NATURAL NATURAL RUBBERRUBBER

Gift of natureGift of nature

Significant influence on the Significant influence on the quality of human lifequality of human life

A green commodityA green commodity

A relatively short historyA relatively short history

Provides livelihood to over 10 Provides livelihood to over 10 million small farmersmillion small farmers

NATURAL NATURAL RUBBERRUBBER

Major source-Major source-Hevea brasiliensisHevea brasiliensis

Total global production (2004) - 8.24 Total global production (2004) - 8.24

million tonnesmillion tonnes

Total consumption (2004) - 8.11 Total consumption (2004) - 8.11

million tonnesmillion tonnes

Production in over 20 countriesProduction in over 20 countries

SALIENT FEATURES

Major producing Major producing

countries : countries :

Thailand,Indonesia Thailand,Indonesia

Malaysia,India,China, Malaysia,India,China,

VietnamVietnam

Major consuming Major consuming

countries : countries :

China,USA,Japan, China,USA,Japan,

India,Malaysia,KoreaIndia,Malaysia,Korea

Special characteristics of NRSpecial characteristics of NR High strengthHigh strength Low heat generationLow heat generation High tack and green strengthHigh tack and green strength Excellent processabilityExcellent processability Excellent resistance to chipping, chunking and tearExcellent resistance to chipping, chunking and tear EconomyEconomy

Relatively inferior resistance to ageing, weathering and Relatively inferior resistance to ageing, weathering and heatheat

Swells in contact with petroleum oilsSwells in contact with petroleum oils High air permeabilityHigh air permeability Relatively inferior traction and wet skid resistanceRelatively inferior traction and wet skid resistance

RUBBER PLANTATIONRUBBER PLANTATION

Ribbed sheet rubberRibbed sheet rubber Concentrated latexConcentrated latex Block rubber Block rubber Crepe rubberCrepe rubber

CROP (RUBBER)CROP (RUBBER)

LatexLatex Field coagulumField coagulum

80 %80 %

Marketable forms of raw rubberMarketable forms of raw rubber

20 %20 %

Typewise production of NR in India (2002-03)Typewise production of NR in India (2002-03)

TypeType Quantity (MT)Quantity (MT) % Share% Share

RSSRSS 450215450215 69.369.3

Latex concentrate (DRC)Latex concentrate (DRC) 7432574325 11.511.5

Solid block rubberSolid block rubber 7494074940 11.511.5

Pale Latex Crepe Pale Latex Crepe 17501750

OthersOthers 4820548205 7.77.7

TotalTotal 649435649435

NATURAL RUBBERNATURAL RUBBER

INDUSTRIAL RAW MATERIAL FROM NATURE

SYNTHESISED BY THE TREE

UNDEGRADED TILL IT COME IN CONTACT WITH AIR

CIS-POLY-ISOPRENE

NATURAL RUBBER – NATURAL RUBBER – MARKETABLE FORMSMARKETABLE FORMS

SHEET RUBBER (RSS)

CREPE RUBBER

TECHNICALLY SPECIFIED RUBBER (TSR)

LATEX CONCENTRATES

NATURAL RUBBER – SHEET NATURAL RUBBER – SHEET RUBBERRUBBER

LOWER PROCESSING COST

SIMPLE MACHINERY

ADOPTED BY SMALL GROWER SECTOR

STEPS INVOLVED IN SHEET RUBBER PROCESSING

Sieving

Bulking

Dilution

Coagulation

Sheeting

Drying

Grading

RSS IX Colour

RSS 1 Extent of dryness

RSS 2 Mould growth

RSS 3 Tackiness

RSS 4 Blisters

RSS 5 Dirt

Ribbed Smoked Sheet Ribbed Smoked Sheet GradesGrades

CREPE RUBBERSCREPE RUBBERS

Field coagulum crepe

Pale latex crepe

PALE LATEX CREPEPALE LATEX CREPE

Removal of pigments

Fractional coagulation

Bleaching

PALE LATEX CREPE - PALE LATEX CREPE - DefectsDefects

Fungal spots – Brown discolouration

Grey or dark colour

White spots and streaks

Tackiness

Poor lamination strength

PALE LATEX CREPE -PALE LATEX CREPE -ApplicationsApplications

Pharmaceutical products

Light coloured and transparent goods

Adhesives

Tapes

Tubings

Derivatives such as chlorinated rubber

TECHNICALLY SPECIFIED TECHNICALLY SPECIFIED RUBBERRUBBER

LATEX GRADES

FIELD COAGULUM GRADES

TECHNICALLY SPECIFIED TECHNICALLY SPECIFIED RUBBERRUBBER

SPECIFICATION PARAMETERS

DIRT

VOLATILE MATTER

PLASTICITY

PLASTICITY RETENTION INDEX (PRI)

NITROGEN CONTENT

ASH CONTNET

Soaking

Initial size reduction Pre-breaker

Blending

Creping

Final size reduction Hammer mill

Drying

Pressing Testing and Grading

Packing

TSR PRODUCTION – FC GRADESTSR PRODUCTION – FC GRADES

TECHNICALLY SPECIFIED RUBBER - TECHNICALLY SPECIFIED RUBBER - ADVANTAGESADVANTAGES

The consumer has the choice

More consistent

Impurities can be assessed

Being marketed in compact polyethylene wrapped bales, contamination on storage handling and transportation is minimum.

