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Compounding unit

The process of combining several raw materials leads to the production of rubber compounds. The main goal of this process is to achieve a uniform mixture with a homogeneous distribution of components, so that its physical and mechanical properties are the same in all parts.

It is worth noting that the basis for the production of rubber products is the preparation and formulation of the rubber compound.

The mixing of materials and the production of the compound are carried out through engineering processes such as internal mixers (Banbury) and double-roller (mill).

کامپاندسازی - صنایع تولید قطعات پلیمری

The Banbury machine has a completely closed mixing chamber in which two spiral-shaped rotors rotate simultaneously. In this process, a special beater is responsible for applying pressure to the materials during mixing.

Due to the nature of the Banbury operation, the output mixture is in the form of a large and compact mass that needs to be converted into sheets of different thicknesses for further processing and shaping in subsequent stages.

For this purpose, mixing rollers are used, which consist of two parallel and horizontal cylinders and rotate in opposite directions to each other to make the mixture uniform and in the desired shape.

دستگاه غلطک لاستیک

Rubber compounding process

At this stage, raw materials including various polymers, fillers, oils, accelerators and other additives are prepared and weighed based on a specific formulation. Accuracy in measuring raw materials is essential to achieve the desired mechanical and chemical properties of the mixture.

The raw materials are fed into the Banbury machine and mixed in a closed chamber under the influence of two helical rotors and the application of percussion pressure. At this stage, the temperature and mixing time are controlled to ensure that the components are well dispersed and combined.

The mixture exits the Banbury in a large mass that needs to be homogenized and reduced in thickness. This is done by passing the mixture between two parallel rollers, rotating them in opposite directions, until the mixture is uniform and reaches the desired thickness.

After the mixing process, the mixture is kept under controlled conditions for a period of time to improve material distribution and reduce mechanical stresses. This step has a great impact on the stability and final performance of the rubber compound.

At this stage, the rubber compound is cut into various shapes (sheet, strip, granules, etc.) based on the final application and prepared for the molding or extrusion process.

In the final stage, the rubber compound is subjected to specific heat and pressure in presses or autoclaves to form a polymer network structure and allow the rubber to achieve its final properties, including strength, flexibility, and chemical resistance.

Why Omega Industrial Group Compounding?

Omega Industrial Group, utilizing advanced technical knowledge, modern equipment, and an experienced team in the field of polymer engineering, implements the compounding process to the highest industrial standards. We have an engineered and precise approach in all stages of production, from raw material selection to proprietary formulation and strict quality control, to provide rubber compounds with optimal mechanical and chemical properties for various industries.

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