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The Complete Book on Rubber Processing and Compounding Technology (Rubber Vulcanization, Compounding, Rubber Gloves, Condoms, Rubber Band, Latex Mattress, Bushings, Gasket, Sheets, Tubing, Tyre, Hoses, Conveyor Belt, Latex and Foam Rubber, Silicone Rubber, Reclaimed Rubber, Waste Tyre Recycling with Manufacturing Process, Machinery Equipment Details and Factory Layout) 3rd Revised Edition
The Complete Book on Rubber Processing and Compounding Technology (Rubber Vulcanization, Compounding, Rubber Gloves, Condoms, Rubber Band, Latex Mattress, Bushings, Gasket, Sheets, Tubing, Tyre, Hoses, Conveyor Belt, Latex and Foam Rubber, Silicone Rubber, Reclaimed Rubber, Waste Tyre Recycling with Manufacturing Process, Machinery Equipment Details and Factory Layout) 3rd Revised Edition ( New Arrival ) ( ) ( ) ( ) ( )
Author P.K. Tripathi ISBN 9788178331621
Code ENI358 Format Paperback
Price: Rs 2275   2275 US$ 58   58
Pages: 632 Published 2023
Publisher Asia Pacific Business Press Inc.
Usually Ships within 5 Days

Description:

Rubber processing and compounding refer to the process of transforming natural or synthetic rubber into various usable products, such as tyres, rubber seals, belts, and hoses. The rubber processing industry encompasses various methods of transforming raw rubber into useful products, which include blending, mixing, extrusion, molding, and curing.

Rubber compounding involves the addition of various additives, such as carbon black, antioxidants, curing agents, plasticizers, and other chemicals, to modify the physical and mechanical properties of the rubber. Compounding ingredients and techniques vary according to the end-use application and the desired properties of the final product. Rubber compounds are widely used in various industries, including automotive, construction, electrical, and healthcare. The unique properties of rubber compounds, such as durability, flexibility, and resistance to heat and chemicals, make them ideal for various applications.

The market for rubber processing and compounding is positive, with increasing demand for high-performance and environmentally sustainable rubber products. Key trends driving this growth include a growing demand for electric vehicles, advancements in tyre technology, and increased demand for rubber products in emerging markets.

The market is expected to grow at a steady rate in the coming years, with a compound annual growth rate (CAGR) of 5.3%. This growth can be attributed to the rising demand for high-performance and eco-friendly rubber products. The increasing demand for rubber processing and compounding services in the Asia-Pacific region is one of the primary drivers of the market growth. China and India are the key markets in the region, with high growth potential due to the growing automotive industry and government initiatives promoting the use of eco-friendly materials. Moreover, the increasing demand for tyres, rubber seals, gaskets, and hoses, coupled with advancements in the manufacturing process, is driving the growth of the market. Another trend driving the market is the growing focus on sustainability and reducing the carbon footprint. Many companies are investing in research and development to develop sustainable rubber products. The rubber processing and compounding industry is witnessing rapid growth in recent years. With the increasing demand for rubber products across various industries such as automotive, construction, healthcare, and electronics, the market outlook for this industry looks promising.

The book's main contents are Mixing Technology of Rubber, Techniques of Vulcanization, Rubber Vulcanization, Rubber Compounding, Rubber Gloves Manufacturing, Condoms Manufacturing, Rubber Band Manufacturing, Latex Mattress Manufacturing, Rubber Bushings Production, Rubber Gasket Manufacturing, Rubber Sheets Manufacturing, Rubber Tubing and Its Manufacturing, Tyre Manufacturing, Waste Tyre Recycling Process, Hoses Manufacturing, Conveyor Belt Production, Latex and Foam Rubber, Silicone Rubber, Reclaimed Rubber, Rubber Natural. The Manufacturing Process, Machinery Equipment Details, and Photographs with Suppliers Contact Details are also given.

A total guide to manufacturing and entrepreneurial success in today’s most demandable rubber processing and compounding industry. This book is one-stop guide to one of the fastest growing sectors of the rubber processing and compounding industry, where opportunities abound for manufacturers, retailers, and entrepreneurs. This is the only complete handbook on the commercial production of rubber. It serves up a feast of how-to information, from concept to purchasing equipment.

