The 4 Most Common Rubber Manufacturing Processes

By Brittney Hoover

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When it comes to producing rubber products, multiple manufacturing processes exist. Each manufacturing process has particular benefits that make it the ideal choice for manufacturing certain types of products. Knowing the manufacturing processes can help you understand cost implications and tradeoffs. Some of the most common rubber manufacturing processes are extrusion, latex dipping, molding, and calendering.

Extrusion begins with an unvulcanized compound being fed into an extruder. Once it’s inside the extruder, it gets carried forward to a dye, which is a specialized manufacturing tool used to shape the rubber. Once the compound reaches the dye, the pressure from the process forces it through the opening of the extruder. Then, the extruded product will need to be vulcanized prior to being defined “usable”. It is important to note that any rubber compound must have a “cure package” already blended in prior to vulcanization. During the vulcanization process the rubber may swell or shrink, after vulcanization the length of the rubber extrusion may be impacted as well. Extrusion manufacturing has the advantage of being able to produce products in high volumes at a lower production cost. Some of the common rubber products produced from extrusion includes profiles, cord, tubing, and gaskets.

Latex dipping occurs when thin walled molds are immersed into latex compounds and then slowly withdrawn. The thickness of the dipped product can easily be increased by simply re-dipping the product in the latex compound. After the dipping process occurs, the product is finished by vulcanization. Depending on the finished dipped product, post treatments may also be needed. At the Hygenic Corporation we use a proprietary dipping method to achieve the optimal finished product. The main advantage of dip molding includes being able to dip latex products with thinner walls and to create more complex shapes than extrusion. Some of the common dip molded products include rubber gloves, grips, bladders, balloons, tubing, etc.

Molding is comprised of three main manufacturing processes, which are compression molding, transfer molding, and injection molding. Compression molding is the oldest and least expensive method. With compression molding, a rubber compound is formed into a blank (chunk of rubber); the blank then gets placed into a mold cavity to be shaped. The heating time is slow, which results in a long curing time; the heating can vary from three minutes for thin walls to several hours for thick walls. Some advantages of this method include being suitable for rubber compounds with large surface areas, and the ability to be used for rubber compounds with high viscosity and poor flow properties. On the down side, the process is time consuming with a low production rate. Some of the common products made with the compression molding process include seals, o-rings, electrical insulators, and silicone wrist bands.

Transfer molding is a natural progression in development to limit the disadvantages of compression molding. The process starts out with a blank being loaded in the chamber, which is then distributed into several cavities. In this beginning stage, pre-heating takes place in the rubber, forcing the rubber to flow through channels. This pre-heating reduces the curing time and allows the rubber to flow easier and fill mold cavities efficiently. However, the molds are more complicated and expensive.

Injection molding is the third most common molding process. With injection molding, the press unit and injection unit act as two separate entities with separate controls. The press unit allows for molds to be placed horizontally or vertically. An extruder unit can also serve several presses by moving in a pre-programmed pattern. All of these result in short injection processes with high amounts of pre-heating. With this type of molding, the handling of blanks is eliminated, processes can be automated and difficult cavities and flow channels can easily be filled.

The last most common manufacturing process is called calendaring, which works by forcing softened material into the center of counter-rotating rollers. Rollers compact the material and the overall thickness of the product is determined by the gap distance between cylinders, which can be adjusted for varying product thicknesses. Once the material passes through cooling rollers, it must be vulcanized. This process works best to produce sheets or films of rubber. Some benefits of calendering include control over product thickness and the ability to produce parts thinner and wider than with the extrusion. However, calendering has high operating costs compared to other processes.

Each manufacturing process is ideal for producing certain types of rubber products. Understanding the processes available can make planning for manufacturing a lot easier because each process has its own cost and time limitations. Although The Hygenic Corporation only specializes in a few of the main rubber manufacturing processes, they will work with companies to help them decide which manufacturing process would be most suitable based on their individual product needs.

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Rubber is a versatile material that has found its way into numerous industries, playing a crucial role in various applications. From automotive to manufacturing, aerospace to construction, industrial rubber has become an indispensable component due to its unique properties and wide-ranging benefits.

