Rubber & Tyre Machinery World

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Global Approach To Rubber Machinery Technology

Make in India is an initiative launched by the Government of India in 2014 to encourage multi-national and national companies to manufacture their products in India. While this initiative has garnered significant international attention and keenly watched, few Indian machinery companies have been steadily building up their repute with global approach and right technology.

In this special edition of Know Your Supplier’s cover story, we feature one such company Bharaj Machineries Pvt. Ltd., through an interactive conversation with Amardeep Singh, Director – Sales & Projects.

Established in 1982 with a vision, to always produce most advanced and quality machinery for the rubber industry, Bharaj has transformed into a giant machinery supplier. Read the full interview here of how Bharaj’s aspiration to be leaders in their various business segments’ is filled with passion and backed with technology.

KYS Cover-June-2016

Click image to read

(This digital edition is available on Youblisher and Yumpu)

Based in Mumbai, India, Bharaj manufactures and supply high-quality and advanced machinery for the rubber industry. They specialise in rubber mould manufacturing, rubber moulding, extrusion and mixing technology.

They are a preferred choice for many rubber related industries starting from Tyre, Automotive, Sports, Footwear, Pharmaceutical, Aerospace and Specialized Silicon Rubber Industry with exports to USA, UK, France, Canada and many Asian Countries.

Here is a teaser from the interview.

Q) What products and services can a prospective equipment buyer expect when they approach you?

ASB: Yes, we offer complete solutions in rubber mould manufacturing, rubber moulding, extrusion and rubber mixing areas. Bharaj designs and manufactures latest technology rubber machinery that saves power, compact in size, has low maintenance, requires minimum labour through smart automation and are user-friendly. Our prospects can choose from a range of Cold Feed Extruders (Plain/Vent Types), Heavy duty Rubber Mixing Mills, Rubber Dispersion Kneaders, Hot Feed Extruders, Refiner Mills, Cracker Mills, Grinding Mills, Calenders with complete lines, Batch-Off Units, Vulcanizers, Bale Cutters, Conveyors, Stock Blenders, Vacuum Compression Type Rubber Moulding Machines, etc.

Bharaj Machineries

Q) How do you compete technologically on your product offerings? 

ASB: Starting as a small manufacturing unit, today Bharaj Machineries has evolved into a well-respected machinery supplier for the rubber industry in India as well as in the Global Market in the areas of rubber mould manufacturing, rubber moulding, extrusion and mixing technology. We focus on providing high quality machinery at a competitive price. The wide range of quality machinery made by Bharaj is well-accepted worldwide. Our competitively priced equipment performs consistently and we extend prompt back-up. We export to developed countries like USA, UK, France, Canada and many Asian countries. Hence, it is also apt to mention here that Bharaj manufactured machinery are considered as a first choice for many rubber related industries starting from Tyre, Automotive, Sports, Pharmaceutical, Footwear, Aerospace and Specialized Silicon Rubber Industry. Depending on the equipment, we offer quick delivery to our customers. Some of our equipment is delivered in as low as 25 days.

Download PDF of this special edition here

As they pursue global growth, Bharaj management respects and value every equipment buyers’ desire for optimum technology in their production floor. Emphasizes, Amardeep Singh Bharaj,

“We recommend the right machinery with right features that gives our customers the best return on his investment. This means we consult him on equipment selection to match his production process, share layout drawings and take great care to clarify his genuine queries in the most practical manner feasible. Depending on availability, we arrange equipment visits for our prospects either at our 30,500 Sft ultramodern and state-of-the-art manufacturing plant near Mumbai or at any of customer sites.”

I hope you find the contents on this leading rubber and tyre industry equipment supplier, and their global approach to rubber machinery technology, informative .

Below is the rubber machinery supplier info image-card of Bharaj Machineries and their contacts, if you would like to reach them quickly.

Bharaj Info Card

In addition, we have two other knowledge-enriching topics from our portal in the ‘Insight’ and ‘Tips’ sections of this special edition.

Let me know your thoughts.


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Why We Love Gear Coupling (And You Should, Too!)

First things first! You choose a coupling to connect two shafts together at their ends to transmit power. The primary purpose of coupling is to join two pieces of rotating equipment while permitting some degree of misalignment or end movement or both.

