Cebu Institute of Technology

UNIVERSITY
N. Bacalso Avenue, Cebu City

COLLEGE OF ENGINEERING AND ARCHITECTURE

DEPARTMENT OF MECHANICAL ENGINEERING

WRITTEN REPORT
ON THE PRODUCTION OF RUBBER AND RUBBER PRODUCTS

ME 513 – P1
Industrial Processes

Submitted by:

LINGO, DARYLL P.
INOJALES, JEFFER DEAN
MAGLASANG, JHUNLY L.
TALIQUIG, JOHN REEVE S.
BSME-5

Submitted to:

ENGR. RODULFO NAVARRO, JR.

Instructor
I. INTRODUCTION
Rubber is one of the most important products to come out of the
rainforest. In material classification, rubber is a kind of polymer classified as
Elastomers – polymers which by their structure allow considerable extensions
that are reversible. These substances are characterized by very high elasticity but
a very low modulus of elasticity, i.e. great extensibility when stressed, and the
capacity for very large rapidly recoverable deformation, e.g. rubber bands.

In the next following chapters, readers will know about the different types
of rubbers, its origin, and will be engaged to the processing of raw rubber which is
sent to manufacturing units for product processing.

II. HISTORY
Prior to Columbus, the American Indians had discovered and made of
rubber, the white milky sap which oozed out of some trees when the bark was
cut. Natural rubber is in fact derived from the sap of the rubber tree Hevea
brasiliensis. The technology of rubber probably began in 1820 when a British
inventor, Thomas Hancock, developed a method in shaping raw rubber; whilst
some 20 years later, in the USA, Charles Goodyear established the “vulcanization”
process by which raw rubber was made to “set” and produce a tough, durable
material, later to be so important in the growth of the motor-car industry.

Following the work of Goodyear in vulcanizing rubber, production grew

rapidly in Brazil, the home of the rubber tree, and the city of Manaus, complete
with an opera house and many other trappings of civilized living, mushroomed in
the middle of the Amazon jungle as the capital of Rubber Empire. In 1876,
however some seeds of the rubber tree were smuggled out of Brazil by British
botanists and planted in greenhouses in Kew Gardens. The young plants were
sent to the Dutch East Indies (now Indonesia) and Malaya so that Britain was able
to establish and control its own rubber industry. This naturally led to a severe
contraction of Brazilian rubber industry and a rather shabby Manaus is all that
remains of its former glory.
 Today, most natural rubber comes from the Far East, while Russia and its
former republics, France, Germany, and the United States are among the world's
leading producers of synthetic rubber. The world's largest single source of latex
rubber is the Harbel Rubber Plantation near Monrovia in Liberia, established in
the 1920s and 1930s by the Firestone tire company.

III. RAW MATERIAL

Raw Rubber – This is the prime raw material for any rubber product which
determines the main characteristics of the final product. Basically, there are two
types of rubber namely: natural and synthetic rubber. To collect natural rubber, a
traditional process called rubber tapping is done to gather the milky sap from the
rubber trees. Over 99 percent of the world's natural rubber is made from the
latex (milky sap) that comes from a tree species called Hevea brasiliensis, widely
known as the rubber tree. This latex is about one third water and one third rubber
particles held in a form known as a colloidal suspension. This unprocessed
substance is very squashy, smelly, and not very useful by itself. In the other hand,
synthetic rubber is any artificial elastomer. These are mainly polymers
synthesized from petroleum byproducts.

IV. PRODUCTS, INDUSTRIAL PROCESS, AND MACHINERY

Before delving in to the different rubber products, its industrial process and
machineries involved in its production, it is important to note that each product
have their unique specification of manufacturing. However, most of the rubber
products are processed with four major steps: Compounding, Mixing, Shaping,
and Vulcanizing.

• Compounding - refers to the addition of certain chemicals to raw rubber in

order to obtain the desired properties. Rubbers are
compounded with additives which includes fillers that acts
either to enhance the rubber’s mechanical properties
(reinforcing fillers) or to extend the rubber to reduce cost
(non-reinforcing fillers).
• Mixing - The additives must be thoroughly mixed with the base rubber to
achieve uniform dispersion of ingredients. To avoid premature
vulcanization, a two-stage mixing process usually takes place:

1. carbon black and other non-vulcanizing additives are

combined with the raw rubber. The term masterbatch
is used for this first-stage mixture.
2. After stage 1 mixing has been completed, and time for
cooling has been allowed, stage 2 mixing is carried out
in which vulcanizing agents are added.

• Shaping - This process helps in providing the shape to the product in the
required form. Shaping processes for rubber products can be
divided into four basic categories:

1. Extrusion- During this process, a high

pressure extrusion machine forces synthetic
or natural rubber materials through a
shaped die in order to get it to take on its
section profile, shape or cut. Screw
extruders are generally used for extrusion
of rubber.
2. Calendaring - is passed through a series of rollers to flatten,
smooth and commingle the two or more
materials.
 3. Coating - This process is used when a fabric is coated with
rubber. The equipment is similar to calendaring
equipment.

