Rubber Processing NC Ii: Module No: 5 Producing Blanketed Rubber Sheets Learner's Manual

RUBBER PROCESSING NC II
Module No: 5 Producing Blanketed Rubber

Sheets
Learner’s Manual
TABLE OF CONTENTS
Page
Introduction 1
How to use this module 2
Expected Outcome 3
Pre Assessment 3
Lesson 1: Prepare Machine for 6
Operation
Definition of Technical Terms 6
Lesson Information 1.0 7
Machineries in Producing
Blanketed Rubber Sheets
Self Check 1.0 16
Activity 1.0 17
Check and Adjust Rollers
Machine Maintenance
Self Check 1.1 22
Activity 1.1 23
Machine Maintenance
Lesson 2: Perform Milling 25
Operation
Definition of Technical Terms 25
Rubber Processing Milling
Operation
Activity 2.0 33
Milling Rubber
Operation Reports
Activity 2.1 36
Prepare Incident Report
Production Report
Activity 2.2 40
Determination of Weight of
Lumps and DRC
Post Assessment 43
Generalization 46
References 47
Acknowledgement 48
INTRODUCTION
Welcome to the course of Rubber Processing NCII!
This Module covers the knowledge, skills, and attitude in Rubber

Processing in accordance to industry standard which leads you to
National Certificate Level II NCII)
You need to complete and pass the self-check of this module

before you can perform higher level of competencies. Practices in this
module will help you prepare machine for operation and perform
milling operation. Desirable values and attitude must also be taken
into consideration.
This module consists of two learning outcomes. Each learning

outcome contains learning activities for both knowledge and skills,
supported with lesson information, activities, and self-checks,
gathered from different sources. Before you perform the exercises,
read the lesson information and activity page that follows. Then
answer the self-check for confirmation that you are equipped with the
knowledge necessary to perform the skills of the particular learning
outcome.
1
How Do You Use This Manual?
To get the most from this Manual, you need to do the following:
1. This Manual contains several Modules.
2. Begin by reading and understanding the Learning Outcome/s.

These would tell you what you should know and be able to do at
the end of this Module.
3. Find out what you already know by taking the Pre Assessment
then check your score. If you get 99 to 100% of the items correctly,
you may proceed to the next module. This means that you need
not go through the Lessons because you already know what it is
about. If you failed to get 99 to 100% correctly, go through the
Lessons and review especially those items which you failed to get.
4. Do the required Learning Activities. They begin with one or

more Information. The Lesson Information contains important
notes or basic information that you need to know.
After reading the Lesson Information, test yourself on how

much you learned by means of the Self-Check. Do not hesitate to
go back to the Lesson Information when you do not get all test
items correctly. This will ensure your mastery of basic information.
5. It is not enough that you acquire content or information. You

must be able to demonstrate what you learned by doing what the
Activity directs you to do. In other words, you must be able to
apply what you have learned in real life.
6. How well did you perform? Accomplish the Scoring Rubrics.
Each Lesson also provides you with references and definition of

technical terms for your guide. They can be of great help. Use them
fully.
2
EXPECTED OUTCOMES:
At the end of this Lesson, you should be able to:
LO1. Prepare machine for operation

LO2. Perform milling operation
Pre-Assessment
What Do You Already Know?
Let us determine how much you already know about producing

blanketed rubber sheets. Take this test.
Read and analyze the statement carefully. Choose the CORRECT

answer and write the letter only in your answer sheet.
1 Mill brakes can be either mechanical or electrical, but they must be

