LATEX COMPOUNDING

Natural latex is a unique natural substance which finds numerous uses in our daily life. We
assume that the reader has the understanding about how latex is colleted, preserved and
concentrated; and also about the usable forms of natural rubbers. This article is limited to
compounding of natural latex and pre vulcanized latex.
The basic and conventional ingredients for latex compounding are Sulphur, Zinc Oxide
(ZnO), and ZDC (Zinc Diethyldithiocarbamate). Apart from these materials, we may
require stabilizers, antioxidants, plasticizers, extenders, fillers, modifiers etc.

The compound design is different for each application. It may appear almost similar, and
a common man may wonder whether certain small variation in percentage of some
chemicals is going bring in any change in properties. The fact is, as in any polymerization
reaction, in rubber also we can bring about variations in properties, very critical for some
applications by suitably adjusting the chemicals used for compounding. This is not very
much thought about because; at present the critical application of latex products is limited
to a very small number of products like surgical gloves, condoms, catheter and medical
tubing. The aim of this article is to point out some vital points in determining the type and
quantity of ingredients for compounding.

Before going further into compounding, we wish to make clear that we use phr (per
hundred parts of rubber) values in this article, which is the universal approach.

Unlike dry rubber compounding, latex compounding requires to satisfy one essential
condition. That is, the stability of latex at the time of compounding and after. The
mechanism of stabilization is beyond the scope of this article. Generally, Potassium
Hydroxide is used as a static chemical stabilizer and Fatty acid soaps as mechanical
stabilizer. The quantity requirement of stabilizers depends on various factors like age,
MST, temperature, load (quantity of powders added, duration of agitation, mechanical
load applied for transfers and in production), viscosity of compound to be maintained,
duration of storage etc. and it ranges from 0.0 phr to 3.0 phr.

The addition of fatty acid soaps brings about some undesirable properties also to the
latex; froth is one among them. The others are reduction of tack and surface tension and
viscosity reduction. Stabilizers are found to have some impact on cure also. Though,
some of these are requirements in certain applications like foam and in spraying, they are
undesirable in most applications. Thus, excess stabilizer is detrimental in most
applications.

Some stabilizers are added for preservation of latex, details of which most producers do
not disclose. Therefore, initial MST of latex should be taken as a base for determining the
quantum of additional stabilization. The MST and drying time taken to form a film can be
used as an indicator. The quantity requirement of stabilizer can vary from 0 phr to 3 phr
in a latex compound and is solely depended on production requirements.

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Another consideration in compound design is the viscosity. Viscosity of raw latex
depends on its concentration. (Sometimes aged latex may show more viscosity due to
thickening which is a different scenario). Commercially available latex has 50% - 60%
rubber content. De-sludged PFL (preserved field latex) which has about 38% rubber
content is also available. Thus, selection of latex becomes very important in compound
design. Modifiers of various types are being used to increase viscosity of compound
where it becomes essential.

Addition of compounding ingredients increases viscosity. Therefore, TSC (total solid

content) of the compound has to be decided before compounding depending on the
required viscosity. For example, a lean compound may be suitable for spraying, but will
be unsuitable for dipping. All ingredients into latex compound are added as their
dispersions, emulsions, solutions, or as water miscible liquids. Therefore, concentration
of dispersions and emulsion is also predetermined in compound design.

Having designed the physical characteristics of the compound, now it is time to decide on
the characteristics of product. Thus, quantity and type of vulcanizing ingredients,
protective system, reinforcing materials and extenders have to be designed according to
required vulcanization properties of the product.

Sulphur is inevitable in vulcanization of rubber except for a sulphurless cure system. The
quantity of sulphur varies from 0.5 phr to 3.5 phr for most latex applications. Hardness
increases with increase of sulphur. Unlike in dry rubber where with high sulphur we get
ebonite, latex gives no similar product. Zinc oxide plays a multiple role. Apart from
activation, some excess zinc oxide forms reinforcing filler. But, it tends to form a
complex with ammonia and gel, which in turn reduce stability. Quantities from 0.1 phr to
5 phr is used depending on the process requirement, which again is dependent on
production requirements.

Latex requires ultra fast accelerators like dithiocarbamates as their Zinc or Sodium salts.
Zinc mercapto benzothiozole is sometimes used as a secondary accelerator for scorch
safety and it also is said to improve tensile properties. About 0.7 to 1.0 phr antioxidants
have been found sufficient for most requirements. Phenolic or trimethyl dihydroquinoline
antioxidants are preferred in latex compounds for they are non-staining or mild staining.
But, if you ask us there is no limit of choices.

Synthetic latex and some polymeric materials generally called modifiers are added to
latex to impart certain properties. Materials like oil, paraffin, metallic stearates etc, which
we generally call plasticizers can increase flexibility. But, consideration in selection of
these modifiers or plasticizers should be based on need and suitability. Many materials
that are compatible with dry rubber cannot be used with latex.

Fillers are considered as cheap materials which add weight. But it is not so. They impart
many properties to the product if wisely used. The common fillers used in latex are china
clay, precipitated silica, and whiting (calcium carbonate). Among these, china clay and
precipitated silica can be considered as reinforcing fillers. The others are extenders used

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either to increase volume or weight. There is a common problem with fillers and
extenders. Their particle size if not reduced properly and dispersed well, settle to the
bottom carrying rubber particles with them destroying the homogeneity of compound or
even coagulating it. Some of the fillers have acidic character, their impact go unnoticed
because of the high pH of latex compound due to ammonia. They give rise to a curd like
compound, not tacky, not coagulated, but unstable.

Natural latex has a unique property, that it is possible to prevulcanize it. Prevulcanized
latex (PVL) finds application in many products which require low temperature curing.
But, it is found that freshly compounded latex gives more tack, tensile strength and
higher modulus than PVL. However, prevulcanized latex also can be suitably modified to
give equal performance.

Finer details of compound design depend on the product. Any reader with a specific
requirement may contact us. We are happy to serve them always.