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Turnkey TSR Processing Experts – Know Your Supplier

If you are into rubber sourcing, you already know that introduction of Technically Specified Rubber (TSR) has standardized the rubber grading (as compared to RSS) and simplified procurement for buyers. Depending on the origin, you get Standard Malaysian Rubber (SMR), Standard Thai Rubber (STR), Standard Indonesian Rubber (SIR), Standard Sri Lanka Rubber (SSR), Standard Vietnam Rubber (SVR), Indian Standard Natural Rubber (ISNR), etc.

Setting up a TSR production line demands a uniquely different series of main and allied machinery lines (starting with cup/crumb rubber to bales from stacked rubber sheets). More importantly, you need an expert to guide you well.

At Rubber Machinery World, our effort to bring you information on an equipment supplier’s Competency, Capacity, Commitment, Communication, Technology, Market Presence, Culture and other details that you seek; continues with this advertorial of ‘Know Your Supplier’.

In this post, I introduce you to a two-decade old Turnkey TSR Processing Machinery Supplier based in India and expanding fast.

Hevea Engineering Works Pvt. Ltd  is into Design, Manufacturing, Supply, Installation, Commissioning and Service of machinery for TSR Processing and Rubber Moulded Goods Industry since 1996 with a glowing reputation in India and overseas.

Hevea Engineering Works

From an exhaustive interview with Tom C. Abraham, Director, we understand that Hevea Engineering Works (HEW) is fast building on its reputation and expertise of very strong pre-sales consulting, customized machinery design and post-sales support for Turnkey TSR processing.

I reproduce for you a teaser of our conversation in this post. Please do read full interview to comprehensively Know Your Supplier on this special edition here or by clicking on the below image.

Hevea_Engineering_Works_Magazine

Flip through Full eEdition

Q. What are the major strengths of Hevea Engineering Works? How do you add value to TSR equipment buyers?

We have established a strong base in TSR processing machinery in last 20 yrs. We understand the complete TSR value chain – right from cup rubber to final usage. This gives us the unique perspective to recommend the right solution to our customers. The ‘solution’ can vary from as basic (though important) as consulting on plant layout and design to supply of customized machinery for TSR processing. For example, you would benefit from different designs for a DRC of 45% as compared to DRC of 80%. Again machinery varies for latex processing, field coagulum, or RSS reprocessing. We understand TSR best. We improve our designs regularly based on our customers’ feedback. Additionally, at our own production facility, we test our products.

This means when customers buy from us, they can be assured of machinery that is improved in design, are user-friendly and has low maintenance.

Competitive pricing is another big strength with us because we control the design and manufacturing in-house.

Q.  I see that you have a vast range of equipment for TSR industry. So, what products and services can a prospective buyer expect when they come to you?

TSR Processing machinery selection can be complex for a new entrant while established processors understand the nuances well. This is because depending on the nature of the raw material (for example latex processing, field coagulum, RSS reprocessing, etc) the machinery design, usage and functionality vary. At HEW, we understand the TSR value chain comprehensively. This means when a prospective buyer comes to us he could discuss his requirement of main TSR Processing Main Machinery like Slab Cutter, Pre-Breaker, Hammer Mill, Creper, Shredder, Dryer, Hydraulic Press together with the supporting machinery Conveyor, Grab Bucket, Crumb Filling Station, Bucket Elevator, Scrubber, Metal detector, etc. For new projects, we recommend that buyer involves us from start like site selection/planning, layout design, machinery selection and a detailed cost estimate. We also help in providing electrical data, water requirements, Effluent Treatment etc. This is highly advantageous for the customers, as it saves a lot of initial time and money, and also greatly reduces the project execution time.

Lately we have diversified into rubber moulding machinery like intermix, kneader and moulding presses. An existing user can discuss with us his reconditioning or service requirements in these ranges of machinery.

Summarizing, our endeavor is to provide quality machinery at a competitive price and continue building our list of satisfied customers in India and abroad.

Q. How do you differentiate yourself as well as compete on price of your products with other brands in the market and of course with the cheaper SE Asian machines?

Hevea Engineering Works has been designing and manufacturing TSR processing machinery since 1996. We did our first export to Srilanka and In 2007, we also set up the first TSR processing factory in North-East India for our customer. Since then, we have built on our strengths of delivering high quality product at competitive pricing, leveraging in-house design and engineering capabilities to customize. Our expertise in TSR processing machinery is built both from our acquired knowledge of the industry and our personal experiences. We have designed our Dryer to minimize the heat loss, yielding greatly reduced fuel consumption. Another example – our crepers, pre-breakers etc have been redesigned to greatly reduce maintenance schedules and costs. The increased machinery uptime influences the efficiency significantly. Our products are built to suit the raw materials available in each region. In India, the manufacturing capacity of a typical TSR plant is 40-60 tons per day. Our machines easily match this capacity. Because of these considerations, and also due to the relatively low manufacturing costs in India, our prices are very competitive. Further, in addition to our competitive prices, we are very strong on pre-sales consulting, customized machinery design, operator training and post-sales support.

So, if you are looking for highest Return-On-Investment with the quickest payback period, our product range is easily the right solution for you.

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Also, in this eEdition, for your comprehensive information we included a box, adjacent to pictures, explaining the utility of each machinery in a TSR Production Line. Download PDF Here

Meanwhile, here is a quick overview of TSR Processing Machinery Solutions from Hevea Engineering Works and their contacts if you would like to reach them quickly.

Contact_Hevea_Engineering_Works


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What the Heck Is Rubber Creper Machine?

