EQUIPMENT.

Energy-saving extruders

MCTD extruders offer users appreciable savings in power because plasticization of the compound is done by mechanical shear instead of by frictional heat developed between the screw and the barrel. This means that less power is required to do the same job. Since all the compound mixing is done in short MCTD sections, there is no need for long L/D ratios. The MCTD-60 non-vacuum extruder is available with an L/D ratio of 10:1. (Kiffer Industries, 4905 Rocky River Dr., Cleveland, OH 44135)

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Low temperature hot oil unit

The Value Line hot oil unit is said to offer excellent temperature control and easy operation at an affordable price. With a maximum operating temperature of 400 [degrees] F, the Value Line series was created for low temperature hot oil applications. The Value Line is specially designed for convenience, according to the company. A premium is also said to be placed on protecting the operator, the process and the oil. (Budzar Industries, 38241 Willoughby Pkwy., Willoughby, OH 44094-7582)

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Internal mixer

Intermeshing rotors on the company's internal mixer are said to deliver improved performance over the previous generation of rotors in many aspects such as temperature control efficiency and increased filling factor. The internal intermeshing mixers are said to be specially suited for sensitive robber and robber-plastic compounds. (Gumix, s.a., Maria Fortuny, 9-11, P.O. Box 18, Cornella (Barcelona), Spain 08940)

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Gear extruder

Uth gear extruders operate independently or in tandem with a screw extruder. This unit can be used as a pre-feed device into a single screw extruder for high quality rubber straining with minimal extrudate temperature rise, according to the manufacturer. It can also be fit to the outlet of the extruder, with the necessary options, for improving output stability in selected applications. The two roll feeder will feed single or multiple strips into the process unit and the rate of the feeding is adjustable via a ratio setpoint or by pressure regulation. The complete unit is said to be prepiped and wired on a common base. (Davis-Standard, 1 Extrusion Dr., Pawcatuck, CT 06379)

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Injection molding 

This state-of-the-art rubber injection molding machine comes complete with Rexroth hydraulics and AB control systems. Shot sizes up to eight pounds or more are available, as well as platens supplied to accept other brands of injection molds, according to the company. Quick mold change mechanisms and automatic unload/load systems are available for turnkey projects. (Sanyu USA, 1725 Corporate Woods Pkwy., Suite #A, Maumee, OH 44685)

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Rotary shears 

Rotary shears cut uncured rubber ranging from thin calendered sheet to densely loaded slabs up to one inch thick and 70 inches wide. Built for continuous production of master batch slabs, and transfer press and compression mold preforms, the machines are said to cut all robber products (including those on PVC liner sheets) cleanly and accurately at feed rates from one to 150 ft./min. Six models handle material up to 16, 24, 32, 42, 60 and 70 inches wide. For cut lengths over 30 inches, or speeds less than 40 cuts/min., the cutter head makes single revolutions on-demand, driven by a large flywheel rotating at 200 rpm, which is engaged by a pneumatically actuated clutch brake. Each cut is made in approximately 0.3 seconds. For cut lengths under 30 inches or rates exceeding 40 cuts/min., the cutter head is rotated continuously by an electronically controlled variable speed drive. Minimum cut length is 0.25 inches. (G.F. Goodman & Son, 2 Ivybrook Blvd., Ivyland, PA 18974)

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Anti-static system

Ionizing curtain transvectors neutralize static electricity, prevent electrostatic discharge, help prevent web misalignment and blow away surface contamination with a powerful laminar airflow, according to the company. The curtain's static neutralizing bar uses a power supply to create positive and negative ions that are delivered to the surface of a product in a nearly uniform laminar sheet of air. (ITW Vortec, 10125 Carver Rd., Cincinnati, OH 45242-4798)

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Rotary union

The Series E75 3" rotary union is an external pressure mechanical seal that has a cartridge seal design that allows users to replace the seal without removing the union from the machine. It also has a clean, unobstructed flow path and wide, separated pre-loaded bearings to minimize vibration, according to the company. Also, its slinger and vented housing protects the bearings from grease washout. It is available in both mono-flow and duo-flow configurations. (Barco, 1100 Alexander Ct., Cary, IL 60013-1892)