checked each shift and the distance checked weekly
a. morning
b. day
c. shift
d. closing time
2. Which one is not involved in mill safety problem?
a. mill height
b. the size of the operator
c. auxiliary equipment
d. safety measure
3. When rubber lumps are fed into the slab machine and is turned to
rubber strips the process is called _____?
a. creping
b. pre-breaking
c. Repairing
d. Slabbing
3
4. Which one best describes of rubber strips are fed into the pre-
breaker machine and is turned into rubber chips.
a. creping
b. pre-breaking
c. slabbing
d. repairing
5.Getting caught in the rotating rolls are major safety hazards during
operation of milling machines. Which ones best describes this
condition?
a. vehicular accident
b. falling accident
c. running nip accidents
d. milling
6. Whom to consult regarding which machine need s most
maintenance in the facility?
a. manager
b. machine operator
c. supervisor
d. technician
7. The process of scheduling preventive maintenance on company
machinery is __.
a. mechanical maintenance planning
b. planning
c. repairing.
d. tasking
8. In instituting preventive maintenance of machineries, start with
the _____.
a. less complicated machineries
b. more complicated machines
c. simple machines
d. all of the above
9. In establishing maintenance procedures, make ____ the number
one priority.
a. supplies
b. worker
c. safety
d. safety measure
10. Maintenance schedule must ____ so it becomes a habit to perform
needed repair
and maintenance on a regular basis.
a. be changed
b. not be changed
c. always change
d. all of the above
4
11. Which machine is used to cut rubber block by the rotating cutters
and moving cutters which bring the work table do the reciprocate
work?
a. rubber slab cutter machine
b. rubber pre-breaker machine
c. creper machine
d. crane
12. A machine knows to be the pre-cleaner of dirt present in the
rubber.
c. creper machine
d. rotary press
13. The creper machine is used to produce_____.
a. cuplump
b. crepe
c. bale
d. latex
14. Rubber Slab Cutter Machine also called _____.
a. rubber pre-breaker machine
b. creper machine
c. bale cutter
d. rotary press
15. Which one is used for milling materials?
a. milling machine
b. rotary press
c. latex
d. crane
5
Lesson 1: Prepare Machine for Operation
 Machine is checked and adjusted

 Machine is maintained
Definition of Technical
Terms
Is a machine with special grooving

is designed for excellent efficiency
Creper Machine for cleaning and crepe thickness
reduction of rubber blocks and
rubber granule at the intermediate
second stages and final stage of
the cleaning process
is the process of prolonging the life
Machine Maintenance span of a machine by applying
certain procedure.
Mechanical Maintenance is the process of scheduling
Planning preventative maintenance on
company equipment and
machinery
Milling Machine is used for milling certain
materials like rubber.
is a machine specially designed for
economy, durability, ease—of—use
Rubber Bale Cutter and versatility. These machines
are widely used for cutting rubber
bales in different sizes
is a machine generally known as
the pre-cleaner. This machine has
been designed for the use as an
Rubber Pre-breaker intermittent size reduction
machine in the lower grade
processing line of natural rubber
industry. It is also capable to serve
as a machine to remove the high
dirt content in the materials.
Is a machine that cuts rubber
Rubber Slab Cutter block by the rotating cutters and
Machine moving cutters which bring
worktable to do the reciprocate
work.
6
What Do You Need To Know?
Read Lesson Information 1.0 very well then find out how much
you can remember and how much you learned by doing Self-
Check 1.0.
Lesson Information 1.0
Machineries in Producing Blanketed Rubber Sheets
There are three kinds of machine used in producing rubber blankets:
Machine Image Description

Rubber Slab Cutter Machine
Cuts rubber block by the

rotating cutters and moving
cutters which bring worktable
to do the reciprocate work.
Rubber slab cutter machine has

a turntable way to cut rubber
(Including nature rubber,
Fig.1 Slab Cutter Machine
reclaimed rubber, synthetic
(http://img.tradeindia.com/fp/
rubber and silica rubber),
1/001/201/917.jpg,3:18PM, 9-5-
which is new and practicality.
2015)
It mainly is suitable for
breaking in the production
process with rubber, also can
use for other materials.
There are rotating cutter and

fixed cutter on the machine
chassis, resistance wheel
equipment set on two sides of
swords.
Fig.2 Slab cutter machine
The machine cut a big rubber
(http://3.imimg.com/data3/IR/ block into a small &thin rubber
QC/MY-5246730/rubber-sheet- block
cutting-machine-
250x250.jpg,3:10PM, 9-5-2015) It is perfect machine and
7
famous for manufacturer to
break, as its low power &
damage, high cutting efficiency,
automatic and convenient.
The broken rubber blocks push

to mesh to remove sundries and
then flow into pool so as to
achieve breaking, washing &
removing sundries.
Fig.3 Slab Cutter machine