Content

1. Introduction

        1.1.   Rubber Applications   

        1.2.   Types of Rubber           

                   1.2.1. Natural Rubber     

                  1.2.2. Synthetic Rubber   

        1.3.   Production of Synthetic Rubber             

        1.4.   Market of Rubber         

  2.   Mixing Technology of Rubber

        2.1.   Introduction   

        2.2.   Mixing Machinery for Rubber  

                  2.2.1. Two-roll Mills         

                  2.2.2. Internal Batch Mixers           

                  2.2.3. Continuous Mixers

                  2.2.4. Development of the Banbury Mixer   

                  2.2.5. Operating Variables             

        2.3.   Mixing Cycles and Procedures 

                  2.3.1. Unit Operations in Mixing   

                  2.3.2. Single-Pass Versus Multiple-Pass Mixing          

                  2.3.3. Types of Mix Cycle 

                  2.3.4. Analysis of Changes to the Mix Procedure       

        2.4.   Mill Mixing      

                  2.4.1. Acceleration of First-pass Compound               

                  2.4.2. Mill Mixing of Speciality Compounds

                  2.4.3. Acceleration in Line with Internal Mixing       

        2.5.   Quality Control And The Mixing Process              

                  2.5.1. Testing of Raw Materials     

                  2.5.2. Elastomers as Raw Materials              

                  2.5.3. Control of Composition        

                  2.5.4. Tracking the Mix Cycle         

                  2.5.5. Compound Testing

        2.6.   Statistical Process Control For Industrial Mixing             

                  2.6.1. Basic SPC Charting               

                  2.6.2. Rheometer Data and its Meaning      

                  2.6.3. Mixing Control Software      

        2.7.   Additives that Affect Mixing     

                  2.7.1. Peptisers in Natural Rubber

                  2.7.2. Peptisers in SBR    

                  2.7.3. Peptisers in Sulphur-containing Polymers       

                  2.7.4. Additives to Increase Viscosity           

                  2.7.5. Preventing Unwanted Chemical Reactions      

        2.8.   Operation and Maintenance of Mixing Equipment          

                  2.8.1. Inspection of Banbury Mixers            

                  2.8.2. Inspection at the Mezzanine Level    

                  2.8.3. Inspection of the Banbury Platform  

                  2.8.4. Mixer Maintenance and Lubrication

                  2.8.5. Anticipating Required Service           

                  2.8.6. Dust Stop Maintenance        

                  2.8.7. SSA Dust Stops       

                  2.8.8. Banbury Mixer — Hydraulic Dust Stops           

        2.9.   Mixing Procedures for Specific Compounds       

                  2.9.1. EPDM Expansion Joint Cover              

                  2.9.2. Expansion Joint Intermediate Layer 

                  2.9.3. Traffic Counter Treadle Cover            

                  2.9.4. SBR/IR Belt Cover 

                  2.9.5. EPDM Low Voltage Electrical Connector          

                  2.9.6. Peroxide-cured Black-filled EPDM Compounds

                  2.9.7. EPDM Concrete Pipe Gasket                

                  2.9.8. Injection-moulded NBR Gasket          

                  2.9.9. CR/SBR Blend        

                  2.9.10. Low Durometer CR/SBR Blend         

                  2.9.11. Non-black CR for Injection Moulding             

                  2.9.12. Hard Rubber Industrial Wheel         

                  2.9.13. High Durometer NBR Masterbatch 

                  2.9.14. NBR/PVC Cable Jacket       

                  2.9.15. NBR/PVC/SBR Blend         

                  2.9.16. Butyl Masterbatch              

                  2.9.17. Butyl Masterbatch, Heat Interacted

                  2.9.18. Chlorobutyl/NR Blend       

                  2.9.19. CSM CORD Jacket

                  2.9.20. Non-black Millable Urethane            

         2.10. Mixing Wire and Cable Compounds      

                  2.10.1. Some Major Changes          

                  2.10.2. Tempered Water 

                  2.10.3. Power-controlled Mixing   

                  2.10.4. Energy Conservation          

        2.11. Mixing Ethylene-Propylene Diene Rubber        

                  2.11.1. Composition of EPDM Elastomers   