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Mold cleaning system

An expanded manual media-blast cleaning system features a weight capacity of 3,000 pounds (1,360 kg) for convenient handling of heavy, oversized molds and bulky components. The Model 10 cabinet has a 60" x 60" x 60" work envelope, and is optionally equipped with a powered transfer cart for safe, easy loading and unloading. The system may be used with plastic grit, glass beads or other mold cleaning media. (Guyson, W.J. Grande Industrial Park, Saratoga Springs, NY 12866-9044)

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Rubber injection molding

This multi-station robber injection molding machine with a horizontal injector is said to cut typical injection cure times over 50%. Particularly suitable for comer molding applications, the Predator is of modular design and can be built in two, three or four station modes. Conversion kits are available for TPEs, liquid silicones, with the standard unit suitable for dense as well as sponge materials. (MTI Manufacturing Technologies International, 1525 Corporate Woods Pkwy., Suite 500, Uniontown, OH 44685)

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Liquid/liquid coalescer

The PhaseSep liquid/liquid coalescer is available for virtually any liquid/liquid separation application in the oil, gas and chemical industries. Developed to efficiently separate liquid/liquid dispersions and remove liquid contamination, the PhaseSep is said to provide high fluid quality and value, thus saving reprocessing, downgrade and transportation costs, according to the company. The PhaseSep features a high performance stack design. (Pall, 25 Harbor Park Dr., Port Washington, NY 11050)

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Tire mold cleaning system

This state-of-the-art, 65", 5,000 lb. capacity automatic horizontal tire mold cleaning system is designed to clean split and segmented tire molds automatically. The unit features fully programmable mold processing, multimedia capability, four blast nozzles, and continuous media recovery and separation. The system can be designed for off-line [CO.sub.2] and/or media blasting, according to the manufacturer. (Friess Equipment, 2222 Akron-Peninsula Rd., Akron, OH 44313)

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Granulators

Sagitta granulators are made for the production of granulated and uniform cube-shaped material, for batch-off or continuous processing. Both natural and synthetic rubbers can be granulated, as well as thermoplastics and various other kinds of hard plastics. The scissors-like cut of the granulator is composed of two sets of circular knives which revolve in the opposite direction and are intermeshing, cutting the rubber into strips, and then cubes. This two-stage design is said to result in a quieter, cooler operation. (Barwell, 460 Tacoma Ave., Tallmadge, OH 44278-2719)

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Buffing wheels

The company's technology for whitewall and tread grinding applications is said to increase productivity and extend tool life two to ten times. Users are said to report cooler grinding temperatures, reduced powder buildup and smear-free finishes. The technology is composed of a proprietary abrasive coating made from tungsten carbide particles formed into razor sharp cutting structures that are then arranged in a pattern. (Friction Coating, 42776 Mound Rd., Sterling Heights, MI 48314)

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End coating

Extrusion end coating equipment can be used to coat the ends of extrusion with Thixon, Color Guard, various types of paint and other molding agents or end sealing agents. The operator slides an extrusion down a guide toward the end coating system. The transfer pad raises up as the operator pushes against it. The pad design varies depending on the thickness of the coating and coating material. The coating resides in a sealed system. (Computer Age Engineering, 867 E. 38th St., Marion, IN 46953)

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Preheater

The company's Turbo Air preheater is available for continuous vulcanization of rubber profiles. The Turbo Air is designed to allow users to achieve a [Alpha] t of 100 [degrees] C in only 4.5 m (15 ft.) of length at speeds up to 30 meters per minute (100 ft. per minute). It is said to be ideally suited to processing of rubber profiles of modest thickness. Features of the Turbo Air include rapid temperature rise in short distance for complex profiles; sophisticated hot air technology incorporating high velocity and high temperature to significantly improve the productivity of profile extrusion lines; turbulent and controlled air flow provides rapid heat transfer; levitating air and driven rollers gently transport extrudate while building green strength and assuring surface quality; and electronic control provides versatility and precision, according to the company. (Cober Electronics, 151 Woodward Ave., South Norwalk, CT 06854)