So, what exactly is Industrial rubber? Industrial rubber refers to rubber products specifically designed and manufactured for industrial applications. These products are made from natural or synthetic rubber, often enhanced with additives to enhance their performance and durability. They come in various forms such as sheets, mats, seals, gaskets, hoses, and belts, each tailored to meet specific industrial needs.

The importance of industrial rubber cannot be overstated. Here are a few key reasons why it is necessary in different industries:

1. Flexibility and Resilience: Industrial rubber exhibits exceptional flexibility and resilience, allowing it to withstand heavy loads, vibrations, and extreme temperatures. This makes it ideal for applications where materials need to adapt to dynamic conditions, such as in automotive components or machinery.
2. Sealing and Insulation: Rubber's excellent sealing and insulating properties make it vital in creating airtight and watertight seals, preventing leaks, and providing insulation against heat, electricity, and noise. It is commonly used in seals, gaskets, and electrical insulation materials.
3. Shock Absorption and Vibration Isolation: In industries where shock absorption and vibration isolation are critical, such as in construction and aerospace, industrial rubber components play a vital role. Rubber pads, mounts, and isolators effectively dampen vibrations, reducing wear and tear on equipment and improving overall performance.

1. Chemical Resistance: Industrial rubber is known for its resistance to chemicals, oils, and solvents. This property makes it suitable for applications where exposure to corrosive substances is a concern, such as in chemical processing plants or oil refineries.
2. Safety and Ergonomics: Industrial rubber is often used to enhance safety and ergonomics in workplaces. Rubber flooring provides slip resistance and cushioning, reducing the risk of accidents and fatigue-related injuries. Additionally, rubber grips and handles improve grip strength and comfort, promoting safer handling of tools and equipment.

As industries continue to evolve and demand higher performance, the need for specialized industrial rubber products is on the rise. Manufacturers are constantly innovating and developing new rubber compounds with enhanced properties, catering to specific industry requirements.

Fact.MR anticipates the global industrial rubber market to value at US$ 36.3 billion in 2023. The Increasing demand from the Construction Industry is expected to drive the growth of Industrial Rubber demand.

Business Potential of Industrial Rubber

1. Market Growth: The global industrial rubber market is expected to witness significant growth in the coming years. Rapid industrialization, infrastructure development, and technological advancements are fueling the demand for rubber products, creating ample opportunities for manufacturers and suppliers.
2. Diverse Applications: Industrial rubber finds application in a wide range of industries, including automotive, construction, manufacturing, aerospace, healthcare, and more. This diverse market landscape provides businesses with opportunities to cater to multiple sectors and expand their customer base.
3. Customization and Specialization: Businesses in the industrial rubber sector can differentiate themselves by offering customized solutions and specialized rubber products. By understanding specific industry needs and developing tailored rubber components, companies can establish a competitive edge and attract high-value customers.

1. Technological Advancements: The industry is witnessing continuous technological advancements, leading to the development of innovative rubber compounds, improved manufacturing processes, and enhanced product performance. Embracing these advancements can enable businesses to stay ahead of the competition and meet evolving customer demands.
2. Sustainability and Environmental Focus: With increasing environmental concerns, there is a growing emphasis on sustainable materials and practices. Industrial rubber, particularly eco-friendly and recyclable rubber products, holds great potential as businesses align with sustainability goals and cater to the demand for environmentally conscious solutions.
3. Global Market Reach: The demand for industrial rubber extends beyond domestic markets. Businesses in this sector have the opportunity to expand their reach globally, tapping into emerging markets and establishing partnerships with international clients and distributors.
4. Aftermarket Services: Along with the manufacturing of rubber products, businesses can also explore opportunities in providing aftermarket services such as maintenance, repair, and replacement of rubber components. This can establish long-term customer relationships and recurring revenue streams.

To capitalize on these business potentials, companies in the industrial rubber sector should focus on product quality, research and development, market intelligence, customer relationships, and sustainability initiatives. By leveraging these factors, businesses can position themselves for growth, profitability, and long-term success in the dynamic industrial rubber market.

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