Minimum storage space

Reduction in processing time

TECHNICALLY SPECIFIED RUBBERTECHNICALLY SPECIFIED RUBBERISNR 3CVISNR 3CV Tyres, Engineering Tyres, Engineering

components, extruded and components, extruded and calendared productscalendared products

ISNR 3LISNR 3L Light coloured pharmaceutical Light coloured pharmaceutical feeding bottle teats, Industrial feeding bottle teats, Industrial rollers for paper and printing rollers for paper and printing industry industry

ISNR 5ISNR 5 Conveyor belts, cycle tubes, Conveyor belts, cycle tubes, engine mountings, footwearengine mountings, footwear

ISNR 10, ISNR 10, 2020

TyreTyre

ISNR 50ISNR 50 Handmade hose, footwear, Handmade hose, footwear, mats, moulded hosemats, moulded hose

NR Quality Issues

Consistency

Contamination

Undried rubber

Packaging

NR Quality Issues – Consistency

NR is subject to inherent variability

Variation in plasticity to be minimum

NR Quality Issues – Contamination

Rubber gets contaminated during tapping, collection, processing and packaging

The contaminants do not disperse during compounding.

NR Quality Issues – Undried rubber

Undried rubber prevents effective dispersion of ingredients during compounding

Cause blisters

Only 13% of total NR production Only 13% of total NR production

Mainly from field coagulumMainly from field coagulum

Proper attention is not given to the collection Proper attention is not given to the collection

and storage of the raw materialand storage of the raw material

TSR production in IndiaTSR production in India

The storage of the field The storage of the field coagulumcoagulum

Often stored in the wet conditionsOften stored in the wet conditions Contaminated with sand and bark Contaminated with sand and bark

particles and other foreign matterparticles and other foreign matter Polythene and jute sack fragments, Polythene and jute sack fragments,

plastic cord/ metallic stringsplastic cord/ metallic strings

Inferior raw material results inInferior raw material results in

Lower quality of TSRLower quality of TSR

Non-uniformity and inconsistency in quality Non-uniformity and inconsistency in quality

Lower resistance to thermo-oxidative degradationLower resistance to thermo-oxidative degradation

The oxidizability of raw rubber has an important The oxidizability of raw rubber has an important bearing on the processing behaviour and bearing on the processing behaviour and vulcanizate performancevulcanizate performance

The plasticity retention index (PRI) test gives a The plasticity retention index (PRI) test gives a rapid assessment of the resistance of raw NR to rapid assessment of the resistance of raw NR to thermo-oxidative degradationthermo-oxidative degradation

OBSERVATIONS…OBSERVATIONS…

PPo o of autocoagulated rubber increases on storageof autocoagulated rubber increases on storage

The PRI of autocoagulated rubbers are lower than the The PRI of autocoagulated rubbers are lower than the acid coagulated rubbersacid coagulated rubbers

PRI falls as the length of time from coagulation and PRI falls as the length of time from coagulation and processing is increasedprocessing is increased

In many cases due to low PRI the rubber may fail to In many cases due to low PRI the rubber may fail to meet the requirements specified for a particular grade. meet the requirements specified for a particular grade. Hence it is very essential to preserve PHence it is very essential to preserve Poo & PRI of the raw & PRI of the raw material.material.

OBSERVATIONS…OBSERVATIONS…

One major reason for the low PRI of field coagulum during storage is the bacterial decomposition of proteins and other non rubber constituents in the rubber.

Copper in fresh latex might complex with Copper in fresh latex might complex with proteins and amino acids and in this form it does proteins and amino acids and in this form it does not impart any adverse effect on the ageing of not impart any adverse effect on the ageing of NR. NR.

When the latex is exposed to microbial activity When the latex is exposed to microbial activity the microbes degrade the complex and release the microbes degrade the complex and release free copper which is reported to be a powerful free copper which is reported to be a powerful pro-oxidant. pro-oxidant.

One major reason for the low PRI of field coagulum during storage is the bacterial decomposition of proteins and other non rubber constituents in the rubber.

Copper in fresh latex might complex with Copper in fresh latex might complex with proteins and amino acids and in this form it does proteins and amino acids and in this form it does not impart any adverse effect on the ageing of not impart any adverse effect on the ageing of NR. NR.

When the latex is exposed to microbial activity When the latex is exposed to microbial activity the microbes degrade the complex and release the microbes degrade the complex and release free copper which is reported to be a powerful free copper which is reported to be a powerful pro-oxidant. pro-oxidant.

MECHANISM…MECHANISM…

The degradation of the field coagulum during

storage can be prevented by treating the fresh

coagulum with a suitable bactericide.

Formalin was identified to be the best

bactericide for the above purpose

The degradation of the field coagulum during

storage can be prevented by treating the fresh

coagulum with a suitable bactericide.

Formalin was identified to be the best

bactericide for the above purpose

The following aspects were studied.The following aspects were studied.