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Extruder

The ZSK 50 Mega co-rotating twin-screw extruder is said to fill a size niche between the ZSK 40 and the ZSK 58, and has a simple, user-friendly design with tie rods instead of individually bolted, flanged barrels. It is heated with cartridge heaters rather than external heater shells. This cost-effective design is said to be the basis for the ZSK 25 World Lab extruder and the ZSK 40 MegaCompounder. They match the geometric design parameters, the speed range (up to 1,200 rpm) and the high torque capabilities of the larger size extruders in the MegaCompounder series, according to the company. The ZSK 40 mega and ZSK 50 Mega, used in the continuous processing of rubber, are said to be ideal for small to medium lot production of 100 to 2,000 plus pounds per hour, and basic research and development of new products. (Krupp Werner & Pfleiderer, 663 E. Crescent Ave., Ramsey, NJ 07446)

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CAD/CAM router systems

This company manufactures standard and custom turnkey CAD/CAM integrated three- and five-axis router systems, including single and double table models with true 30", 36", 42" and 48" material operating heights. Complete turnkey project solutions that include process design assistance, CAD/CAM software and on-board part digitizing are available. These machines are said to be ideal for high-speed, accurate cutting, trimming and routing. (Quintax, 315 Pekin Dr., S.E., East Canton, OH 44730)

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Oil weighing and feeding

The OWS Series oil weigh system is said to deliver fast, accurate oil weighing and feeding into intensive mixers. It automatically meters up to 16 different process oils to rubber batch mixers, ensuring uniform batch characteristics and cycle times while reducing scrap, according to the company. The unit features an enclosed cabinet, vibration-isolated pump-motor assemblies and stand-alone or integrated controls. (Budzar Industries, 38241 Willoughby Pkwy., Willoughby, OH 44094-7582)

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Spark extinguishment system

The company's spark detection and extinguishment system's sensors contain photo elements which detect a spark's infrared radiation. The smallest spark triggers the sensing element and the system immediately releases a fine mist of water downsteam, extinguishing the spark without interrupting production. Optional suppressant methods can also be employed in lieu of water. The system is said to reduce the risk of fire damage. (GreCon, 7747 S.W. Cirrus Dr., Beaverton, OR 97008-5968)

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Industrial water treatment

A self-monitoring electronic water treatment and filtration system is available for industrial process and cooling water. This system is said to reduce or eliminate chemicals and increase equipment life and efficiency, resulting in substantial savings and EPA approval, according to the company. Each custom-designed unit features a solid-state power supply, built-in warning alarm and 24-hour positive performance indicator. (Progressive Equipment, 413 E. 9th St., Erie, PA 16503)

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Rotocure

This rebuilder and supplier of rubber processing machinery offers the 60" Pirelli Rotocure. Technical features of the Rotocure include: curing drum diameter of 1,200 mm (60"); upper and lower drum diameter of 1,000 mm (40"); band width of 1,500 mm (60"); welded band length of 14,300 mm; stainless steel band thickness of 1 mm; maximum drum temperature of 360 [degrees] F; maximum curing field length of 2,800 mm (110"); network pressure of 170 psi; working pressure in the steam heated platens of 142 psi; press speed from 15 to 150 m/hr. (50-500 ft./hr.); and main motor power of 15 hp, d.c. This unit was built in the late 1980s and was used less than two years. Take-up, wind-up and labeling units are available. (Gomaplast Machinery, 500 E. Henry St., Wooster, OH 44691)

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Tread extrusion

The Duplex tire tread extrusion system incorporates a newly designed mechanism allowing tread size to change with remarkable time savings, according to the manufacturer. A European bicycle tire manufacturer has commissioned this machine. (Gumix, s.a., Maria Fortuny, 9-11, P.O. Box 18, Cornella (Barcelona), Spain 08940)