                  2.11.2. Variables in EPM and EPDM Elastomers        

                  2.11.3. How Processing Relates to Structure

                                   and Rheology   

                  2.11.4. Practical Guidelines for Mixing EP Elastomers             

                  2.11.5. Downstream Processing Equipment

                  2.11.6. Summary              

        2.12. Mixing of Tyre Compounds      

                  2.12.1. Rework  

                  2.12.2. Phase Mixing       

                  2.12.3. Natural Rubber Viscosity Reduction              

                  2.12.4. Measurement of Mixing Efficiency  

        2.13.           Mixing Fluoroelastomer (FKM) Compounds           

                  2.13.1. Special Considerations      

                  2.13.2. Raw Materials     

                  2.13.3. Typical Formulations         

                  2.13.4. Internal Mixing   

                  2.13.5. Mill Mixing           

                  2.13.6. Summary              

                  2.13.7. Accounting Methods          

        2.14. Continuous Mixing      

                  2.14.1. Farrel Continuous Mixer   

                  2.14.2. Operating Principles of the FCM      

                  2.14.3. Commercial Applications for the FCM            

                  2.14.4. Farrel Mixing Venting Extruder (MVX)           

        2.15. Evaluating the Performance of Internal Mixers              

                  2.15.1. Designing the Rotor           

                  2.15.2 Analysis of Dispersive Mixing           

  3.   Techniques of Vulcanization

         3.1. Introduction     

                  3.1.1. Pressureless Vulcanization  

        3.2.   Pressurized Vulcanization        

                  3.2.1. Rubber Moulding  

                  3.2.2. Factors of Mouding              

                  3.2.3. Moulding

                  3.2.4. Compression Moulding        

                  3.2.5. Transfer Moulding

                  3.2.6. Injection Moulding

        3.3.   Mould Shrinkage          

        3.4.   Moulding Defects          

        3.5.   Pressurized Liquid Continuous Vulcanization   

        3.6.   High-Velocity Gas Cure

                  3.6.1. Helicure  

        3.7.   Finishing           

        3.8.   Recycling of Vulcanized Rubber Products          

                  3.8.1. Buffed Tread Crumb             

                  3.8.2. Incineration and Pyrolysis of Tyres   

                  3.8.3. Reclaimed Rubber

  4.   Rubber Vulcanization

        4.1.   Vulcanization And Its Effects    

        4.2.   Vulcanization Reaction Stages 

        4.3.   Vulcanization of Thick Rubber Articles

        4.4.   Determination of State of Vulcanization              

                  4.4.1. Physical Property Tests        

                  4.4.2. Free Sulphur Determination

                  4.4.3. Solvent-swell Method            

                  4.4.4. Mooney-Rivlin Equilibrium Modulus

                  4.4.5. Differential Scanning Calorimetry     

                  4.4.6. Determination of Spring Constant     

        4.5.   Vulcanization Systems

                  4.5.1. Sulphur Vulcanization         

        4.6.   Overall Course of Accelerated Sulphur Vulcanization    

                  4.6.1. Peroxide Crosslinking          

                  4.6.2. Resin Vulcanization             

                  4.6.3. Electron Beam Vulcanization             

                  4.6.4. Nitroso Compounds              

                  4.6.5. Metal Oxides           

  5.   Rubber Compounding

        5.1.   Introduction   

                  5.1.1. General Compounding Principles      

        5.2.   Vulcanizate Physical Properties and their Significance

                  5.2.1. Tensile Strength     

                  5.2.2. Tear Resistance     

                  5.2.3. The Crescent Tear Test         

                  5.2.4. The Hardness of Rubber      

                  5.2.5. Set            

                  5.2.6. Abrasion Resistance             

                  5.2.7. Flex Cracking Resistance     

                  5.2.8. Resilience

                  5.2.9. Heat Build-up        

                  5.2.10. Temperature Resistance    

        5.3.   Compound Properties Desired for Different

                     Rubber Compounds  

