PRODUCT & COMPOUND DEVELOPMENT
At Rubber Consultants, we offer comprehensive product and compound development services, specialising in the formulation and processing of both natural and synthetic elastomers.
Our team of experienced technologists operates in a modern mill room equipped with state-of-the-art machinery, enabling us to meet clients' specific requirements with precision and efficiency.
Compound and Process Development: Our technologists excel in small-scale specialised custom compounding, where we can create tailor-made formulations and optimise mixing cycles to meet your unique needs. Whether it's developing new formulations or modifying existing ones, we are committed to delivering compounds that match your specifications. Additionally, we provide independent assessment of rubber compounds to validate clients' existing certifications.
Product Design and Manufacturing: With our product design, development, and manufacturing service, we can produce parts ranging from one-off prototypes to small production runs, all under the quality standards of ISO 9001:2015. Our expertise extends beyond manufacturing in-house, as we can assist in identifying suitable partners for larger volume production, leveraging our strong relationships within the global manufacturing industry.
Rubber Processing Facilities: Our fully equipped Mill Room offers cutting-edge machinery for processing and characterising rubbers, thermoplastic elastomers, and thermoplastics.
Internal Mixers: We have five internal mixers with varying batch capacities, ensuring efficient and precise mixing. These machines, including the Polylab PL2000, BR Banbury, OOC Banbury, and Intermeshing Mixer, are equipped with PC control for seamless data collection during the mixing process.
Mills: Our ten two-roll mills are capable of handling different capacities, with one mill specifically designed for Technically Specified Rubber (TSR) testing and another for breaking down high viscosity materials.
Extruders: Two cold feed rubber extruders, with screw diameters of 30mm and 60mm, facilitate continuous mixing of TPE and TPR. Our Prism twin screw compounding extruder enables precise mixing with its modular barrel and advanced PLC control system.
Calender: For precise calendering, we have an 800mm three-bowl vertical calender with take-up and lining equipment fitted.
Injection Moulding: Our LWB Steinl Injection Moulding Press and Arburg Allrounder 220-90-350 provide excellent capabilities for both rubber and thermoplastics injection moulding.
Compression Moulding Presses: Ten steam and electrically heated compression moulding presses offer a wide range of platen sizes, operating at pressures up to 140MPa and temperatures up to 250°C.
Processability Analyses: We utilise Monsanto Rheometers (MDR2000 and MDR2000E) and MooneyViscometers to analyse cure behaviour and rubber viscosity. The RH7Twin-Bore Capillary Rheometer evaluates material flow behaviour under shear.
Rubber Bonding Facilities: Our dedicated laboratory features equipment for surface preparation and bonding, including ultrasonic degreasing tanks, grit-blasting machine, and spray booth for the application of bonding systems.
Miscellaneous Equipment: To ensure quality and accuracy, we have a dispergrader for filler dispersion assessment, pneumatic guillotine for slicing rubber bales, Blackfriars Granulators for chopping raw rubber or plastic, Fielder Blenders for mixing and blending, and a comprehensive stock of rubbers, fillers, and rubber chemicals.