( http://www.alibaba.com/product-
detail/2015-New-Designed-Rubber-
Sheet-cutting_60056227508.html)
Used Goodman 35" rubber slab

cutter, cuts 1" thick rubber.
Cuts rubber cured strips
suitable to feed into an
extruder. 10 HP, 1800 RPM,
208-220/440 volts. Belt drive.
Controls: Start/stop, reject,
motor starter, 2 E-stops. Model
Fig.4 Slab Cutter machine 35 HD. #001699IP
(http://
www.rubberandplasticmachinery.co
m/home/used_rubber_machinery/
used-rubber-cutters/used-
goodman-35-rubber-slab-cutter)
Product Produced: Slabs
Fig.5 Slabs (Courtesy of Aballe,

A.)
8
Machine Image Description
Rubber Pre-Breaker machine
is generally known as the pre-cleaner.
This machine has been designed
for the use as an intermittent
size reduction machine in the
lower grade processing line of
natural rubber industry. It is also
capable to serve as a machine to
remove the high dirt content in
the materials.
Fig.6 Rubber Pre-breaker Machine makes use of the
Machine rotating roller and fixed sword to
(http://img.dhstatics.com/pr- do the opposite movement so
2013-04-16-68816- that cut rubber block into small
174440791333-220x220/crumb- rubber block or as your request.
rubber-prebreaker-machine1.jpg, The broken rubber blocks push
3:27PM, 9-5-2015) to mesh to remove sundries and
then flow into pool so as to
achieve breaking, washing &
removing sundries.
is a high efficient machine for

crushing rubber block and the
most important machine for
rubber processing. It crushes all
rubber blocks to be small sizes
and show out sundries to clean
Fig.6.Rubber Pre-breaker Machine clearly, which is easy to do next
(http://img2.en.china.cn/ work of dehydration
0/2_393_33641_800_445.jpg, processing....
3:29PM, 9-5-2015)
Dry Pre-breaker Machine is

useful equipment not only for
reducing water, removing white
spot, enhancing consistency from
Fig.7 Rubber Pre-breaker rubber, but also stir and mix
Machine several kind of rubber to make
(http://i01.i.aliimg.com/photo/ into a special rubber.
v1/1879104567_2/
Rubber_dry_pre_breaker_machine
_in_Vietnam.jpg)
9
Fig. 8 Rubber Prea-breake
Machine
(http://
weidajixie.en.alibaba.com/
productshowimg/661725663-
801929268/
Rubber_Slab_Cutter_Machine.html
)
Product produced:
Small pieces of lumps
Fig.9 Rubber lumps ( Courtsesy:

Aballe,A.)
Creper Machine
with special grooving is designed
for excellent efficiency for
cleaning and crepe thickness
reduction of rubber blocks and
rubber granule at the
intermediate second stages and
final stage of the cleaning
process. Its special designed
Fig. 10 Creper Machine Rollers and methodology grooving
(http://www.rubber- can perform the intermediate
processing.org.cn/pro/creper.jpg, cleaning process and
3:32PM, 9-5-2015) simultaneously reducing the size
of the thick blankets of crumb
rubber crepes enhancing a better
constant drying efficiency after
the trolley dryer.
10
Fig.11 Creper machine
(http://i00.i.aliimg.com/photo/
v0/132605332/
Rubber_Creper_Machine_Small.jpg
,3:34PM, 9-5-2015)
rubber mixing mill/two roll

mill/rubber machine/open
mill,rollingbearing instead of
bronze bush,harden finished
gearbox,coupling
Fig 12. Creper machine
(http://www.bl-machinery.com/
general-rubber-machine/rubber-
sheeting-mill/)
For sheeting of masticated

material with internal mixer.
Fg. 13 (http://www.bl-
machinery.com/general-rubber-
machine/rubber-sheeting-mill/)
11
Mangle machine used to produce
rubber sheets
Rubber lump is passed through

the mill which squeezes most of
the water out f it. The rollers of
Fig. 14 Mangle machine the mills are patterned with ribs
(http://sarawak- which impart their imprint into
rubbertapper.tripod.com/ the sheet hence its named-
machine-rollrub.jpg, 3:20PM, 7- ribbed.
11-2015)
Fig. 15 Mangle machine