4. Moulding - Rubber molding creates molded rubber parts by

pressing a block of rubber into a rubber
molding metal cavity.
There are different types of moulding processes
followed. The major types are as follows:
➢ Compression Moulding
➢ Transfer Moulding
➢ Injection Moulding
• Vulcanizing – It is he treatment that accomplishes cross-linking of
elastomer molecules, so that the rubber becomes stiffer
and stronger but retains extensibility.

Following is the discussion of the manufacturing process of some rubber

products.

PRODUCT NO.1: COVEYOR BELTS

Diagram:

Raw material Skimming and

incoming and Mixing coating of Jointing
weighing fabric

Finishing and
Packing Quality Check Curing
Steps:

Raw materials weighing and mixing

• Rubber: Natural and Synthetic

• Fillers
• Accelerators
Input
• Process Oils
• Curing Agents

• Raw materials are procured from suppliers and are stored in the
storage place
• Quality of the raw materials are ensured by the testing certificates
obtained by the supplier or through internal testing procedures
Process • Various raw materials are weighed according to formulation and are
Description prepared as a batch for mixing process
• The raw materials are fed in the milling machine (kneader / open
mixing mill) in a predefined sequence where mastication of rubber
takes place
• The above chemicals are masticated in the mixing mill to form sheets
• Quality checks such as rheometric properties testing is done on the
compound prepared
Output Rubber compound in the form of sheets

Machinery Kneader Milling Machine (Mixing Mill)

Skimming and Fabric Coating

Input • Rubber compound from mixing

• Nylon Fabric

• Rubber is coated into the nylon fabric through calendaring process

• The nylon fabric provides the strength to the belts (Alternatively
Polyester or steel cords may be used depending on end user purpose)
Process • This rubberized nylon fabric (plies) would form the inner layers of the
Description belt
• The ply passes through steel drums for uniform coating and these
drums are steamed to remove any moisture in the plies
• This ply provides the strength for the conveyor belts to move the
objects
Output Rubberized nylon fabric (plies)

Calendaring Machine
Machinery

Calendaring

Input Rubber compound from mixing

• Rubber compound is calendared which will be used for the outer layer
Process of the belt (both top and bottom side of the belt)
Description • The width of the ply and the calendared rubber sheet should be even
• The quality of the cover should be made as per end product
requirement such as fire resistance belt, Oil and chemical resistance,
cut resistance, etc.
Output Calendared rubber sheets of uniform width
Machinery Calendaring Machine
Jointing

Input • Rubberized nylon sheet

• Rubber sheets

• The rubberized nylon sheet and calendared sheets are joined to make
the belts
• The number of plies used is as per the specification of the belts (it may
Process
vary according to the end user requirement)
Description • The evenly joined plies are passed between two rollers so that they
remain bonded. This is then rolled with cotton cloth so as to prevent
joining between two adjacent layers of the roll
• This forms the carcass of the conveyor belts
• Calendared rubber sheets are placed at the top and bottom of the
joined plies
Output Uncured Belt
Machinery Rollers

Curing

Input Uncured rubber sheet

• Before curing process, pricking process is done on the belts to remove
Process any trapped air between the layers of the belt
Description • After pricking, the uncured belt is passed through the hydraulic press
for curing
• If there is any minor defect in the belt like bubbles, it is rectified and
fresh rubber is pasted over the defected area. It is then again passed
through the press for curing
Output Cured conveyor belt

Machinery
Hydraulic Press
 Quality Test

Input Cured belt

• The cured belt is allowed to cool for certain period in the room
Process temperature
Description • Quality check such as hardness test, elongation test, etc. are done to
ensure quality
• Other lab test on abrasion and specific product testing is also done. For
example: heat resistant belt is checked for temperature resistant check
Output Packed belts

Finishing and Packing

Input Cured belts

• The cured belt is allowed to cool for certain period in the room
Process temperature
Description • Then finishing process such as trimming is done on the belts
• Quality check such as hardness test, etc. are done to ensure quality
• Once the end product is ready, it is being packed and dispatched as per
the delivery
Output Packed belts

PRODUCT NO.2: BRAIDED/KNITTED HOSE (SMOOTH FINISHED)

Diagram:

Raw Rubber
material compounding Tube Semi - Knitting/
incoming (Mixing) extrusion vulcanization Braiding

Measurement Mandrel Vulcanization/ Mounting Cover

and cutting Extraction Curing on mandrel extrusion

Washing Packing and

and drying Inspection dispatch
Steps:

Raw material weighing and mixing

• Rubber : Natural and Synthetic Rubber
• Fillers
Input • Accelerators and Accelerators
• Process oils
• Curing agents such as Sulphur
• Raw materials are procured from suppliers and are stored in the go
down / storage place appropriately
• Quality of the raw materials are ensured by the testing certificates
obtained by the supplier or through internal testing procedures
Process • Various raw materials are weighed according to formulation and are
Description prepared as a batch for mixing process
• The raw materials are fed in the milling machine (kneader / open
mixing mill) in a predefined sequence where mastication of rubber
takes place
• The above chemicals are masticated in the mixing mill to form sheets
• Quality checks such as rheometric properties testing is done on the
compound prepared
Output Rubber compound in the form of sheets
Machinery • Kneader
• Mixing Mill