                  5.3.1. Tyres        

                  5.3.2. Retreading Materials           

                  5.3.3. Conveyor Belting, Transmission Belting and Hose        

                  5.3.4. Footwear

                  5.3.5. Rubber Roller         

                  5.3.6. Medical Applications           

                  5.3.7. ‘O’ rings and Seals 

        5.4.   Compounding Ingredients        

                  5.4.1. Rubber Blends       

                  5.4.2. Master Batches      

                  5.4.3. Choice of Rubber  

                  5.4.4. Fillers       

                  5.4.5. Vulcanizing Agents               

                  5.4.6. Peptizers 

                  5.4.7. Accelerators           

                  5.4.8. Activators               

                  5.4.9. Anti-oxidants         

                  5.4.10. Retarders              

                  5.4.11. Softeners and Plasticizers 

                  5.4.12. Rubber Crumb     

                  5.4.13. Factice  

                  5.4.14. Processing Aids   

                  5.4.15. Special Purpose Additives 

        5.5.   Basic Compound Formulations

                  5.5.1. Unvulcanized compound properties

                  5.5.2. Vulcanized compound properties      

  6.   Rubber Gloves Manufacturing

        6.1    Synthetic rubber gloves             

                  6.1.1. Nitrile gloves         

                  6.1.2. Vinyl gloves            

        6.2.   Use of Rubber Gloves  

                  6.2.1. Medical Use            

                  6.2.2. Food Preparation 

                  6.2.3. Cleaning  

                  6.2.4. Salons & Spas         

                  6.2.5. Automotive Work  

                  6.2.6. Construction          

                  6.2.7. Security & Police Investigations        

                  6.2.8. Laboratories          

                  6.2.9. Gardening & Outdoor Work

                  6.2.10. Child Care             

        6.3.   Can Reuse Rubber Gloves?        

                  6.3.1. Reusable 

                  6.3.2. Disposable              

        6.4.   Glove Manufacturing Process   

                  6.4.1. Latex Collection     

                  6.4.2. Coagulant Dipping

                  6.4.3. Drying     

                  6.4.4. Latex Dipping        

                  6.4.5. Leaching 

                  6.4.6. Beading  

                  6.4.7. Vulcanization        

                  6.4.8. Post Leaching        

                  6.4.9. Slurry Dipping       

                  6.4.10. Stripping              

                  6.4.11. Tumbling              

                  6.4.12. Quality Control    

                  6.4.13. Packing 

  7.   Condoms Manufacturing

        7.1.   History              

        7.2.   Manufacturing process               

                  7.2.1. Collecting the raw materials               

                  7.2.2. Compounding        

                  7.2.3. Storage    

                  7.2.4. Dipping   

                  7.2.5. Tumbling

                  7.2.6. Condom Testing Procedures               

                  7.2.6. Packaging              

                  7.2.7. Packaging for Retail            

                  7.2.8. The finished product            

  8.   Rubber Band Manufacturing

        8.1.   Rubber Band Dimensions and Measuring          

        8.2.   Sizes

        8.3.   Rubber Types Used in Rubber Bands   

        8.4.   Rubber Band Uses        

        8.5.   Applications of Rubber Bands 

        8.6.   The Manufacturing Process      

                  8.6.1. Processing the natural latex

                  8.6.2. Mixing and milling

                  8.6.3. Extrusion

                  8.6.4. Curing     

                  8.6.5. Quality Control      

  9.   Latex Mattress Manufacturing

        9.1.   Types of Latex

        9.2.   Benefits of a Latex Mattress      

        9.3.   Manufacturing Process               

                  9.3.1. Collecting the Raw Material

                  9.3.2. Processing of Liquid Latex 

                  9.3.3. Forming the latex foam       

                  9.3.4. Inspect the Latex Foam Layers for Quality      

                  9.3.5. Finishing the Latex Foam with Fine Details    

                  9.3.6. Covering the Latex Foam with Fabric              

