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Rubber Machinery Selection Is An Art – Jacob Peled

Rubber Machinery selection is an art by itself and should be done by people who have visions, both technical and commercial, says Jacob Peled, Executive Chairman of Pelmar Engineering Ltd, Isreal in an exclusive interview with Rubber Machinery World.

(Starting this month, I bring to you a new series comprising of interviews with rubber leaders – aptly titled “Know A Rubber Leader in 10 Questions”. I hope you find the wisdom, experience and vision shared here inspirational and energizing.) 

Know A Rubber Leader

Here is Jacob’s full interview reproduced for you.

  1. Hello Jacob. First of all thank you for accepting an interview with Rubber Machinery World and sharing your thoughts. After a degree in Polymer Science and an MBA from Tel-Aviv University, you started Pelmar in 1966 and grew the brand to a revered name in reconditioned and pre-owned machinery, and tooling for the tire industry. Your growth history is fascinating and I have always found you very inspirational in our conversations. So, let me start with a personal question – Was your entry into Tire Industry planned or it just happened? Is there a story that could inspire and motivate the next generation of rubber leaders?

Thank you for your kind words. My entry to the Tire Industry happened as a combination of coincidence and probably hidden motivations. During my studies I worked as a compounder at Samson Tire and Rubber Co., which was a licensor of General Tires at the time. This has given me the first taste of rubber combined of course with a lot of dust, noise and dirt. Later on the same company has commissioned me to carry out a market survey for them, which showed me other sides of this fascinating industry. I have never left since – 49 years now.

  1. In our last communication, you cited that there have been very few changes in tire industry in the last 100 years. To a buyer, this is a surprise because their general perception is that tire technology is revolutionizing fast and leading tire producers compete on technology to garner market share. Could you elaborate on your view for our readers?

Indeed the changes in tire construction and production have not been significant, with the exception perhaps of the invention of radial tires by Michelin and tubeless tires by Continental.  Compounds have also developed to achieve better physical and chemical properties, but with relatively few significant improvements.

  1. How much of this stagnation or lack of change do you attribute to the machinery being used for tire manufacturing?

Tire rubber machinery have attributed to the slow development mainly because the function of machinery developed in the middle of the last century was satisfactory to the tire companies. The high prices of tires, combined with relatively low life expectancy, have caused the stagnation. Significant changes in automation of tire building only started approx. 15 years ago.

  1. At Tire Technology Expo 2014, you pointed out that tire production using the pre-cure method lends itself well to the manufacture of new tyres? Isn’t this unconventional? What changes in machinery would this demand on the shop floor for a tire manufacturer?

My concept at TTE2014 presentation indeed mentioned this as an option. Pre-cured tread achieved better results than virgin tread. This is true in many cases also in hot retreading, particularly on aircraft tires. This leads to the possibility of casings will be manufactured slick and the tread applied later, as per the market requirements. It enables keeping smaller stocks and fast response to customer wishes.  While this idea could be used on all tire sizes, I know that this has already started, but mainly on industrial tire production. The changes on the shop floor would not only be a result of using PCT. We shall see the gradual disappearance of duplex and triplex extrusion lines, as well as large calender lines, which will be replaced by strip-winders and roller-dies respectively.

  1. I observe that environment conservation has always been a subject close to your heart. However, rubber processing has always been and continues to be an energy intensive process with significant wastage. Is it possible to strike a balance? Are the rubber machinery manufacturers doing enough on this subject?

You are quite right. Environmental conservation and recycling have always been close to my heart. In fact, for many years and still true, retreading is the No. 1 recycling method in the tire industry. It is the most effective and economical. True enough, it is not a final solution, but it is the most significant preventer for more scrap tires in the landfills. Tire and rubber machinery and the process in general have traditionally been accompanied by significant wastage. This is changing very quickly in the last 10 years. The rubber machinery producers are paying a lot of attention and results are already there.

  1. What would future tire plants look like?

Tire plants will become smaller and more specialized in certain types and sizes of tires. Part of my answer is in Point 4. I also believe that future tire plants will have no compounding facilities of their own, as mixing would be done by outside custom compounders specialized in these products (similar in a way to what happened to fabric production and dipping).

  1. Which machinery or manufacturing technology, do you foresee, has the potential to disrupt the rubber and tire industry in the next 15 years?

Disrupt is probably not the right term to use. I suppose you mean what machinery will change significantly or disappear? As mentioned above, calender lines and extrusion lines will disappear. This is particularly true for innerliner calenders since innerliner will be replaced by a film, which is already being used by some tire companies.  Passenger tire building machines have already changed and their capacity increased to 35 seconds per tire and they will reach 10 or 15 seconds. This will require a change in curing presses, and particularly shortening curing time. Curing bladders will either disappear or be made to endure thousands of curing cycles.

  1. What do you envision for Pelmar in the next 10 years?

Pelmar will hopefully continue to expand its services to more parts of the world. It will deal more intensively with new machinery made to its design, which is already being done now. It will also be involved more extensively in equipment refurbishment and upgrading.

  1. What level of support can a customer, who desires to set up a green-field project, expect from Pelmar?

The support that a green-field customer can expect from Pelmar is A through Z services starting with engineering, technology transfer, complete plant design or alternatively a line. These will also include assistance in R&D, quality control, testing of end product and a future forecasting and continued assistance. The exception is any commercial activity related to tires, which we refrain from completely as an iron clad principle.

  1. Great! And one last question. What advice on “machinery selection” would you give to buyers in rubber and tire industry?

Machinery selection is an art by itself and should be done by people who have visions, both technical and commercial. Our advice is always to check references, compare technical capabilities and prices.

Download the full interview in PDF here.