Normally, couplings do not allow shafts to disconnect during operation, however there are torque limiting couplings which can slip or disconnect when some torque limit is exceeded. Hence, you should carefully select, install and maintain couplings; as this could give you substantial savings in the form of reduced maintenance costs and downtime.

Gear Coupling

A gear coupling is a mechanical device to join two rotating shafts (that are not collinear) for efficient transmission of mechanical power. These are crucial because although you may align the shafts (for example, between the gearbox and the mixing mill roll) at the time of installation, it is likely that during the operation there may be disruption to this alignment.

Disruptions could occur due to setting of foundation, thermal expansion, shaft deflection, wearing out of other parts, improper maintenance and many more reasons. At these times, where the misalignment occurring during the operation is unavoidable, a gear coupling compensate or minimize the effect of misalignment thus providing a good solution to prevent your rubber machinery, bearings, seals and shafts from being subjected to the additional forces.

Gear couplings are power intensive and considered as the king of the coupling types. You would see the gear couplings being adopted for wide range of application in drive technologies. Hence, we love love gear coupling (and I think, you would too!).

Gear Couplings and Universal Joints

Gear couplings and universal joints are used in similar applications. Gear couplings have higher torque densities than universal joints designed to fit a given space, while universal joints induce lower vibrations. The limit on torque density in universal joints is due to the limited cross sections of the cross and yoke.

The gear teeth in a gear coupling have high backlash to allow for angular misalignment. The excess backlash can contribute to vibration.

Structure of a Gear Coupling

Gear couplings are torsionally rigid and consist of hubs with multi crowned teeth at flank, tip and chamfering on teeth, gaskets, sleeve and O-rings. The hubs attach to the machinery shafts, and sleeves span the gap from one hub to the next. They are available in two designs – completely flexible and flexible/rigid.

The hub is the heart of any gear coupling. Hence manufacturers take great care to impart a superior design and mostly manufacture the hub on CNC machine for precision. Together with the tooth profile of the hub, these aspects enable the gear coupling to function well under all operating conditions with increased reliability and long life.

The tooth flanks and outer diameter of the external gear are crowned to allow for angular displacement between the two gears. The multi crowned teeth reduce the alignment adjustment and improve the load carrying capacity of the teeth. The backlash between the teeth is minimal due to multi-crown tooth design.

A completely flexible coupling comprises two hubs with an external gear and two outer sleeves with an internal gear. It’s a universal coupling for all sorts of applications and accommodates all possible misalignment (angular, radial and combined) as well as large axial moments.

Structure of a Gear Coupling

A flexible/rigid coupling comprises one flexible geared half and one rigid half. It does not accommodate parallel displacement of shafts but does accommodate angular misalignment.

Information to order Gear Coupling

When you are buying rubber machinery, your machinery supplier or OEM would take care of this. However, you need to understand that there is a check list of information that needs to be provided to a gear coupling supplier that includes,

  1. Specify quantity required and delivery expectations.
  2. Specify shaft or bore sizes and key-way dimensions. You need to give exact dimensions with tolerances.
  3. Specify load – HP and/or torque at a specific RPM. State the normal and maximum conditions of use.
  4. Specify Speed of operation – Minimum, Normal and Maximum.
  5. Specify Application. Most Rubber & Tyre Machinery (Mixers, Kneaders, Mills, Calenders, Extruders, etc) conforms to a service factor classification where heavy shock conditions or frequent reversing peak loads that do not exceed 150 per cent average horse power is observed. Uneven load is usually present during operation. Service factor ranges from 1.25 to 1.50.
  6. Specify Coupling Series, Type and Size.
  7. Specify Space limitations – envelope dimensions, shaft extensions and shaft spacing.
  8. Specify unusual misalignment conditions if any.
  9. Specify Modifications – tapered bores, special keys, hub cut off, counter bores or others
  10. Specify unusual operating conditions ambient temperatures and atmospheres, if any.

