KPM-profile(2022)
46Pages

Started by myself, an Engineering graduate, specialized in rubber technology. Myself, Syllabus committee member in anna university for Master degree rubber technology MOU Signed with premier Engineering educational institutional institutions in India My successor is about to join in our company who is pursuing Masters in Rubber Technology. Two locations between 9 kilometer distance, buildup area @ 50,000 sq ft Second plant established in 2018 150 employees, General Manager, Department wise Managers, Asst Managers, Supervisors, Operato

Overview • Manufacturers of • Rubber parts • Rubber – Metal bonded parts • North American countries • Cast Polyurethane Parts • European Union countries • Cast Pu with Metal Bonding • Bakelite parts • Middle East Asia • Sub Assemblies • 400+ Formulations • 1000 + Products

• Butyl Rubber ( IR ) • Polyurethane Rubber ( PU ) • Vinyl Methyl Silicone ( VMQ ) Styrene Butadiene Rubber ( SBR ) Acrylonitrile Butadiene Rubber ( NBR ) • Fluorinated Rubber (FEPM ) Carboxylated Nitrile Butadiene Rubber ( XNBR) • Perfluoro Elastomer (FFKM ) Hydrogenated Nitrile Butadiene Rubber ( HNBR ) Ethylene Propylene Diene Monomer ( EPDM ) Ethylene Propylene Rubber ( EPM ) Fluoro Vinyl Methyl Silixone Rubber ( FVMQ ) Cholorosulfonated Polyethylene Rubber ( CSM )

Batch weighing Computerized Batching Weighing line Dispersion Kneaders Mixing Mills Rubber Calendaring Preform Sheet cutting Vacuum spin trimming Oil Seal trimming machines Manual trimming

Compounding – Mixing Mills

Metal Bonding – Surface treatments & Adhesive Application • Chemical treatments Grit Blasting Ultrasonic cleaning Manual spray Booth Robotic spray booth Manual brush coating

Molding Machines Vacuum Compression Molding Line • 28 Vacuum compression molding machines between 65 - 500 tons Injection molding machine 55 tons for precision pa

Molding Machines Compression Molding Line • 4.2 meter long press with 1200 tons 17 Hydraulic compression molding machines between 20 - 600 tons 2 Manual molding machine with 5 – 10

Polyurethane Casting Line • Polyurethane line up to 48” size - 2 Lines 90% parts are exported to NA Countr

Calendaring Machine • Rubber Calendaring Rubber to fabric Calendaring Multi layer Cale

Deflashing and Inspection Line - 68 seat

Laboratory Over View • Inspection instruments Specimen Storage Racks Test Reports Storage Racks Un interrupted Quality power supply Controlled Atmosphere Endurance Tests

NSF / ANSI / CAN 61 Approved for EPDM & NBR

Laboratory Rheometer • To Measure viscoelastic properties To study the process behavior To determine the scorch time To check shelf life of the green

Laboratory Mooney Viscometer • Measure Mooney Viscosity To measure stress relaxation of the compound To measure the pre-vulcanization characteristics of the compound

Laboratory Hardness testers • Shore °A For Soft Rubber – ASTM D 2240 Shore °D For Hard Rubber – ASTM D 2240

Laboratory Specific Gravity analyzer • Can measure solid and liquid densities

Laboratory Universal Testing Machine • Tensile Strength - ASTM D 412 Tear Strength - ASTM D 624 Adhesion Strength – ASTM D 429 Method B Elongation at Break – ASTM D 412 Modulus at % Elongation - ASTM D 412 Stress – Strain Analysis Load Vs Deflection study Fatigue Tests

Laboratory Aging Oven • Minute wise data recording Step programmable Swell Tests – ASTM D 471

Muffle Furnace Program callouts per standards Close tolerance in temperature

Measuring Instruments • VMS for part inspection – 3 Axis Height gauges Dial gauges Radius gauges Pitch gauges Bore Dial gauges Surface tables Feeler gauges, Thickness gauges Groove micrometers

Development Activities • Product feasibility study Rubber shrinkage study Productivity requirements Mold concept Mold cavities Mold design Mold material Mold manufacturing Surface finishing requirements Mold assembly

Rubber Compression molds Rubber Transfer molds Rubber Tear trim molds Bakelite molds Cast polyurethane molds Rubber Oil-seal trim type molds Rubber to metal bonded molds Loading fixtures Single cavity to 1936 cavities

VMC – tool room type Turning lathes Milling machine with Digital readout Radial drilling machine Design – Solid works Surface coating

Mold Materials & Storage • Different materials used against its application Selection of mating materials to improve tool life Special guiding tools for precise profile matching of multiple plates Each tool conditioned after molding and kept ready for production at its dedicated loc

23 years of prototype tooling at inhouse Experienced tool designers Experienced management guidance Long tool life materials Tooling module enabled software Genuine tooling materials

Tool room Advantages • Tool design inputs from manufacturing department heads & professionals Special molds for shrinkage calculation against specific compounding needs Parting line guidance for best in class product field performance Tool Rework data storage for 3 years Parts producing experience for global markets Manufacturing guidance to improve productivity Heat transfer based desig

Metal Encapsulated Valve Parts

Custom Molded Parts

Butterfly valve parts

Aluminium Back up Butterfly valve seats

Replaceable liners

Hard Rubber parts

Leveler Mounts

Metal Bonded parts

Bakelite parts

Rubber Sockets

Rubber Diaphragms

Rubber Grommets