Effect of concentration of Effect of concentration of

formalin solutionformalin solution

The optimum soaking period.The optimum soaking period.

The effect of period of storage The effect of period of storage

of the treated coagulum.of the treated coagulum.

Effect of formalin concentration on Po & PRI

30

40

50

60

70

80

0 0.25 0.5 0.75 1 1.25

Formalin concentration (%)

Po/

PR

I PRIPo

Effect of formalin concentration on Po & PRI

30

40

50

60

70

80

0 0.25 0.5 0.75 1 1.25

Formalin concentration (%)

Po/

PR

I

PRI Po

Effect of soaking period on Po & PRI

30

40

50

60

70

80

0 2 4 6 8 10 12 14 16 18

Time of immersion, h

Po/

PR

I PRIPo

Effect of formalin treatment on Po

30

40

50

60

0 10 20 30 40

Storage period, days

Po

Treated

Untreated

Effect of formalin treatment on Mooney viscosity

86

88

90

92

0 10 20 30 40

Storage period (days)

Mo

on

ey v

isco

sity

Treated

Untreated

Effect of formalin treatment on PRI

50

60

70

80

0 10 20 30 40

Storage period, days

PR

I Treated

Untreated

It was observed that soaking the It was observed that soaking the

field coagulum in 1% formalin field coagulum in 1% formalin

solution for a period of 16 hours solution for a period of 16 hours

gives sufficient protection against gives sufficient protection against

bacterial degradationbacterial degradation

It was observed that soaking the It was observed that soaking the

field coagulum in 1% formalin field coagulum in 1% formalin

solution for a period of 16 hours solution for a period of 16 hours

gives sufficient protection against gives sufficient protection against

bacterial degradationbacterial degradation

Preparation of Formalin solutionPreparation of Formalin solution

Add 100ml of formalin to 10 litres of waterAdd 100ml of formalin to 10 litres of water Prepare the required quantity of Formalin Prepare the required quantity of Formalin

solution as abovesolution as above Soak the field coagulum in the solution for one Soak the field coagulum in the solution for one

dayday Transfer the coagulum from the solution on the Transfer the coagulum from the solution on the

next daynext day The same solution can be used after filtering for The same solution can be used after filtering for

treatment of the next days crop. Extra quantity of treatment of the next days crop. Extra quantity of Formalin solution should be added to soak the Formalin solution should be added to soak the coagulum completelycoagulum completely

FarmerFarmer

Group processing facilityGroup processing facility

Block Rubber processing Block Rubber processing unitunit

The crop (field coagulum and latex coagulum)

from the Central Experimental Station, Ranni

is being subjected to the above treatment and

the material is processed at the Pilot Crumb

Rubber Factory, RRII since Jan 2004. The

treated material is brought to the factory

normally within a period of 15-25 days

The crop (field coagulum and latex coagulum)

from the Central Experimental Station, Ranni

is being subjected to the above treatment and

the material is processed at the Pilot Crumb

Rubber Factory, RRII since Jan 2004. The

treated material is brought to the factory

normally within a period of 15-25 days

0

10

20

30

40

50

60

70

80

Per

cent

age

of p

rodu

ctio

n

ISNR 10 ISNR 20 ISNR 50 OFF

2002-03

2004-05

Effect of formalin treatment on the Effect of formalin treatment on the quality of Block Rubber (PCRF)quality of Block Rubber (PCRF)

Based on the data available for one year the

cost of the treatment has been worked out to

be Rs 70/ tonne of rubber

Based on the data available for one year the

cost of the treatment has been worked out to

be Rs 70/ tonne of rubber

Environmental issues….Environmental issues….

The effect of residual formalin if any, on the effluent Treatment System of the factory is being studied

The workers handling the field coagulum at CES have been supplied with hand gloves. No complaints have been so far registered

The treated field coagulum provided a more hygienic environment in the collection centres.The mosquitoes and flies are virtually absent

The effect of residual formalin if any, on the effluent Treatment System of the factory is being studied

The workers handling the field coagulum at CES have been supplied with hand gloves. No complaints have been so far registered

The treated field coagulum provided a more hygienic environment in the collection centres.The mosquitoes and flies are virtually absent

NATURAL RUBBER – MODIFIED NATURAL RUBBER – MODIFIED FORMSFORMS

Viscosity Stabilized Rubber

Deproteinised Natural Rubber

Superior Processing Rubber

Epoxidised Natural Rubber

Chlorinated Rubber

EPOXIDISED NATURAL RUBBEREPOXIDISED NATURAL RUBBER

Gas impermeability

Resistance to hydrocarbon oils

Increased damping and good bonding

DEPROTEINISED NATURAL DEPROTEINISED NATURAL RUBBERRUBBER

Electrical and Engineering Applications

Reduced creep and stress relaxation

CHLORINATED RUBBERCHLORINATED RUBBER

Adhesives

Paints

Printing inks

Paper coating

SUPERIOR PROCESSING RUBBERSUPERIOR PROCESSING RUBBER

Low die swell, better finish

Can be effectively blended with synthetic rubbers like EPDM, SBR.

Allows wide range of extrusion temperatures and roll speeds.