10.  Rubber Bushings Production

        10.1. Rubbers Used in Rubber Bushing Manufacture              

                  10.1.1. Natural Rubber   

                  10.1.2. Styrene Butadiene Rubber (SBR)    

                  10.1.3. Nitrile Butadiene Rubber (NBR)     

                  10.1.4. Silicone Rubber   

                  10.1.5. Ethylene Propylene Diene Monomer (EPDM)     

        10.2. Uses of Rubber Bushings          

                  10.2.1. Automotive Manufacturing              

                  10.2.2. Rubber Bushings in Skateboards    

                  10.2.3. Shock Bushings   

                  10.2.4. Tank Bushing      

                  10.2.5. Bushings in Fans

        10.3. How are Bushings Made?          

        10.4. Extrusion Procedure  

                  10.4.1. Raw Rubber Compound    

                  10.4.2. Feed Hopper        

                  10.4.3. Extruding the Rubber Compound    

                  10.4.4. Hot and Cold Feed Extrusion            

                  10.4.5. Vulcanization Process       

                  10.4.6. In Line Curing and Off Line Curing 

11.  Rubber Gasket Manufacturing

        11.1. Industrial Applications of Rubber Gaskets        

                  11.1.1. Pipe Fittings and Industrial Piping 

                  11.1.2. Plumbing and Water Utility              

                  11.1.3. Automotive          

                  11.1.4. Aerospace            

                  11.1.5. Marine  

                  11.1.6. Tanks, Vessels, and Containers         

                  11.1.7. Manufacturing of Food and Drugs 

        11.2. Manufacturing Process              

                  11.2.1. Die-Cutting           

                  11.2.2. Water Jet Cutting

                  11.2.3. Laser Cutting       

                  11.2.4. Flash Cutting       

                  11.2.5. Injection Molding

                  11.2.6. Extrusion of Rubber Gaskets            

        11.3. Processes of Vulcanization       

                  11.3.1. Steam Curing       

                  11.3.2. Continuous Curing             

                  11.3.3. Hot Splicing         

12.  Rubber Sheets Manufacturing

        12.1. Benefits of Rubber Sheets        

        12.2. Types of Rubber Sheets            

                  12.2.1. Natural Rubber Sheets       

                  12.2.2. Neoprene Rubber Sheets   

                  12.2.3. Nitrile Rubber Sheets         

                  12.2.4. Hydrogenated Nitrile (HNBR)         

                  12.2.5. Rubber Ethylene Propylene (EPDM Rubber Sheets)

                  12.2.6. Silicone Rubber Sheets      

                  12.2.7. Fabric Reinforced Rubber Sheets    

                  12.2.8. Styrene-Butadiene Rubber (SBR) Sheet         

                  12.2.9. Viton Sheets         

                  12.2.10. Butyl (IIR)          

        12.3. Rubber Sheet Materials            

                  12.3.1. Thermoplastic Polymers    

                  12.3.2. Thermoset Polymers           

                  12.3.3. Rubbers in Rubber Sheets 

                  12.3.4. Compounding Ingredients

        12.4. Manufacturing Process of Rubber Sheets          

                  12.4.1. Molding

                  12.4.2. Extrusion              

                  12.4.3. Latex Dipping      

                  12.4.4. Calendering         

                  12.4.5. Rubber Sheet Joining         

13.  Rubber Tubing and Its Manufacturing

        13.1. Rubber Materials Used in the Production of

                     Rubber Tubing

        13.2. Types of Rubber Materials       

                  13.2.1. Fluoroelastomer Rubber Tubing (FKM or Viton™)      

                  13.2.2. Butyl Rubber Tubing          

                  13.2.3. Hypalon Rubber Tubing (Chloro sulfonated

                                  Polyethylene of CSM)        

                  13.2.4. Natural Rubber Tubing (NR)           

                  13.2.5. Neoprene Rubber Tubing (Polyisoprene)      

                  13.2.6. Nitrile Rubber Tubing       

                  13.2.7. Styrene Butadiene Tubing (SBR)     

                  13.2.8. Silicone Rubber Tubing     

                  13.2.9. Thermoplastic Rubber Tubing (TPE)              

                  13.2.10. Ethylene Propylene Diene Monomer

                                    Rubber Tubing (EPDM)