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Cold air gun

The company's cold air gun uses a compressed air source to produce cold air. The gun is said to speed dry machining of rubbers, plastics, etc. It is said to outperform mist coolants, and improves cycle and process time, surface finish, parts tolerance and tool life, according to the company. The gun comes complete with compressed air filter, directional cold air discharge Flex-Line and is said to be easily installed. (ITW Vortec, 10125 Carver Rd., Cincinnati, OH 45242-4798)

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Vulcanization

Extruders, microwave ovens, hot air tunnels and fluid beds are all available from the company. Economically priced extruders for rubber profiles are said to offer significantly lower operating costs, higher output and smaller space requirements. Short microwave ovens with a power rating and capability to suit the needs of profiles are available. The units are said to offer many advantages. Complementary hot air tunnels, made to length that will match the line speed, are available with gas or electrical heating. Fluidized beds of ballotini are offered as a possible alternative curing system. (Kiffer Industries, 4905 Rocky River Dr., Cleveland, OH 44135)

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Prototyping

This manufacturer of vertical injection molding machines offers machines for testing or prototyping molds. The company is said to have extensive experience in corner molding of rubber window and door seals, as well as injection molding of the latest TPEs. (Gluco, 0-794 Chicago Dr., Jenison, MI 49428)

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Clamping system

With the telescope clamping system, the company is said to follow the tradition of using a fully hydraulic clamping stroke. The reason for this is that only a fully hydraulic system provides the best protection from deflection of the moving platen, according to the company. This is said to be the most important point for any rubber or robber-to-metal injection production. With this system, the company is said to help customers protect hardened cavities from any damage that may occur with the usual three-step closing systems available on the market. In addition to full clamp cylinder support of the moving plates, the LoBoy design is said to give the customer a very effective operating work height without a platform or placing the machine in a pit. The company offers a 790 mm clamp stroke with full clamp pressure and no mechanical adjustment over a 200 mm stroke. Custom designs are also available from the manufacturer. (LWB Sales and Service, 730 Plum Industrial Ct., Pittsburgh, PA 15239)

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Rubber injection presses

The G8 rubber injection press allows operators to use a simplified function display and plain text parameter condition display for easy interaction and quicker access to relevant press condition status. It is said to be an industrial PC on a press. The G8's improved plasticizing and injection unit is said to be unrivaled in its ability to deliver precise shot volumes of homogenous material through the injection nozzle. Significant improvements include a redesigned check valve for perfect shot size control and absolute seal, plus injection units which can accommodate the unique flow characteristics and shear sensitivity of LS and TPEs. A variable displacement pump is standard on the G8 close/clamp units, resulting in a 30-50% savings in electricity and cooling water consumption, according to the company. Available in standard models from 175 to 450 tons clamp force, G8 presses are equipped with an array of software packages. (REP, 8N470 Tameling Ct., Bartlett, IL 60103-8146)

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Die-face pre-form cutters

Extruder die-face pre-form cutters are said to cut compression mold pre-forms at the die face of cold-feed or hot-feed extruders, eliminating off-line cutting operations and downtime of recharging ram-type extruder-cutters. Pre-forms can be solid cross sections, ID/OD sections or any other shape. The extruder die supports the parts as they are cut, precluding the distortion associated with off-line cutting. Freezing of ID/OD sections to prevent collapse when cutting off-line is said to be eliminated. Models 300 and 364 cut solid cross sections up to 4 in. OD (up to 6 in. if ID/OD cross section area is no greater than 12 sq. in.). Models 600 and 696 cut cross sections up to 6 in. OD (up to 9 in. if ID/OD cross section area is no greater than 28 sq. in.). Models 364 and 696 incorporate a spray lubrication system for the cutting blade, and an integral stainless steel pre-form dip tank with inclined, cleated, mesh conveyor belt. (G.F. Goodman & Son, 2 Ivybrook Blvd., Ivyland, PA 18974)