(http://1.bp.blogspot.com/-
2BOYEUCUAXk/Te9hP-X87MI/
AAAAAAAAAWQ/nZZIlclbwzM/
s400/DSC_7309m-slr.jpg,
3:17PM, 7-11-2015)
Fig. 16 Mangle Machine

(http://www.azom.com/work/
pBKnXBD780gNt037R04O_files/
image004.jpg, 3:;03PM. 7-
11.2015)
12
Fig 17. Mangle machine
http://www.bouncing-balls.com/
serendipity/pictale.htm, 12:25PM,
7-12-2014
Product Produced:
Rubber Sheets
Fig. 18 Rubber Sheets (Courtesy:

Aballe,A.)
Procedure in Checking and adjusting roller distance.
1. Read the manual

2. Study the parts
3. Locate for the roller blade
4. Test drive
5. Push start button
6. Manipulate the adjusting bolts for rollers
7. Observe for fault
8. Observe safety
9. Shut down the machine, push button off.
10. Submit report
Small Scale Rubber Processing
13
The small scale rubber processing usually involved a backyard
processing only or sometimes a village. The inputs in the processing is
not too expensive because the machineries and other processing
inputs are available locally. However, farmers who would like to
venture on the method should undergo training in order to know the
different standard operating procedure so that high quality rubber
blanket sheets are produced.
A strict implementation of the procedures below must be adhered:
1. Ensure that during tapping, the latex collection cup must be

thoroughly clean and no foreign objects inside it.
2. Collected latex from the farm must be properly strained.
3. Correct mixing of rubber latex-water-formic acid should be
observed.
4. Coagulating vessel/mould usually measured at 1x2 ftx2inches
thick is acceptable.
5. Manually operated roller or creping machine is acceptable where
to process the coagulated latex.
6. Ensure that an area is available for drying the rubber blanket
sheet either through:
a. Air drying
b. Sun drying
c. Solar cum smoke drying
d. Furnace outside the chamber
e. Smoking @ smoke house
Air drying
Fig. 19a Fig 9b
a(http://www.commodityonline.c
om/images/3156964414cee5a0ee
eb50.jpg, 3:05PM. 7-11-2015)
b.(http://www.bouncing-
balls.com/serendipity/
pictale.htm, 12:25PM, 7-12-2014)
14
Sun drying
Fig. 20 (Courtesy: Aballe, A.)
Smoking @ Smoke House
Fig.21 (Courtesy: Aballe, A.)
If you have questions, ask your

teacher for assistance.
How much did you

learn? 15
Self-Check 1.0


work?
c. creper machine
d. crane
rubber.
c. creper machine
d. rotary press
a. cuplump
b. crepe
c. bale
d. latex
b. creper machine
c. bale cutter
d. rotary press
a. milling machine
b. rotary press
c. latex
d. crane
16
Activity 1.0
Check and Adjust Rollers
Materials:
1 .manual
2. wrench
3. PPE-gloves, safety shoes, hard hat, apron
4. ball pen
5. record book/note book
Tools and Equipment:
1. Slab cutter machine
Procedure:
1. Read the manual