I would love to hear your thoughts on this interview.

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Become an Expert on Tire Debeading Machine by Watching These 5 Videos

Tire Debeading Machine is an important machinery if you plan to recycle waste tire.And today in this post, I bring to you 5 videos that could make you an expert in comprehending this machinery.

So what exactly is a Tire Debeading Machine or Tire Debeader?

When you refer to a tire construction image, you will observe that every tire consists of a bundle of harmonic steel beads that act as the supporting structure of the tire.

Image of a Cut Tire

Tire debeader is a specially designed equipment to mechanically pull out the bead wires completely that are inside the sidewalls. After debeading, you send the tire for the shredding process. Removal of this bead bundle prior to shredding gives a cleaner end product and assures longer life of the operating blades of your shredder machinery. This allows a smooth shredding operation and also cuts down on your maintenance down time.

So now that you have the process concept clear, let’s look at these 5 videos (click on each picture for its video) that could deepen your understanding and make you an expert on tire debeading machine.

1.  Bead Remover

I found this video of Bead Remover by “Engineering & Equipment Co” as a good starting tutorial to understand tire debeading further. In this video, you will see the bead bundles cut out in a neat fashion from the side wall of a tire. Of course in this video, prior to this step, sidewalls have been separated from the tire with the sidewall remover (which is another machinery in itself).

Bead Remover

2. Manual Tire Debeader

This video by “Meliksah Makina” will introduce you to the feature of “hook” that is an essential feature of all tire debeaders. When you watch this video, notice how the hook shape surface latches on the edge of the tire, which has the bead bundle and pulls out the beads using sheer mechanical pull.

Tire Debeader 1

3. Semi Automatic Tire Debeader

This video by “Evashred Shredders” attracted my attention for its instructional nature. I am sure you too will find the operational instructions enhancing your knowledge on tire debeader machine and give you additional inputs on safety and operational ease of this machinery.

Tire Debeader 2

4. Heavy Duty Tire Debeader

This video by “AAA Engineering” is descriptive and increases your working knowledge on state of the art electronic controls, hydraulic and mechanical systems together with PLC and load sensing features introduced into a tire debeader machine.

Tire Debeader 45. Automated Mobile Tire Debeader

When you see this video from “Eagle International” for OTR Tires, you will appreciate the evolution of features in a tire debeading machine. Covered here is the advancement in automation, user friendliness, production efficiency and the mobility aspects of tire debeader. I trust you will agree.

Tire Debeader 3

Summarizing after watching these 5 videos, you now know that a Hydraulic Tire Debeading Machine is designed for pulling the bead bundle out of a tire that is being processed for recycling. You could select a tire debeader based on the maximum size of the tire, level of automation, transportation requirements, user friendliness you require or you can afford and the reputation of the manufacturer.

I would love to hear your thoughts on this post and videos.

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A Beginner’s Guide to Rubber Refiner Mill

Are you looking for a rubber refiner mill? Great. Now you try searching this key word in google or any other search engine and explore a few sites.

How many direct search results did you get without linkages to rubber mixing mills or two-roll mills? Even more importantly, how many sites gave you clarity of information you sought for on this category of rubber machinery? Less than 2-3, on the brightest side, if I may say so.

And this is why I am prompted to write a beginner’s guide to rubber refiner mill.

First things first. You need a rubber refiner mill mainly for the refining of reclaimed rubber. The operational ease and functional performance makes this mill your preferred machinery in reclaim rubber industry for refining pure and fine rubber powder from waste.

Refiner Rubber Mill

A Rebuilt Refiner Mill From Deguma

Similar in construction to an open mixing mill, you will observe that its distinguishing feature is that both the rolls have different diameter. The front roll is smaller in diameter as compared to the back roll. And hence when you see a refiner mill identified as 21″ x 24″ x 36″, you simply need to decode it as Front Roll diameter is 21 inches, Rear Roll diameter is 24 inches and both the rolls have same face length of 36 inches.

The Rear Rolls have a higher surface speed than the Front Rolls again a similar feature of a regular rubber mixing mill. However, in your refiner mill, the differential sized rolls turning at considerably different speeds provides a high friction ratio. The ratio of speed of your Front Roll to Rear Roll could vary in the range 1:1.75 to 1:2.50 depending on your process requirement.

When the rolls are set quite tightly to each other (i.e. close nip-gap adjustment of 0.05mm), refined rubber in thin-sheet form (~ 0.10mm) is produced. This sheet that you get is usually smooth, uniform and free of grain or lumps. In this refining process, the impurities contained in reclaimed rubber are squeezed by rolls to the both sides of rubber sheet which can be removed. Therefore, the purity of your reclaimed rubber is increased in refiner mills.

In the past, this finished rubber sheet was pulled towards a wind-up attachment and layered few times to increase the thickness of the sheet (approx. 25mm), post which they are cut using a hand knife by your operator (video from YouTube). The cut sheet are then dusted and stacked. Today some reclaim rubber manufacturers rely on balers to package the rubber sheets.

These sheets are stored and sold for a wide variety of end products like new tires (especially carcass, side-wall, under-tread of passenger, light-truck and off-road tires; inner liner of tubeless passenger tires; semi-pneumatic tires), tubes, automotive floor mats, de-vulcanisation for low technology pressed or extruded rubber goods, tread rubbers, adhesives, sealing and tape compounds, belting, battery containers, molded products, and rubberized asphalt.

Summarizing, though Rubber Refiner Mill is similar in appearance, construction and features of safety and operation; as a beginner, you simply need to absorb that these are special types of two-roll mill used in reclaim rubber industry to produce smooth and homogeneous rubber sheets.

Would you like to add more thoughts?

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