Extrusion (inner tube)

Input Rubber sheets from the milling process

Process • Extrusion machine is made ready for operation by fixing appropriate
Description die and maintaining adequate temperature
• The rubber compound in the mill is cut into strips for extrusion
purpose
• This strips of rubber compound passes through the extruding machine
and comes out in a tube form
• The physical characteristics of the extruded rubber is as per the die
fixed in the extruding machine
• Temperature of the machine needs to be constantly monitored to
prevent compound from getting cured
• This extruded product forms the inner tube of the hose
Output Extruded rubber collected from the extrusion machine

Machinery Extrusion Machine

Vulcanization of inner tube

Input Inner tube from the extrusion process

Process • The inner tube is then sent for curing process
Description • The Inner tube of hose is vulcanized under steam pressure for three to
four hours in vulcanizing chamber
Output Vulcanized inner tube
Machinery Vulcanizing Machine

Braiding

Input • Inner tube from the extrusion process

• Yarn
Process • The inner tube is passed through the braiding machine where it is
Description reinforced with yarn
• This yarn forms the outer cover for the inner tube and provides
strength for the hose
Output Braided inner tube

Machinery
Braiding Machine

Cementing

Input • Braided inner tube

• cementing solution
Process The braided inner tube is passed through a cementing solution which
Description increases the tube’s strength
Output Cemented inner tube
Drying in steam chamber

Input Cemented inner tube

Process • The compounded tube is dried in the steam chamber for three to four
Description hours
• This process id done to dry the cementing solution
Output Finished inner tube

Machinery Steam chamber

Extrusion

Input • Finished inner tube (with braiding)

• Rubber compound
Process • The dried inner tube is again passed through the extruder to cover it
Description with an outer layer of rubber compound
• The rubber compound is fed into the extruder which forms the outer
cover of the rubber hose
• Parameters such as temperature, time and pressure needs to be
monitored and ensure that they are as per the specification
Output Rubber hose (With uncured outer cover)
Machinery Extrusion Machine

Mounting on Mandrel

Input Rubber hose (With uncured outer cover)

Process The uncured hose (green hose) is cut as per the required length and is
Description mounted on the mandrel
Output Wrapped hose
Vulcanization/Curing

Input Wrapped hose

Process • The hose in the mandrel is put in the vulcanizing chamber for certain
Description period as per the specification
• Parameters such as pressure, temperature and curing time needs to be
set appropriately in the vulcanizing chamber
Output Cured hose
Machinery Vulcanizing Machine

Demandrelling and Quality Check

Input Cured hose

Process • The cured tubes are dismantled from the mandrels
Description • The hose is then cut as per the measurement mentioned in the
specification of the product
• Quality checks such as dimension, hardness test, etc. are performed on
the finished hose
Output Finished hose

Cutting and Packing

Input Finished hose

Process The inspected product is then measured, cut and packed as per
Description customer’s requirement
Output Packing
V. DEFINITION OF TERMS

Mastication - the process by which the viscosity of natural rubber is reduced to

a suitable level, is an important step in the mixing process.

Rheometry - generically refers to the experimental techniques used to

determine the rheological properties of materials, that is the
qualitative and quantitative relationships between stresses and
strains and their derivatives.

Colloid - In chemistry, a colloid is a mixture in which one substance of

microscopically dispersed insoluble or soluble particles is suspended
throughout another substance.

Carcass – the “strength member” of the conveyor belt

Pricking – the process of making small holes using a sharp point

Curing - also known as vulcanization, causes the long polymer chains

that rubber is composed of to become cross linked. This prevents the
chains from moving independently, allowing the material to stretch
under stress and then return to its original shape when the stress is
released.

Skimming – to remove a layer of something from the surface of a liquid

Mandrel - a round object against which material can be forged or shaped; or a

flanged or tapered or threaded bar that grips a workpiece to be
machined
VI. CONCLUSION
Rubber is a material that is l widely used in today’s era. Rubber products
undergo industrial processes in order to achieve the desired properties in line
with its usefulness. Most of these processes utilize mechanical equipment or
machinery which makes the manufacturing to finish as timely as it is especially in
massive production. We can know that quality rubber products depend on the
success of its industrial processes.

VII. REFERENCES
• Materials for Engineers and Technicians, Sixth Edition by W.Bolton
and R.A. Higgins
• introduction-to-rubber-processing.pdf
• Ch14-Rubber-Wiley.pdf
• rsdc-skill_gap_study-Rubber-Technology-and-Manufacturing-
process-of-rubber-products.pdf
• https://www.explainthatstuff.com/rubber.html
• Rubber Technology by Maurice Morton. Springer, 1999.
• Google Search (for displayed pictures and other definition of terms)