2. Study the parts
3.Locate for the roller blade
4. Test drive
5. Push start button
6. Manipulate the adjusting bolts for rollers
7. Observe fro default
8. Observe safety
9. Shut down the machine, push button off.
10. Submit report
RUBRIC
17
(Check & Adjust Roller)
tasks score Range of Score
Manual read
Parts studies
Roller blades located
Test drived Scoring is
Start button pushed 1-5
Adjusting bolts for rollers
1 being lowest
adjusted
5 being highest
Default parts observed
Scoring 3& below
Safety observed
means repeat the
Off button pushed, machine
activity
shut down..
.Report submitted
Total
__________________________________
Trainee
___________________________________
Trainer/Supervisor
18
Machine Maintenance
Regular equipment maintenance adds years to the life of machinery

and minimizes operational downtime. Preventive maintenance on a
machine can include several aspects conducted at multiple times, and
is frequently conducted by more than one employee. Replacing filters,
changing oil or coolant, as well as inspecting for and repairing rust
damage are types of actions performed according to an equipment
maintenance program. Understanding the equipment thoroughly and
formalizing a schedule for upkeep are key components in establishing
an equipment maintenance program.
1. Consult with machine operators and maintenance technicians to

identify which machines in the facility require the most maintenance.
Research the preventive maintenance tasks associated with every
machine, and the time frame for conducting those tasks.
2. Examine market conditions and facility-specific information to
determine whether to use a staggered maintenance program, so that
two machines are not inactive at the same time, or to institute a
periodic time frame where all or most of the machines are down at
once to conduct mass maintenance routines.
3. Create an overarching maintenance procedure as well as
procedures for each machine, listing what preventive maintenance
needs to be done on it, the time frame for each task and the operator
responsible for completing the task. Assign machine operators to
complete simple tasks such as coolant, lubrication or oil replacement,
but a dedicated maintenance technician should be assigned for more
involved tasks. Inform employees of the tasks they are individually
responsible for.
4. Begin instituting the maintenance program. Shut down the

department and conduct maintenance if employing a total shut-down
method. Start with the machines with more complicated maintenance
procedures if implementing a staggered approach, then work down to
less complicated machines. Study the time frames for the
maintenance work and avoid a schedule that involves more than a
single inactive machine in one area at any given time.
5. Use the date of the initial complete maintenance checkup to

institute a timetable for future maintenance work. Coolant may have
to be changed weekly, filters changed monthly, wires and pipes
19
cleaned and inspected once per year, and parts replaced every five
years -- track and plan for it all. Hang a checklist on each machine
with areas to fill in what type of work is done, when the work was
done and who did it. Keep a master equipment maintenance schedule
with the maintenance department or area supervisor
6. Create, document and institute a procedure for the reporting and

tracking of machine breakdowns and concerns for any non-routine
maintenance work. The idea behind an equipment maintenance
program is to be proactive and catch small problems before they turn
into large ones. Track all time, costs and non-routine work associated
with each machine to identify problem areas.
How to Plan Mechanical Maintenance
Mechanical maintenance planning is the process of scheduling

preventative maintenance on company equipment and machinery.
Good maintenance is necessary to extend the life of the items and to
prevent costly and time-consuming repairs. It will keep work in
progress, preventing production from slowing or halting. It also will
extend the life of equipment. Maintenance should be proactive instead
of reactive. Just as an airplane has a flight check before takeoff,
companies should have their own regular, routine methods of
checking and maintaining their assets.
Planning Mechanical Maintenance
1. Post a large 12-month calendar where all who are involved with
regular maintenance can see and refer to it often. Have a schedule
that does not vary, so it becomes a habit to perform needed repairs
and maintenance on a regular basis. For example, the first of the
month a company can schedule all air conditioning filters to be
replaced; oil can be changed in all company vehicles; or belts and
lubricants on factory machinery can be checked at specific times.
2. Regularly schedule maintenance will extend the life of company

assets. Keep a log book of all repairs and maintenance. This provides
accountability to the staff and back up information on the who, what,
when, and where of the maintenance in question. Potential problems
and concerns can be notated for other shifts. This log book is also a
great resource for providing information to insurance companies and
for warranty conflicts.
3. Train employees on the importance of regular, scheduled

maintenance, and make sure they have the essential tools and time to
do their jobs correctly and efficiently. Some employees do not
understand the impact that failure to maintain expensive equipment
has on the bottom line. The main issues to concentrate on in dealing
20
with staff and mechanical maintenance are discipline, proper job
skills, safety and attention to detail.
4. Schedule outside preventative maintenance vendors at specific

times every month to provide consistency in the maintenance process.
Staff and security will also be aware of who is supposed to be on the
property at a given time. Supervision of outside vendors and
inspections of completed job duties are essential to cost-effective
maintenance
5. Make safety a number one priority when establishing maintenance

procedures. Managers should ensure that employees always have
proper equipment, ventilation and lighting, and that all equipment is
code compliant. Having an effective mechanical maintenance program
in place will assist in making your workplace safe and assure staff of
steady, uninterrupted employment.
(CBLM Rubber Processing NC2, Module 2, Produce Blanketed Rubber