                  13.2.11. Hytrel® Rubber Tubing  

        13.3. Types of Rubber Tubing           

                  13.3.1. Food Grade Rubber Tubing              

                  13.3.2. Medical Grade Rubber Tubing         

                  13.3.3. Conductive Rubber Tubing               

                  13.3.4. Microbore Rubber Tubing

                  13.3.5. Air Rubber Tubing             

                  13.3.6. Chemical Rubber Tubing  

                  13.3.7. Heat Shrink Rubber Tubing              

                  13.3.8. Fabric Reinforced              

                  13.3.9. Non-Reinforced Rubber Tubing      

        13.4. Industries that Use Rubber Tubing     

                  13.4.1. Automotive          

                  13.4.2. Agriculture           

                  13.4.3. Aerospace            

                  13.4.4. Food Processing 

                  13.4.5. Marine  

                  13.4.6. Medical and Pharmaceutical           

        13.5. Manufacturing Process              

        13.6. Mandrel Process

                  13.6.1. Rubber Roll

                  13.6.2. Milling

                  13.6.3. Cutting

                  13.6.4. Mandrel

                  13.6.5. Reinforcement Layer

                  13.6.6. Final Layer

                  13.6.7. Taping

                  13.6.8. Vulcanization

                  13.6.9. Removing from the Mandrel

         13.7. Extrusion Method

                  13.7.1. Feeding

                  13.7.2. Revolving Screw

                  13.7.3. Rubber Tubing Die             

                  13.7.4. Vulcanization

14.  Tyre Manufacturing Process

        14.1. The Parts of a Tyre      

                  14.1.1. Beads    

                  14.1.2. Belt        

                  14.1.3. Ply          

                  14.1.4. Sidewall

                  14.1.5. Sipe and Groove  

                  14.1.6. Shoulder

                  14.1.7. Tread     

        14.2. Raw Materials               

        14.3. Production Process     

                  14.3.1. Body, beads, and tread      

                  14.3.2. Tyre-building machine      

                  14.3.3. Curing   

15.  Waste Tyre Recycling Process

        15.1. Application of Recycling Waste Rubber              

        15.2. Benefits of Tyre Recycling        

                  15.2.1. Creates New Products        

                  15.2.2. Reduces Volume of Tyre on Landfill Space    

                  15.2.3. Helps to Prevent Diseases  

                  15.2.4. Prevents Fires and Pollution             

        15.3. Pyrolysis Process for Waste Rubber Tyre Recycling      

        15.4. Application of Products Derived From Pyrolysis Process

        15.5. Process of Tyre Recycling         

                   15.5.1. Collection of Waste Tyres  

                  15.5.2. Tyre Processing (Shredding)            

                  15.5.3. Steel Liberation   

                  15.5.4. Screening Stage  

                  15.5.5. Cleaning Stage    

                  15.5.6. Packaging and Transporting Stage

16.  Hoses Manufacturing

        16.1. Design of Hoses             

        16.2. Hose Manufacture       

        16.3. Braided/Spiralled Hoses          

17.  Conveyor Belt Production

        17.1. Parts of a Conveyor Belt            

                  17.1.1. Strength member

                  17.1.2. Inter ply rubber   

                  17.1.3. Cover rubber        

                  17.1.4. Breaker 

        17.2. Manufacturing Process              

                  17.2.1. Fabric preparation            

                  17.2.2. Preparation of cover rubber            

                  17.2.3. Slitting of plies    

                  17.2.4. Raw belt making 

                  17.2.5. Vulcanization      

                  17.2.6. Inspection and repair        

                  17.2.7. Finished belt testing           

                  17.2.8. Belt grade             

        17.3. PVC Belting     

        17.4. Steel Cord Belting        

        17.5. Advantages of steel cord belting            

18. Latex and Foam Rubber

        18.1. Introduction  

        18.2. Products From Latex  

                  18.2.1. Selection of Raw Materials

                  18.2.2. Preparation of Raw Materials          

                  18.2.3. Compounding and Design

                  18.2.4. Maturation           

                  18.2.5. Processing and shaping    

                  18.2.6. Dipped Goods      

                  18.2.7. Latex Thread       

                  18.2.8. Vulcanisation      

                  18.2.9. Hot Air Cure         

                  18.2.10. Hot Water Vulcanisation

                  18.2.11. Autoclave Vulcanisation 

                  18.2.12. Radiation Vulcanisation 

                  18.2.13. Ultrasonic Wave Curing  

                  18.2.14. Testing of Rubber Products            

                  18.2.15. Packing and Marketing   

                  18.2.16. Conclusions and Recommendations             

        18.3. Latex Foam     

                  18.3.1. Manufacture of Latex Foam             

                  18.3.2. Dunlop Process    

                  18.3.3. Mechanism of Gelling        

                  18.3.4. Compounding      

                  18.3.5. Foaming and Gelling         

                  18.3.6. Construction of Moulds     

                  18.3.7. Curing   

                  18.3.8. Washing               

                  18.3.9. Drying   

                  18.3.10. Finishing            

        18.4.Common Defects in Foam Making          

                  18.4.1. Shrinkage             

                  18.4.2. Foam Collapse     

                  18.4.3. Setting   

                  18.4.4. Complete Distortion of the Foam     

        18.5. Estimation of Protein Contamination in Latex 

                  18.5.1. Protein estimation protocol             

                  18.5.2. Conlusion             

19.  Silicone Rubber

        19.1 Introduction   

        19.2.Types of Silicone Rubber           

                  19.2.1. Electronics and Electrical Industries              

