COMPRESSION MOULDING OPERATION

(Rubber)

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ELYSIUM TECHNOLOGIES

Rubber Industry

Need of Rubber

• Rubber in one of the source for global

economic.

• The need of the rubber in increase in

world wide.

• It is use many application in regular use

• things.

About Rubber Industry

• Around 25 million tones of rubber is

produced each year.

• About 48% of the global demand for

natural rubber comes from China,

India and Malaysia which are three

major natural rubber consuming

countries within the ANRPC

(Association of Natural Rubber

Producing Countries)

Rubber Industry in India

• India is the third largest producer

of rubber in die world It is the

fourth largest consumer of natural

rubber.

• Comparatively, with the world

India's production of rubber is

consistent at the rate of 6% per

annum

• India is the world's largest

manufacturer of reclaim rubber.

Size of the Industry 6000 unit comprising 30 large scale, 300 medium scale and around 5600 small scale and tiny sector units

Geographical distribution Kerala is the leading producer of rubber, followed by Punjab and Maharashtra.

Output per annum Today Indian Rubber Industry consists of turnover of Rs 12000 crores.

Percentage In World Market India is the world's largest producer and the third largest consumer of natural rubber.

Market Capitalization India's Rubber production varies between 6 and 7 lakh tons annually which amounts to Rs. 3000 crores.

Rubber Consumption

• This statistic shows the global consumption of natural and synthetic rubber from 1990

to 2014. In 1990, around 5.18 million metric tons of natural rubber were consumed

worldwide. This amount increased to almost 11.4 million metric tons in 2013.

Rubber Consumption in Different industrial sectors• Around 70 percent of the

world's natural rubber is

used in tires.

• Remaining large amount is

used in medical goods and

commercial purpose.

Rubber Consumption in India

• Kerala is the leading consumer

of rubber, followed by Punjab

and Maharashtra.

Rubber Consumption in India Different industrial sectors• India's exports of rubber products, which

include tyres, exceeded Rs.2000 cores

according to a recent estimate. Products

exported are as follows:

• Automotive tyres and tubes

• Rubber and canvas footwear

• Cycle tyres

• Pharmaceutical goods

• Rubber hoses, cots and aprons

• Belts and beltings

• Sheeting

  Industrial Sectors Percentage Of Consumption

1 Automotive tyre sector

50% consumption of all kinds of rubbers

J Bicycles tyres and tubes

15%

3 Footwear 12%

4 Belts and hoses 6%

5 Camelback and latex products

7%

6 (Win Products 10%

Industry/Section

Industry/Section

Rubber manufacturing

Rubber• Rubbers are loosely described as materials which show

"elastic" properties. Such materials are generally long chain

molecules known as "polymers" and the combination of

elastic and polymers has led to the alternative name of

"elastomers". Rubbers and elastomers will be considered to

be synonymous in this work. Products made from rubber

have a flexible and stable 3 - dimensional chemical structure

and are able to withstand under force large deformations

• Based on the source of raw material, there are two kinds of

rubber natural rubber (NR) and synthetic rubber (SR).

Natural Rubber

• Natural rubber is made from a runny, milky white liquid

called latex that oozes from certain plants when you cut

into them. (Common dandelions, for example, produce

latex; if you snap off their stems, you can see the latex

dripping out from them. In theory, there's no reason why

we couldn't make rubber by growing dandelions, though

we'd need an awful lot of them.) Although there are

something like 200 plants in the world that produce latex,

over 99 percent of the world's natural rubber is made from

the latex that comes from a tree species called Hevea

brasiliensis, widely known as the rubber tree

Synthetic Rubber• Synthetic rubber is made by the polymerization of a variety of

petroleum-based precursors called monomers. The most prevalent

synthetic rubbers are styrene-butadiene rubbers (SBR) derived from the

copolymerization of styrene and 1,3-butadiene. Other synthetic rubbers

are prepared from isoprene (2-methyl-1,3-butadiene), chloroprene (2-

chloro-1,3-butadiene), and isobutylene (methylpropene) with a small

percentage of isoprene for cross-linking. These and other monomers

can be mixed in various proportions to be copolymerized to produce

products with a range of physical, mechanical, and chemical properties.