Sheetsp.9-10, 4:16PM,9-5-2015, Angelito Aballe..4:23PM, 9-5-2015)
If you have questions, ask

your teacher for assistance.
21
How much did you learn?
Self-Check 1.1


a. manager
b. machine operator
c. supervisor
d. technician
machinery is __.
b. planning
c. repairing
d. tasking
the _____.
c. simple machines
d. all of the above
one priority.
a. supplies
b. worker
c. safety
d. safety measure
needed repair and maintenance on a regular basis.
a. be changed
b. not be changed
c. always change
d. all of the above
22
Activity 1.1
MACHINE MAINTENANCE
Materials:
1. Brush
2. rags
3. oil
4. PPE-gloves, safety shoes, hard hat, apron
5. broom
Tools and Equipment:

a.Slab cutter machine
b.Steel brush
c.Adjustable wrench
d.Screw driver
Procedure:
a.Inspect machine
b.Clean the machine
c.Wipe dust from machine
d.Check wirings for fault.
e.Check start buttons
f.Check for loosen bolts
g.Fasten bolts tightly
h.Lubricate parts where needed
i.Apply oil where needed
j.Clean the surroundings
k.Observe safety
l.Tag out faulty parts if any
m. Prepare maintenance report
23
RUBRIC
(Machine Maintenance)
Range of Score
Tasks Score
Machine inspected
Machine cleaned Scoring is

1-5
Machine wiped of dust
Wirings checked for fault 1 being lowest

5 being highest
Start button checked
Scoring 3& below
Loosen bolts checked means repeat the
activity
Bolts fasten tightly
Parts lubricated
Parts applied with oil
Surroundings cleaned
Safety observed
Faulty parts tagged out
Maintenance report prepared
Total
__________________________________
Trainee
___________________________________
Trainer/Supervisor
24
Lesson 2: Perform Milling Operation
Definition of Technical Terms
Creper Machine with special grooving is designed

for excellent efficiency for cleaning
and crepe thickness reduction of
rubber blocks and rubber granule
at the intermediate second stages
and final stage of the cleaning
process.
Milling Operation is the process of producing rubber

blankets from the collection of
rubber lumps to the production of
rubber blankets in accordance
with enterprise procedure and
occupational health and safety
procedures through the use of
PPE and the observance of proper
feeding of rubber in the machines
Rubber Pre-breaker Machine is a high efficient machine for
crushing rubber block and the
most important machine for
rubber processing. It crushes all
rubber blocks to be small sizes
and show out sundries to clean
clearly, which is easy to do next
work of dehydration processing.
Rubber Slab Cutter Machine cuts rubber block by the rotating

cutters and moving cutters which
bring worktable to do the
reciprocate work. . There are
rotating cutter and fixed cutter on
the machine chassis, resistance
wheel equipment set on two sides
of swords.
25
What Do You Need To Know?
Read Lesson Information 2.0 very well then find out how much
you can remember and how much you learned by doing Self-
Check 2..0.
Rubber Processing Machine Operation