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Fluidized bed mixer

A mechanically fluidized bed mixer is said to provide a superior finished product in significantly shorter time compared to current processing technology in the preparation of hot melt adhesives which utilizes jacketed kettles. The company's mixer, when equipped with a heated jacket, is said to easily mix the resins, crumb elastic polymers, solvents or water-based solutions. Once the material has tranformed to a viscous liquid, the mix can be dynamically deaerated by operating the mixer under vacuum. Variable speed drives for slower operation can be supplied for some elastic polymers which may shear degrade during the solvation cycle. The finished product will be thoroughtly mixed and free of bubbles at the end of the cycle, according to the company. Gasketing material can also be processed with excellent pre-mixing of all dry ingredients, according to the manufacturer. Also, high speed built-in chopping mills can assist in defibering fibers used to reinforce the gasket. The resin or elastomer can be premixed with dry ingredients or solvated prior to adding to the dry ingredients. The mixmill can distribute the solvated elastomer uniformly without solvent losses by containing the environment. Also, the elastomer can be premixed and wetted with solvent to provide a uniform feed material to the sheeting machinery. (Processall, 10596 Springfield Pike, Cincinnati, OH 45215)

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C-frame vertical presses

In the area of vertical presses characterized by high clamping forces, the company offers c-frame presses without tie-bars. This configuration is said to offer the advantage of accessibility. The absence of tie-bars makes it possible to reach the mold area from three of the press sides, and the clamping system from the top guarantees that the mold always remains at the same height. These two characteristics allow the machine to operate with many different automatic systems. This design is said to be especially useful in producing rubber-to-metal parts. (Rutil, s.r.l., Via S. Lucio 67, 21050 Lonate Ceppino, Italy)

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Dust collection system

The Dust-Hog Supra-Blast, developed to remove harmful pollutants and eliminate air quality concerns, is available in either a single- or double-filter configuration. The Supra-Blast is said to remove dust, fumes, composites, powders and other pollutants, while delivering more cubic feet of air per minute than other dust collectors, according to the company. Supra-Max Series cartridge filters offer 310 sq. ft. of media. (United Air Specialists, 4440 Creek Rd., Cincinnati, OH 45242)

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Multi-zone hot water system

The MWT multi-zone hot water system provides up to eight independent temperature control zones. Operating each zone at separate set points is said to maximize production. Each zone has its own pump, heater, cooling mode and controller to regulate each zone separately. The system is designed for processes requiring fluid temperatures up to 250 [degrees] F. It is available in both direct-injection or closed-loop operation. (Budzar Industries, 38241 Willoughby Pkwy., Willoughby, OH 44094-7582)

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Roller head

Roller head extrusion lines are said to incorporate new control features which have dramatically increased the accuracy and reliability of robber sheets produced on the line, according to the company. One system has been used with specialty compounds in the European aerospace industry. (Gumix, s.a., Maria Fortuny, 9-11, P.O. Box 18, Cornella (Barcelona), Spain 08940)

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TPE presses

This manufacturer of vertical injection molding machines offers presses specifically designed for molding complicated TPE applications. The company has worked with TPE manufacturers to develop optimal performance in bond strength and accuracy. The company has experience in molding TPE to rubber and plastic. Increased cycle times are made possible with machines ranging in size from 10-200 tons. (Gluco, 0-794 Chicago Dr., Jenison, MI 49428)

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Rubber press

The RSOX 400 machine is the latest development in the company's RSOX line of four-tiebar horizontal presses. Starting from the RSOX layout, the company has increased the clamping force and the machine dimensions, especially the platen size. The press is equipped with the RS type clamping unit and a first in, first out injection unit. This configuration is said to offer great advantages both in terms of clamping power and uniformity, and in terms of control capacity during the plasticizing and injection phases. The RSOX 400 was developed to meet the requirements of all manufacturers of large- and medium-sized parts. The large-sized platens are said to make this machine ideal for this type of production, while its configuration allows automation of the production cycle. (Rutil, s.r.l., Via S. Lucio 67, 21050 Lonate Ceppino, Italy)

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