The monomers can be produced pure and the addition of impurities or

additives can be controlled by design to give optimal properties.

Polymerization of pure monomers can be better controlled to give a

desired proportion of cis and trans double bonds.

Use of Rubber

• Majorly used in tyers.

• Medical, Engineering, commercial and industrial

Manufacturing Process

Rubber Manufacturing Sequence

Role of Extruder Operator

• The extruder operator is responsible for feeding the

rubber compound to the extruder, performing the

extrusion operation using the Extruder and it is his

responsibility to follow correct procedures as per

the SOP of the company List of the activities that

are performed by the extruder operator:

Hazards, safety and health

Hazards

• A hazard is a situation that poses a level of threat to life, health,

property, or environment. Most hazards are dormant or

potential, with only a theoretical risk of harm: however, once a

hazard becomes "active", it can create an emergency situation.

A hazardous situation that has come to pass is called an

incident. Hazard and possibility interact together to create risk.

Symbols

• Types of Hazards:

i. Chemical hazard.

ii. Physical hazard

iii. Ergonomic hazard.

Chemical Symbols

Explosive

Flammable

Oxidizing

Corrosive

Toxic

Environmental

Irritant

Human-health

Gas-bottles

Physical Symbols

Ergonomic Symbols

Personal protective equipment (PPE), Safety measures PPE

The Requirement for PPE

• To ensure the greatest possible protection for

employees in the workplace, the cooperative efforts of

bom employers and employees will help in

establishing and maintaining a safe and healthful

work environment. In general, employees should:

i. Properly wear PPE,

ii. Attend training sessions on PPE,

iii. Care for, clean and maintain PPE, and

iv. Inform a supervisor of the need to repair or replace PPE.

Types of PPE

• Eye and Face Protection

• Head Protection

• Foot and Leg Protection

• Hand and Arm Protection

Safety Measures

1. Observing all equipment special safety rules (for your individual pieces of equipment), including general site safety rules, when

using any of the equipment.

2. The Extruder Machine has moving parts and hot areas. Read and follow the manufacturer's operating instructions and safety

precautions for each piece of equipment.

3. Wear gloves while handling warm/hot concentrate. DO NOT PERMIT HOT CONCENTRATE TO CONTACT ANY PART OF

THE BODY AS A SERIOUS BURN WILL RESULT.

4. Training of staff in the correct selection in the use and maintenance of PPE.

5. Training of staff in the correct use of machinery and safety devices. Redesign manual processes to avoid heavy lifting/ slash

repetitive activities.

6. Good standard of lighting

7. Installing automatic alarms and shutoff systems

8. Providing local fire department a list of products stored in the premises

Housekeeping

Housekeeping

• Workplace Housekeeping is fundamental to maintain a clean, tidy and safe

working environment.

• Effective housekeeping can eliminate some workplace hazards and help get a

job done safely and properly

• Poor housekeeping can be a cause of accidents

5’S Concept

Japanese's Translation English 'S'

Seiri Organization Sorting

Seiton Neatness Simplifying Access

Seiso Cleaning Sweeping

Seitetsu Standardization Standardization

Shitsuke Discipline Self-Discipline

Workplace skills

• Oral communication.

• Reading and comprehension skills

• Writing skills

• Work ethics and professionalism

Sample question

• How much rubber is produced per year in the world?

• What is the place of natural rubber consumption in India?

• Which country produce the highest amount of NR in the year 2010?

• What is the percentage of rubber used in tyer industries?

• What is the percentage of rubber used in the footwear in Indian industrial sector?

• What is the types of rubber?

• What is the roll of Extruder operator?

• Why the extruder wear the Personal protective equipment ?

• Type of PPE(Personal protective equipment) ?

• What is the need of 5’s concepts?

Material Provide

• Power point slides.

• Document about the theory

Session plan

S.NO Topics Duration

Theory Practical

1.1 Introduction to rubber industry

30min 01.2 Introduction to factory and section

1.3 Rubber manufacturing

1.4 Role of extruder operator

2.1 Hazards

15min 45min2.2 PPE , safety measurement and legal

issues

2.3 Introduction to housekeeping

3.1 Oral communication15min 03.2 Reading and comprehension skills

3.3 Writing skillsWork ethics and professionalism

Total 1hour and 45 min