such as tread, sidewall, inner liner, body ply, bead, and cord body together to build green tyres. Each cycle is programmed to carry out the various operations automatically and concurrently, to give a balanced building cycle.

VMI_TBM

Image: VMI Holland

Automation of TBM especially for quicker synchronization of machine sections, including let-off, feed cutter, splicer, and wind-up; achieve better tension and edge control, ergonomics and operator safety, higher accuracy of cut-to-length independent of machine speed, slip correction between belts and tire building material; and capability to make adjustments in tire dimensions with demands for advancements in fault diagnosis would be more rigorous.

Tyre producers are regularly involved in either green field or brown field projects to meet their growing market demands. They demand from you the lowest set-up time for TBM integration, mechanical and electrical optimization and wiring. Leading TBM manufacturers like VMI have advanced models for cycle times of 36 seconds, full hands-off/eyes-off production, with automatic splice checking systems, a robot for green tire removal, connection to a green tire transport system, apexed bead unstacking and loading.

Tyre Curing Press

Curing is the process of applying pressure to the green tire in a mould in order to give it its final shape.  This is traditionally the bottleneck of every tyre manufacturer. For curing presses, the emphasis would be on enhancing the process efficiency and reducing the energy consumption.

One visible trend among tyre manufacturers is to produce smaller lot sizes. This will require more moulds and more frequent mould changes. Quick mould-change devices will become a unique selling feature for machinery builders to compete on. Leading manufacturers like HF have models that achieve the mould-change-time in less than 30 minutes.

HF_curing press

Image: HF

Hydraulic curing presses are preferred (over its mechanical counterparts) because they have repeatable accuracy over their life time. Secondly, they offer higher output which keeps the tyre manufacturers process cost under control. To improve the process efficiency and reduce curing time, post cure inflators are desired.

Curing presses occupy a large real estate space within a plant. So when the curing press manufacturers offer equipment with high-efficiency, tire manufacturers save substantially – not only by reducing the investment in quantity of machinery required (CAPEX) but also in terms of space utilization. Jacob Peled, Executive Chairman of Pelmar Engineering, foresees that split curing (tread and carcass separately) will eventually dominate the industry.

Summarizing, it’s the rapid pace of change faced by tyre producers that is driving the tyre machinery manufacturers to invest more in R&D, evolve rapidly in technology and offer customized automated solutions for maximum output to their customers. For tyre manufacturers, the consequence of increasing the automation to eliminate human errors will be that stringent testing on 100 per cent of tyre production will be a binding procedure in future.


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The Ultimate Guide to Asset Management

If you had read my earlier post “A New Hope: Top 6 Things I Learnt At NRC 2015 Mumbai“, then you would have also read my learning from Naushad Shikalgar of J.N.Engineering – ‘Proactive Machinery Maintenance is not an expense and is an investment that has long-term benefits’.

Maintenance is important in any organization. Without proper maintenance, assets deteriorate over time reducing the quality of your output produced. It can also impact the safety of your asset or your people who operate it.

Traditionally, maintenance has been viewed as a cost center in an organization because it costs you money to hire maintenance technicians and purchase the spare parts to keep your systems running smoothly. Too often, senior executives ignore the value-add that maintenance can bring to your organization. These include:

  • A reduction in reactive maintenance costs
  • Reducing costs to restart production after a breakdown
  • Limiting production scrap
  • Costs of downtime such as missed orders and lost revenue
  • Customer perception/satisfaction
  • Improved quality of products
  • Reduced environmental impact

 

By definition, Asset management is a systematic process of deploying, operating, maintaining, upgrading, and disposing of assets cost-effectively.

During his talk, Naushad spoke extensively on Asset Management Strategy-Plan-Execution including the various approaches to maintenance that I found interesting and hope you too would like it when you read. Hence, I have reproduced the 34 slides (click on the picture below) here that effectively forms a comprehensive guide on asset management.

Asset Management

Click on Image

Summarizing, asset management focuses on assuring your people, parts and processes are optimized to improve asset performance. Reducing inventory, maintenance costs and the number of downtime events raises your productivity, while simultaneously driving financial performance and predictability. It also helps your employees with the right tools to make good decisions about driving your plant performance.

Do you agree? How do you look at Asset Management?


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