Maintenance of Gear Coupling

Gear Coupling maintenance is mostly simple – requiring a regularly scheduled inspection of each coupling. Your schedule should consist of:

  • Performing visual inspections – checking for signs of wear or fatigue, and cleaning couplings regularly.
  • Checking and changing lubricant Each coupling half is provided with grease nipple/plug on the housing from where grease can be filled directly. The coupling is supplied with some quality of grease to facilitate assembly. It is recommended to fill the required quality and quantity of grease before putting the coupling in operation. This maintenance is required annually for most couplings and more frequently for couplings in adverse environments or in demanding operating conditions.
  • Documenting the maintenance performed on each coupling, along with the date.

Here’s a 1:17 min video of dismantling of a gear coupling so you could appreciate the components that make-up this coupling much better.

Video of Dismantling of A Gear Coupling

Video

Failure of Gear Coupling

Caution! Even with proper maintenance, your gear couplings can fail. The other causes of failure include:

  • Improper installation
  • Poor coupling selection
  • Operation beyond design capabilities

The only way to improve your coupling life is to understand what caused the failure and to correct it prior to installing a new coupling. You could check for some external signs that indicate potential coupling failure like,

  • Abnormal noise, such as screeching, squealing or chattering
  • Excessive vibration or wobble
  • Failed seals indicated by lubricant leakage or contamination

Summarizing, gear coupling is a mechanical device to join two rotating shafts for efficient transmission of mechanical power, are power intensive and is the king amongst the coupling types. They offer the highest load capacity and stiffness, yet easy to maintain. These are some of our reasons to love this gear coupling on the rubber machinery. 

Do you have more? Let us know your thoughts.


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10 C’s of Supplier Evaluation That Benefits You Quicker

Have you ever finalized and transacted with a supplier, only to realize, later, that you’d made the wrong choice?

This could be in any form.

For example, you may have found a supplier that offered a good price, but later realized that its quality standards were low, or that its communication was unacceptably poor.

Or in cases of sub-contracting, equipment supplied and branded with your logo are substandard.

It makes no difference what business you are in; suppliers and vendors play a key role in your company’s success.

The real cost of mismatches between your needs and a supplier’s offerings are not always obvious. Such mismatches can add costs, delay projects and even damage your organization’s reputation when the equipment supplied is substandard.

Selecting your right supplier (for machinery, equipment or spares) includes much more than a focus purely on cost.

If you are actively involved in supplier selection you already know that it can be an exhaustive process. Because there are a wide range of variables to consider that make the supplier selection process complex and time-consuming.

You may introduce standardization criteria through an assessment framework or template for selecting suppliers. Having a formalized system in place to track and evaluate supplier and vendor performance is essential to the smooth operation and profitability of your company. This also helps you level the playing field whilst giving you a standardized procedure removing some of the guesswork from the process.

But how should you evaluate your potential suppliers? Here’s where Ray Carter’s work assumes significance.

To the uninitiated, Ray Carter (Director of DPSS Consultants) first outlined his Seven Cs of Supplier Evaluation in a 1995 article in ‘Purchasing and Supply Management’.  He later added three new Cs to the model.

The “10 C’s of Supplier Evaluation” help you avoid supplier or vendor problems. Such a checklist helps you to outline organizational needs, understand how suppliers can meet them, and identify the right supplier for you.

10-Cs-of-Supplier-Evaluation

While your criteria of selection for rubber and tyre machinery suppliers may be subtly different – developing a standardized set of requirements will help simplify the process and remove subjectivity.

So what to consider in 10 C’s of Supplier Evaluation that benefits you quicker?

  1. Competency:

Does your supplier have the skills to deliver the products you require?

This is fundamental to being a good supplier and competency needs to have evidence to back it up, there is no point in you simply making assumptions. Your supplier needs to provide hard evidence.

So, make a thorough assessment of the supplier’s capabilities measured against your needs, but then also look at what other customers think. How happy are they with the supplier? Have they encountered any problems? And why have former customers changed supplier?

When you evaluate, look for customers whose needs and values are similar to yours, to ensure that the information you gather is relevant to your organization.

  1. Capacity

Your supplier needs to have sufficient capacity to enable it to operate flexibly. The more flexible the supplier is, the more it can meet fluctuations in demand.

Look at the supplier’s entire resources (including staff, equipment, storage, and materials). Does it have the resources to meet your needs, particularly when commitments to other clients are considered? Can your supplier flex their capacity in line with your requirements?

