Key Facts About Rubber Manufacturing

Rubber products are widely used throughout the world. There are many similarities between rubber manufacturing and the manufacture of plastic products. However, the two industries are considered separately. The raw material that is required for the process can be obtained in two ways; naturally or synthetically. The natural type is obtained from trees while the synthetic type is manufactured from petroleum.

Processing of rubber to make the final products occurs at what are termed fabricator plants. In these fabricators a number of process take place including mixing, compounding, mixing, shaping and vulcanizing. Although there are many forms of products that are produced, tires have taken the largest share of the market. Tires are highly demanded by the automobile and aviation industries. They are also a major component of conveyor belts in many industries.

To produce natural rubber, the starting product known as latex has to be obtained from trees. The trees exist in plantations in some parts of Southeast Asia, West Africa and various other places. Latex is a colloid dispersion solid particles of a polymer known as polyisoprene in water. There is about 30% of the final product in this initial emulsion. Tapping of the latex is done in large tanks so as to get a blend from several trees.

Obtaining rubber from the latex involves several stages the first of which is coagulation. In coagulation, an acid is added to the emulsion and the two left to mix for 12 hours. The coagulum formed is then passed through a series of solid rollers to squeeze out any remaining water. The final thickness measures about 3 millimeters. The next stage is drying the product in a smoke house. This may take several days.

After drying, the product, now known as ribbed smoked sheet, takes dark brown colour. It is folded and packed into bales which are then shipped to various processors. It is common for the sheets to be dried in hot air instead of smokehouses. Whenever this happens, the sheets are called dried sheets. The dried sheets are usually graded more highly. To get even better quality, two steps of coagulation may be done followed by air drying.

Synthetic rubber production starts with the synthesis of polymers from petroleum. The processes that are involved here the same that are used in the production of any form of polymers. The only difference is that the polymers that are produced are in the form of bales rather pellets or liquid resins. At the fabricators, the first process that takes place is compounding in which other substances are added. The type of additive that is added depends on the intended use of the product.

Carbon black is an important additive. The carbon is produced by decomposing hydrocarbons using thermal energy. The resultant product has greater tensile energy and is less predisposed to tears. The presence of this carbon makes most products to have a black colour. The presence of carbon also helps in conferring protection from harmful ultraviolet radiation.

Other additives that are commonly used to enhance certain properties include antioxidants, styrene, phenolics and china clay. It is important to do through mixing so as to enhance dispersion of all the ingredients used. Shaping and filament reinforcement are then done before the final product is ready for use. Filament reinforcement helps in the reduction of extensibility but all the other properties are maintained.

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