                  19.2.2. Silicone Rubbers to Mimic Flesh      

        19.3. Synthesis Of Silicone Polymers              

        19.4. Vulcanisation

        19.5. Compounding Ingredients       

                  19.5.1. Silicone Polymers

                  19.5.2. Silicone Rubber Elastomers              

                  19.5.3. Reinforcing Fillers              

                  19.5.4. Semireinforcing or Extending Fillers              

                  19.5.5. Additives              

                  19.5.6. Curing Agents      

        19.6. Compounding

                  19.6.1. Mixing   

        19.7. Fabricating     

                  19.7.1. Freshening           

                  19.7.2. Moulding              

                  19.7.3. Extrusion              

                  19.7.4. Calendering         

                  19.7.5. Dispersion Coating of Fabric           

                  19.7.6. Heavy-duty Hose 

                  19.7.7. Bonding

                  19.7.8. Bonding Unvulcanised Silicone Rubber         

                  19.7.9. Bonding Vulcanised Silicone Rubber             

                  19.7.10. Post-baking       

        19.8. Liquid Silicone Rubber Compounds     

                  19.8.1. Condensation Cure—One-component            

                  19.8.2. Condensation Cure—Two-component           

                  19.8.3. Addition Cure      

        19.9. Relation Between Properties of Crude and

                     Cured Silicone Compounds    

20.  Reclaimed Rubber

        20.1. Introduction  

        20.2. Types of Reclaim          

                  20.2.1. Whole Tyre Reclaim           

                  20.2.2. Minimum Staining Reclaim              

                  20.2.3. Drab and Coloured Reclaims            

                  20.2.4. Butyl Reclaim      

        20.3. Evolution of Reclaiming Processes       

        20.4. Reclaiming Processes

                  20.4.1. Scrap-rubber Preparation

                  20.4.2. Reclaimed Rubber              

                  20.4.3. Digester Process  

                  20.4.4. Reclaimator Process          

                  20.4.5. Pan Process          

                  20.4.6. Engelke Process   

                  20.4.7. Testing and Evaluations of Reclaimed Rubber             

        20.5.Dynamic Devulcanisation          

                  20.5.1. Millroom Operations          

        20.6. The Advantages of Using Reclaimed Rubber    

                  20.6.1. Special Strengths Through Reclaiming          

                  20.6.2. Further Advantages of Reclaiming–Applications        

                  20.6.3. Major Uses of Reclaimed Rubber     

        20.7. Rubberised Asphalt    

                  20.7.1. Applications        

        20.8. Reclamation of Waste Rubber from Latex Based

                     Rubber Industries    

                  20.8.1. Process  

                  20.8.2. Characterisation of Reclaimed Waste

                                   Latex Rubber (WLR)

21.  Rubber Natural

        21.1. Agriculture     

        21.2. Exploitation                                   

        21.3. Latex Composition       

        21.4. Types and Grades        

        21.5. Production     

        21.6. Latex Concentrate       

        21.7. Processing      

        21.8. Chemistry       

        21.9. Physical Properties     

        21.10. Economic Aspects     

        21.11. Applications

22.  Flow Diagram and Factory Layout

23.  Photographs of Plant and Machinery with

           Suppliers Contact Details

·         Waste Tyre Recycling Machine

·         Glove Making Machine

·         Auto Latex Condom Making Machine

·         Rubber Open Mixing Mill

·         Automatic Rubber Sheeting Machine

·         Rubber Bands Cutting Machine

·         Rubber Gasket Cutting Machine

·         Rubber Hose Machine

·         Rubber Tire Crusher Machine

·         Tyre Cutter

·         Rubber Dispersion Kneaders

·         Fully Automatic Rubber Bale Cutter

·         Rubber Calender Machine

·         Tyre Block Cutter

·         Rubber Extruder

·         Tyre Shredder Machine

·         Hydraulic Presses

·         Tyre Building Machine

·         Cold Feeding Extruder

·         Tyre Building Machine

·         Rubber Bushing Making Machine

·         Rubber Vulcaniser

·         Tyre Strip Cutting Machine

·         Mixing Mills

·         Compression Moulding Press

·         Tyre Ring Cutter

·         Rubber Tube Making Machine

·         Tyre Strip Cutter

·         Rubber Refiner Mill

·         Injection Moulding

·         Cyclone Separator

·         Banbury Mixer

·         Tyre Re-Treading Machine

·         Granulator

·         Stripping Column

 

ABOUT NPCS

NIIR Project Consultancy Services (NPCS) is a renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

Our Services

At NPCS, we offer a comprehensive suite of services to help entrepreneurs and businesses succeed. Our key services include:

  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
  • Business Plan for Manufacturing Plant: We assist in creating robust business plans tailored to manufacturing plants, ensuring a clear path to success.
  • Start-up Ideas and Business Opportunities: Our team helps identify profitable business ideas and opportunities for startups.
  • Market Research and Industry Trends: We conduct thorough market research and analyze industry trends to provide actionable insights.
  • Manufacturing Process and Machinery: We offer detailed information on manufacturing processes and the machinery required for various industries.
  • Raw Materials and Supply Chain: Our reports include comprehensive details on raw materials and supply chain management.
  • Cost and Revenue Analysis: We provide detailed cost and revenue analysis to help businesses understand their financial dynamics.
  • Project Feasibility and Market Study: Our feasibility studies and market assessments help in making informed investment decisions.
  • Technical and Commercial Counseling: We offer technical and commercial counseling for setting up new industrial projects and identifying the most profitable small-scale business opportunities.