The supplier needs to have enough capacity to handle your firm’s requirements. So, how quickly will it be able to respond to these (and to other market and supply) fluctuations?

  1. Commitment

Quality is a key requirement for any business.

Your supplier needs to provide evidence that it’s committed to high quality standards. Wherever appropriate, look for quality initiatives such as ISO 9001 and Six Sigma, within the supplier organization.

The supplier also needs to show that it is committed to you, as a customer, for the duration of the time that you expect to work together. This is particularly important if you’re planning a long-term relationship with the supplier. You’ll need evidence of its ongoing commitment to delivering to your requirements, whatever the needs of its other customers.

Does your supplier have the commitment to maintain suitable quality performance?

  1. Control

Query how much control this supplier has over its policies, processes, procedures, and supply chain. Control is important because it is control of the processes and internal procedures that needs to be looked at, so that a full profile can be established of the supplier and how much control the supplier has.

Control can take various forms, for example, how much control does the supplier have in terms of its suppliers warning it when goods become scarce or even stop being produced.

So there are lots of different aspects to control. Is your supplier in control of their policies and procedures? How will it ensure that it delivers consistently and reliably, particularly if it relies on scarce resources, and particularly if these are controlled by another organization?

  1. Cash

This is the financial standing of the supplier. Your supplier should be in good financial health.

Cash-positive firms are in a much better position to withstand the ups and downs of an uncertain economy. So, does your supplier have plenty of cash at hand, or is it overextended financially? And what information can the supplier offer to demonstrate its ongoing financial strength? Does your supplier have adequate financial standing? Are they in a robust position or are they teetering on the edge of financial meltdown?

  1. Cost

Look at the cost of the product that this supplier offers. You will find it interesting to observe that cost is not listed as the No. 1 issue and is in the middle of the 10 C’s of Supplier Evaluation list for a reason: other factors, such as a commitment to quality and financial health, can potentially affect your business much more than cost alone, particularly if you will be relying on the supplier on an ongoing basis.

What is the cost of products from the supplier? How does this compare with the other firms that you’re considering?

(On a related note, you may also read our post on Total Cost of Ownership)

  1. Consistency

How will this supplier ensure that it consistently provides high quality goods or services?

No one can be perfect all of the time. However, the supplier should have processes or procedures in place to ensure consistency. Ask your supplier about its approach, and get a demonstration and a test product, if possible.

Does your supplier guarantee a consistent product time and time again?

  1. Culture

This is an interesting point. Carter felt that the supplier should be one that has the same values and ways of operating as the customer. In a sense this is almost about compatibility, but it makes sense for the supplier and the customer to have some shared values and practices, otherwise the relationship could be strained in the future, simply due to the clash in different cultures.

The best business relationships are based on closely matching workplace values. For example, what if your organization’s most important value is quality and your main supplier cares more about meeting deadlines? This mismatch could mean that it’s willing to cut corners in a way that could prove to be unacceptable to you.

So evaluate, does the supplier share the same cultural values as your organization? Does it make sense that your supplier shares similar values and attitudes to avoid strains in the future relationship?

  1. Clean

This is a reflection of increased environmental awareness and refers to your supplier’s commitment to sustainability, and its adherence to environmental laws and best practices.

So in a sense, suppliers are asked to demonstrate their ‘green credentials’. What is it doing to lighten its environmental footprint? Ask to see evidence of any green credentials that it’s earned.

Also, does this supplier treat its people (and the people around it) well?  Does it have a reputation for doing business ethically? Does your supplier have an appropriate sustainability policy?

  1. Communication

Although it may seem obvious, query how the supplier plans to keep in touch with you. Will it be by fax, email or telephone?

Communication also covers the ICT software and applications that the supplier has. What tools will you utilize to communicate with your supplier? Will its proposed communication approaches align with your preferred methods? And who will be your contact person at this firm?

It’s also important to find out how the supplier will handle communications in the event of a crisis. For example consider how you will manage problem resolution and issue escalation. How quickly will it notify you if there’s a supply disruption? How will that communication take place? And will you be able to reach senior people, if you need to?

Summarizing, the Carter 10 C’s of Supplier Evaluation model is an internationally recognized approach, taught in procurement studies, and acknowledged as an all-inclusive means of making sure that a thorough method is adopted to evaluate suppliers in a fair manner for all potential entrants.

