Introduction Indusrty Profile
In 1735 a French explorer, Charles de la Cond amine,
took home some hardened rubber latex from Peru. In 1770 an English chemist discovered
that the material rubbed out pencil marks, and so we get the name rubber.
Scientists discovered that latex dissolved in turpentine made a liquid that
could make fabric waterproof. In the 1820s English inventor Thomas Hancock
built a machine that kneaded scraps of latex into a solid mass, and this led to
the rubber processing of today. In 1832 Scottish chemist Charles Macintosh
began making raincoats by putting a layer of rubber between two layers of
cloth. This kind of coat is still called Macintosh. Manufacturers started
making rubber products, including shoes, elastic bands, hoses and tubes.
Trees are generally tapped
every day for 15 days, then rested
for 15 days. It takes about six years before a rubber tree is ready to be
tapped. In the past, an acid was added to the latex to make the sap set like a
jelly. The latex jelly was then flattened and rolled into sheets and hung out
to dry by workers.
A way of making rubber stronger and more elastic was invented by Charles
Goodyear in 1839. This method was called vulcanising, and it stopped rubber
from perishing.
Liquid latex is now shipped to factories where the
rubber is made by machines. It can be coloured and made into many products. The
latex is poured into tanks, and an equal amount of water is added. This liquid
is strained to remove dirt. Formic acid is added to make the mixture form solid
particles, which rise to the surface to form a crust of rubber. This is fed
through rollers to squeeze out the water to make a solid sheet of rubber. This rubber
is crude rubber, and is ready to be shipped to factories to be processed in
different ways to make many different products.
Applications of Rubber :
Most rubber is used for
tyres for cars, large vehicles and planes. Rubber is also used to make many mechanical
parts such as gaskets, belts and seals. Rubber products include waterproof
clothing, gloves, hats, shoes and household products. Medical equipment made of
rubber includes hot water bottles, gloves, syringes, tapes, oxygen tents,
hearing aids and many more. Swimmers wear goggles, caps and flippers made of
rubber. Many sports have rubber equipment, such as golf balls and other rubber
balls. Rubber products seal jars, are used in toys and paints and for
recreation. Sponge and foam rubbers are used to make bedding and other
furniture, cushions and pillows, and as insulation.
Rubber
Products a successful and service oriented company in the field of producing
engineering products in Rubbers Since 1970. A Company which a wide range of
advanced engineering products in rubber like O rings, Oil seals, Chevron
Pickings, Rubber Bushes , ‘U’ an ‘V’ Packings, Grommets, Diaphragms, Gaskets
and many more .The vision and mission of the company is to set a high standard
in producing top class rubber products for the engineering industries. With a
lot of hard work and experience the company has reached high levels of
sophistication in production of rubber products and is now able to produce the
mouldings and extrusion in various synthetic rubber like Viton, Silicon, Neoprene,
EPDM, Nitrile, SBR, Butyl , Natural and Polyurethane rubbers.
The rubber
products industry comprises three sub-industries: tire and tube, hose and
belting, and other rubber products. An industrial rubber product includes hose
and belting, and other rubber products, but excludes tires and tubes. While
industrial rubber products are used by virtually all industries, the dominant
market is automotive (for example, hoses, belts, gaskets, weather-stripping,
glass encapsulation, air dams and deflectors, and door, window and closure
seals). Other important markets include conveyor belts for mining and forestry
operations, roll flooring, and consumer products.
The rubber products
industry comprises three sub-industries:
tire and tube, hose and belting, and other rubber
products. An industrial rubber product includes hose and belting, and other
rubber products, but excludes tires and tubes.
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Agricultural Industry |
Medical Industry |
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Aerospace/Aviation Industry |
Mining Industry |
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Automobile Industry |
Petroleum Industry |
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Chemical Industry |
Power
Generation Industry |
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Constructions |
Printing and Paper Industry |
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Defense Industry |
Textile Industry
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There are unique features
of rubber which makes it important product finds use in diverse fields such as
transportation, material handling, healthcare and sport activities.
Production of rubber in
the world was considered to be very unstable during the last few years
.Comparatively with the world India’s Rubber production is consistent at the
rate of 6% per annum. the Indian Rubber Industry has been growing tremendously
over years.
The Rubber Consumption is as follows:
- Automotive tyre sector:
50% consumption of all kinds of rubber
- Bicycle tyres and tubes:
15%
- Footwear: 12%
- Belts and hoses: 60%
- Camelback and latex
products: 70%
- Other products: 10%
PRODUCTION DEPARTMENT
Production
can be defined as the methods procedure or arrangements which includes all
functions required to accumulate the inputs, process or reprocess the input and
deliver the marketable outputs.
The main function of the production
department was coordinating the different departments. After receiving the
market plan, annual production plan is made which is broken down in to monthly
and weekly plans. The structure of the said department is as follows:
Ø General manager
Ø Production manager
Ø Plant manager
Ø Supervisor
Ø Foreman
Ø Workers
Production
system utilizes material, infrastructure,funds and to produce required output
in the form of goods. Mechanical or chemical steps involved with the use of raw
materials, machinery, manpower to create multiple units of same product.
Bhargave
Rubber Private Limited produces oil seal, o rings , moulded rubber products
available in wide range to match the applications in
● Trucks, Tractors, LCVS
● Tiller,Stationery Engineers,pumps
,Grinders
Rubber products to Japan,Switzerland and various countries
both inside and outside Madurai
After receiving the market plan, annual production plan is
made which is broken down in to monthly and weekly plans.
Process of making the rubber products
ü Raw Materials
ü Spring chemicals
ü Mold
ü Packaging material
ü Carbon Black Oil
The firm purchases all
machines and equipments imported from Taiwan. They produce 180 parts per month.
Nearly 40 – 60 employees are working. There are 60 customers.
Making
Kneader reactor is a
machine that specializes in mixing and kneading substances that are with high
viscosity. This is used to mix raw material .The kneader takes 10 min to
complete the process.
After the mixed compound gets heated or warmed the performer
dies which is an auto cutter in which shape it will be fixed manually based on
the dye.
Mould
In this process rubber
will be shaped based on the mould fixed. The mould drawings will be provided or
given by the customer. It takes 6 min at the temperature of 175℃
POLYMERS
USED IN PRODUCTION
·
NBR
·
FKM
·
Silicon
·
EPDM
·
Polyacrylic
·
HNBR, Natural Rubber
Functions
Design and development of
production process.
Production planning and
control.
Implementation of the plan
and related activities to produce the desired output.
Administration and
co-ordination of the activities of various components and departments
responsible for producing the necessary goods and services.
Metal
Processing Area
Degreasing: It is an electroplating or painting process. It uses
chlorine or alcohol based solvents to dissolve machining liquids
Rinsing: After electroplating rinsing takes place to dry the electroplated
material
Rust Remover Dryer: it is the process of removing the
rust from the degreased metal
Bonel agents: After the rust remover bonel agents will be added.
Rinsing: Again rinsing takes place
Centrifuge dryer: After dipped in bonding
agents the centrifuge takes place to make the bonding agents fixed to the metal
by centrifugal force expelled by spinning. The above process takes place 45mins
per cycle
Testing Lab
The lab contains:
§ Moving the dye rheometer : used to test the rheo
property of the material UTM –Universal Testing Machine. It is used to test the
tensile strength and elongation.
§ Densimeter: It is used to test the specific
gravity.
§ Mooney Viscometer: Used to
test the viscosity
§ MELTING POINT APPARATUS
§ DUMBELL COUNTER
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