Last month, on a visit to God’s Own Country and Land of Rubber – Kerala, I had the privilege of getting acquainted with a different class of rubber machinery namely the TSR Processing Machinery.

Most of you would know that TSR stands for Technically Specified Rubber. And for few hardcore rubber machinery enthusiasts, like me, TSR also means Twin Screw Roller.

So during my various interactions with rubber entrepreneurs, the words RSS, TSR and Creper were being spelt-out at frequent intervals.

Fortunately for me, RSS and TSR were familiar terms!

If you are into rubber sourcing, you already know that introduction of Technically Specified Rubber (TSR) has standardized the rubber grading and simplified procurement for buyers. This means, you now have the choice of not relying only on visual assessments (read RSS) that are subjective.

Instead, you assess the actual content of foreign and volatile matter in TSR to pick up the right choice of rubber grade according to your product processing requirement.

Depending on the origin, standards may marginally vary. You have Standard Malaysian Rubber (SMR), Standard Thai Rubber (STR), Standard Indonesian Rubber (SIR), Standard Sri Lanka Rubber (SSR), Standard Vietnam Rubber (SVR), Indian Standard Natural Rubber (ISNR), etc which I consciously leave for the rubber experts to comment.

During first few exchanges, I gathered that Creper referred to specific rubber machinery for TSR, while subsequent meetings helped me put together a first-hand perspective.

CREPER

Image: Creper by Hevea Engineering Works Pvt. Ltd.

So, What the Heck is Rubber Creper Machine?

To understand better, let’s start with a holistic view.

Any TSR production line (starting with cup/crumb rubber to bales from stacked rubber sheets) involves a series of main machinery and allied machinery lines as you will observe from the flow chart below.

TSR-Processing-Flow-Chart

Image: Processing Flow Chart From Web

And Rubber Creper Machine is the main TSR processing equipment used for cleaning, thinning and flattening. They are also known as ‘Crepe Rubber Machine’, ‘Macerator’ or just ‘Creper’.

It can flatten your rubber to creping piece which have a certain water and thickness prior to granulating.

Tom C. Abraham, director of Hevea Engineering Works Private Limited informs me, “This machinery can be used as a pre-cleaning or size reduction machine as well as for the blending of crepes prior to final size reduction.”

Tom definitely knows better since Hevea Engineering Works (HEW) is one of the leading TSR Processing Machinery Manufacturers having executed many turnkey projects in the last 20 years.

TSR Processing Units can be seen in Brazil, Cambodia, Cameroon, Congo, Gabon, Ghana, Guatemala, India, Indonesia, Ivory Coast, Liberia, Malawi, Malaysia, Mexico, Myanmar, Nigeria, Papua New Guinea, Philippines, Vietnam, and Thailand.

The sizes of the units do vary.

Construction of a Rubber Creper Machine

Structurally, a Rubber Creper consists of front roll and rear roll that are mounted on Cast Iron (CI) frames, adjusting mechanism, transmission mechanism, gear reducer, motor and heavy-duty Mild Steel base plate.

One Creper unit may consist of 1-5 sets of individual Crepers.

Mostly, the rolls are made of Cast Iron (CI) and the connecting gears are made of EN-8 material.

Operation of a Rubber Creper Machine

The Rolls of this Creper have special grooving that is designed for excellent shearing effect on rubber. The shearing effect reduces crepe thickness of rubber blocks and rubber granule.

Reduction in the size of the thick blankets of crumb rubber crepes happen at the intermediate second stages and final stage of the cleaning process. After several passes through the Creper, the crumb rubber can be easily dried without the occurrence (or appearance) of white spots after the trolley dryer in your TSR production process.

rubber-creper-machinery

Image from Web

The connecting gear mounted, with friction ratio imparts relative movement for the rolls, which makes the material flatten out. The shearing effect of the Creper together with the spraying of water on the rolls further assists in efficient dirt removing of foreign contaminants trapped in the rubber coagulum.

Simultaneously, this speed difference between front roll and rear roll induces knead action and shred rubber material into granulating shape, bar shape and honeycomb shape.

Various equipment suppliers offer you roll diameter sizes ranging from 8-inches to 24-inches with electric motor drives of 10 HP to 125 HP. Roll speeds, drive arrangement, friction ratio and grooving patterns can be customized and selected to suit your requirement.

The throughput of a Rubber Creper varies from 1 to 10 Ton DRC /hour depending on roll speeds. (DRC means Dry Rubber Content). Reputed manufacturers offer robust and accurately built Creper machine to meet your requirements.

Here’s a wonderful short animation video from Golsta that shows the Rubber Creper Machine, quite informatively.

Creper-Animation-Video

Click on the image to see video

While investing, you may have to decide the production capacity of Rubber Creper Machine according to your production line and layout requirements.

Adds, Tom C. Abraham of Hevea Engineering Works (HEW), “For a unit planning 40T/Day, your TSR processing line may need appropriate sizes of Slab Cutter (1 No.), Pre-breakers (2 Nos.), Hammer Mill (1 No.), Rubber Crepers (6-7 Nos.), Shredder (1 No.), Dryer (1 No.), Baling Press (2 Nos.) together with its ancillaries depending on your processing and/or layout. HEW’s advantage is we can consult turnkey and offer all of these machinery under one roof”.

Summarizing, a Rubber Creper Machine is the main machinery used for cleaning, thinning and flattening in your TSR processing. Different customized features are available helping you pick the right equipment meeting your requirement.

Let me know your thoughts on rubber creper.


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