Operation of the rubber processing machine is not an easy task.
Knowledge and skill in the operation of the machine is imperative in
order to be successful. Production of rubber products starts in the
milling process wherein the coagulated rubber slabs pass through a
roller that rotates in different direction. Hence producing a long, flat
strips called sheets.
For neophytes, reading the manual of machine operation and

constant manipulation has great advantage in becoming rubber
processors. Familiarization and frequent exposure to the work tasks
will widen your experienced and hone your potential of becoming
rubber processor.
Milling Operation
Milling Operation is the process of producing rubber blankets from

the collection of rubber lumps to the production of rubber blankets in
accordance with enterprise procedure and occupational health and
safety procedures through the use of PPE and the observance of
proper feeding of rubber in the machines; in every machine there is a
blocker, which sets as a precautionary gauge..in feeding rubber to the
machine.
26
Three procedures in Milling Operating
1. Slabing - rubber lumps are fed into the slab machine and is turned
to rubber strips.
Fig.1 Rubber lumps in sacks

Sheetsp.14, 4:16PM,9-5-2015, Angelito Aballe..
Rubber Lumps)
2. Pre-Breaking - rubber strips are fed into the pre-breaker machine
and is turned into rubber chips
Fig. 2 Rubber Chips

CBLM Rubber Processing NC2, Module 2, Produce Blanketed Rubber
27
Fig.3
Sheetsp.16, 4:16PM,9-5-2015, Angelito Aballe..4:23PM, 9-5-2015
Fig 4.Rubber Sheets

Sheetsp.16, 4:16PM,9-5-2015, Angelito Aballe..4:23PM, 9-5-2015)
3. Creping - Rubber chips are fed into the creper machine and are
processed into rubber blanket sheet. In creping, series of massive
passing through the rollers is required in order to produce clean
rubber blanket sheets.
Fig 5
28
Occupational Safety and Health Standards
Mills and calenders are used extensively
throughout the rubber industry. Running nip
accidents (getting caught in the rotating rolls) are
major safety hazards during operation of these
machines. In addition, there is a potential for
accidents during repair and maintenance of these
Mill Safety
and other machines used in the rubber industry.
This article discusses these safety hazards.
In 1973 in the United States, the National Joint
Industrial Council for the Rubber Manufacturing
Industry concluded that for in-running nip points,
a safety device that depended on action of the
operator could not be regarded as an effective
method of preventing running nip accidents. This is
especially true of mills in the rubber industry.
Unfortunately, little has been done to force code
changes. Currently there is only one safety device
that does not require operator action to activate.
The body bar is the only widely accepted automatic
device that is an effective means of preventing mill
accidents. However, even the body bar has
limitations and cannot be used in all cases unless
modifications are made to the equipment and work
practice.
The problem of mill safety is not a simple one; there are several major
issues involved:
Mill height makes a difference as to where the

operator works the mill. For mills less than 1.27 m
high, where the height of the operator is greater
than 1.68 m, there is a tendency to work too high
1.mill height on the mill or too close to the nip. This allows for a
very short reaction time for the automatic safety to
stop the mill.
The size of the operator also dictates how close the
operator needs to get to the mill face to work the
2. the size of the mill. Operators come in many different sizes, and
operator often must operate the same mill. The majority of
the time no adjustment is made to the mill safety
devices.
29
Auxiliary equipment such as conveyors or loaders
can often conflict with safety cables and ropes.
Despite codes to the contrary, often the safety rope
or cable is moved to allow for the operation of the
3.auxiliary auxiliary equipment. This can result in the operator
equipment working the mill with the safety cable behind the
operator’s head.
While the height of the mill and the auxiliary

equipment have a part in the way a mill is worked,
there are other factors which enter into the picture.
If there is no mixing roll below the mixer to
4. the way the distribute the rubber evenly on the mill, the
mill is worked operator will have to physically move the rubber
from one side of the mill to the other by hand. The
mixing and moving of the rubber exposes the
operator to increased risk of strain or sprain
injuries in addition to the hazard of the mill nip.
The tack or stickiness of the stock poses an

additional hazard. If the rubber sticks to the mill
roll and the operator has to pull it off the roll, a
body bar becomes a safety hazard. Operators of
5. the tack or mills with hot rubber have to wear gloves. Mill
stickiness of the operators use knives. Tacky stock can grab a knife,
stock glove or bare hand and pull it toward the running
nip of the mill.
Even an automatic safety device will not be effective