How do you evaluate and select your suppliers?


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The Collectors Edition Of Most-Read Topics in 2015

The year 2015 has been an exciting one for RUBBER MACHINERY WORLD. This portal now brings to you increasing range of topics on rubber and tyre machinery regularly.

A passion that started out on Valentine’s Day to share information on machinery is now a well regarded Knowledge Portal on Rubber & Tyre Equipment closing in on 40k hits with a fast growing reader base of equipment buyers across 5 continents.

As 2015 draws to a close, reflecting on your progress is a sure way to move ahead. Because, though you cannot change your past, by learning from the ‘misses’ and building confidence from your ‘hits’, you can ‘plan’ for greater success in 2016.

Till date this year, we received amazing feedback on the differentiated style of presenting valuable knowledge concisely in a refreshing, simple and easy-to-access manner. Few topics really stood out for the reader’s interest and its recurring need.

In this concluding issue of 2015, we chose to reciprocate your appreciation and feedback in the most apt manner. So, we compiled the 3 most-read topics on our portal into a single ‘collector’s edition’ for your quick reference always.

Here’s the collectors edition of 3 Most-Read Topics in 2015

Collectors-Edition-Best-of-2015

Click on the cover image above to flip through or download PDF

I hope this collector’s edition of Rubber & Tyre Machinery World’s e-Publications finds space in your digital library – either as your favorite bookmarks or valuable PDF downloads.

I wish you Happy Holidays, Merry Christmas and A Prosperous New Year. May all your dreams turn into reality and all your efforts into great achievements in 2016.

Please continue to encourage, help us improve with your feedback and comments in 2016 as well.

(Disclaimer: Any pictures and quoted statements in our special supplements 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.)


If you liked this article, please do share with your colleagues, customers and friends. And If you would like to be informed of our articles regularly, please register with us for free updates today.

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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8 Common Defects In Rubber Calendering (And How You Can Fix It)

Rubber Calendering, the mechanical process by which rubber is pressed into textiles (cloth, fabric, tire cord) forming composite sheets, is amongst the oldest rubber processing technology.

Today, you have a wide range of new and used calender purchase options (albeit of varying nature of quality, features and durability) for your budget. And this post is not on price or quality.

Rather I draw your attention on a more significant aspect of rubber calendering – operating this rubber machinery itself.

You could have chosen your rubber calender wisely but if you do not operate it smartly, you are likely to have defects in the calendered sheet. And when you know the causes leading to the defect, it becomes easy for you to investigate them deeper,  resolve and continue production.

So, here is a detailed info-sheet of 8 common defects in rubber calendering (and how you can fix it)

8-Common-Calendering-Defects

Summarizing, while choosing the right rubber calender is important, learning to operate it smartly to avoid these 8 common calendering defects is equally key for your success with this machine.

Let me know your views.


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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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Rubber Calenders At A Glance

From our earlier post,  you would already know that a Rubber Calender is heavy-duty rubber machinery consisting of two or more rolls that revolve in opposite directions. And that the Classification of Rubber Calenders is based on

  1. The Number of rolls
  2. The Position or Orientation of the rolls

Precisely, the reason why you will see various rubber calender manufacturers offering you,

  • 2-Roll Horizontal Type Calender
  • 2-Roll Vertical Type Calender
  • 2-Roll Inclined or Tilted Type Calender
  • 3-Roll Vertical Type Calender
  • 3-Roll Offset Stack Calender
  • 4-Roll Vertical Type Calender
  • 4-Roll Offset Stack Calender (Inverted ‘L’ Type)
  • 4-Roll Offset Stack Calender (‘S’ Type)
  • 4-Roll Offset Stack Calender (‘Z’ Type)

Your selection of the type of rubber calender depends on the calendering process you require.

Here is a info-sheet to help you grasp the different rubber calenders quickly.

Know Your Different Rubber Calenders At A Glance

Rubber-Calenders-At-A-Glance

Know Your Different Rubber Calenders At A Glance

Download this Info-Sheet in PDF

Let me know if you found this info-sheet informative.


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Do you have any blog suggestions? Let us know on rubbermachineryworld@gmail.com