Publications

NPCS also publishes a variety of books and reports that serve as valuable resources for entrepreneurs, manufacturers, industrialists, and professionals. Our publications include:

  • Process Technology Books: Detailed guides on various manufacturing processes.
  • Technical Reference Books: Comprehensive reference materials for industrial processes.
  • Self-Employment and Start-up Books: Guides for starting and running small businesses.
  • Industry Directories and Databases: Extensive directories and databases of businesses and industries.
  • Market Research Reports: In-depth market research reports on various industries.
  • Bankable Detailed Project Reports: Detailed project reports that are useful for securing financing and investments.

Our Approach

Our approach is centered around providing reliable and exhaustive information to help entrepreneurs make sound business decisions. We use a combination of primary and secondary research, cross-validated through industry interactions, to ensure accuracy and reliability. Our reports are designed to cover all critical aspects, including:

  • Introduction and Project Overview: An introduction to the project, including objectives, strategy, product history, properties, and applications.
  • Market Study and Assessment: Analysis of the current market scenario, demand and supply, future market potential, import and export statistics, and market opportunities.
  • Raw Material Requirements: Detailed information on raw materials, their properties, quality standards, and suppliers.
  • Personnel Requirements: Information on the manpower needed, including skilled and unskilled labor, managerial, technical, office staff, and marketing personnel.
  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
  • Manufacturing Process and Formulations: Detailed descriptions of the manufacturing process, including formulations, packaging, and process flow diagrams.
  • Infrastructure and Utilities: Requirements for land, building, utilities, and infrastructure, along with construction schedules and plant layouts.

Financial Details and Analysis

Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
  • Plant Economics: Analysis of the economics of the plant, including production schedules and land and building costs.
  • Production Schedule: Detailed production schedules and timelines.
  • Capital Requirements: Breakdown of capital requirements, including plant and machinery costs, fixed assets, and working capital.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses, including utilities, salaries, and other costs.
  • Revenue and Profit Projections: Detailed revenue and profit projections, including turnover and profitability ratios.
  • Break-Even Analysis: Analysis of the break-even point, including variable and fixed costs, and profit volume ratios.

Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
  • Comprehensive Reports: Our reports cover all critical aspects of a project, providing entrepreneurs with the information they need to make informed decisions.
  • Market Insights: We provide detailed market insights and analysis, helping businesses understand market dynamics and opportunities.
  • Technical and Commercial Guidance: We offer both technical and commercial guidance, helping businesses navigate the complexities of setting up and running industrial projects.
  • Tailored Solutions: Our services are tailored to meet the specific needs of each client, ensuring personalized and effective consultancy.

Market Survey cum Detailed Techno Economic Feasibility Report

Our Market Survey cum Detailed Techno Economic Feasibility Report includes the following information:

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
  • Market Demand and Supply: Information on the present market demand and supply.
  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
  • Market Opportunity: Identification of market opportunities.

Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
  • Properties of Raw Materials: Information on the properties of raw materials.
  • Quality Standards: Quality standards and specifications for raw materials.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
  • Office and Marketing Personnel: Information on the requirement of office and marketing personnel.

Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

  • Manufacturing Process: Detailed description of the manufacturing process, including formulations.
  • Packaging Requirements: Information on packaging requirements.
  • Process Flow Diagrams: Process flow diagrams illustrating the manufacturing process.

Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
  • Built-Up Area: Details on the built-up area required.
  • Construction Schedule: Information on the construction schedule.
  • Plant Layout: Details on the plant layout and utility requirements.

Project at a Glance

Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
  • Capital Requirements: Breakdown of capital requirements.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.

Annexures

Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
  • Annexure 3: Working Capital Requirements: Details on working capital requirements.
  • Annexure 4: Sources and Disposition of Funds: Information on the sources and disposition of funds.
  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.

Testimonials

Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.

FAQs

Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.