unless the mill can be stopped before the operator
reaches the running nip of the mill. Stopping
distances must be checked at least weekly and the
brakes tested at the beginning of each shift.
Dynamic electrical brakes must be checked on a
6. stopping regular basis. If the zero switch is not adjusted
distance. properly, the mill will move back and forth and
damage to the mill will result. For some situations,
disc brakes are preferred. With electrical brakes a
problem can arise if the operator has activated the
mill stop button and then tried an emergency mill
stop. On some mills the emergency stop will not
work after the mill stop button has been activated
1. A body bar should be used on the working face of
each mill, but only if the bar is adjustable for the
height and reach of the operator.
30
2. Mill brakes can be either mechanical or
electrical, but they must be checked each shift and
the distance checked weekly. The stopping
There have been distances should comply with the American
some National Standards Institute (ANSI) stopping
adjustments distance recommendations.
made that have 3.Where mixer mills have hot, tacky stock, a two-
improved mill mill system has replaced the single-mill system.
safety. This has reduced operator exposure and improved
the mixing of the stock.
The following 4.Where operators are required to move stock
steps have across a mill, a mixing roll should be added to
greatly reduced reduce operator exposure.
exposure to 5.Current mill work practices have been reviewed to
running nip insure that the operator is not working too close to
injuries on the the running nip on the mill. This includes small lab
mills: mills, especially where a sample may require
numerous passes through the running nip.
6.Mill loaders have been added on mills to load
stock. This has eliminated the practice of trying to
load a mill using a fork truck, and has eliminated
any conflict with the use of a body bar as a safety
device.
7. Current mill work practices have been reviewed
to insure that the operator is not working too close
to the running nip on the mill. This includes small
lab mills, especially where a sample may require
numerous passes through the running nip.
8. Mill loaders have been added on mills to load
stock. This has eliminated the practice of trying to
load a mill using a fork truck, and has eliminated
any conflict with the use of a body bar as a safety
device.
Currently technology exists to improve mill safety. In Canada, for
example, a rubber mill cannot be operated without a body bar on the
working face or front of the mill. Countries receiving older equipment
from other countries need to adjust the equipment to fit their
workforce
http://www.ilocis.org/documents/chpt80e.htm, 1:05AM, 8-24,2015
If you have questions, ask

31
How much did you learn?
Self-Check 2.0

1.·Mill brakes can be either mechanical or electrical, but they must be

checked each shift and the distance checked weekly.
a. morning
b. day
c. shift
d. closing time
a. mill height
d. safety measure
3. When rubber lumps are fed into the slab machine and is turned
to rubber strips the process is called _____?
a. creping
b. pre-breaking
c. repairing
d. slabbing
a. creping
b. pre-breaking
c. slabbing
d. repairing
5.Getting caught in the rotating rolls are major safety hazards
during operation of milling machines. Which ones best
describes this condition?
b. falling accident
d. milling
32
Activity 2.0
Milling Rubber
I.Equipment
Slab-cutter
Pre-breaker machine
Roller machine
II.Supplies / Materials:
PPE
Raw materials /rubber lumps
Water supplies
Procedure in Performing milling operation
Note: All supplies, materials and equipment needed during processing

operations should be readily available at the site
III.Procedure in Performing Milling Operation
1. Switch " ON" the Slab Cutter Machine.

2. Feed the lumps into the slab cutter machine carefully.
3. Collect the rubber slabs.
4. Switch "ON" the Pre-Breaker Machine.
5. Feed the collected rubber slabs into the Pre-Breaker Machine
6. Collect the rubber chips
7. Switch "ON" the Creper Machine
8. Feed the rubber chips into the Blending Machine in five stages. In
every stage it should be passed in the roller 6-7 times.
9. Switch "OFF" the processing machines
10. Record the produced rubber blankets
11. Hang the rubber blankets for drying
12. Prepare the production operation report
13. Proper waste disposal; where it should pass 6 silting pans before
disposing to the river, for environment protection.
33
RUBRIC
Perform Milling Operation)
Tasks Performance
YES NO Remarks
1. Switching “ON” slab cutter
2. Feeding the lump into slab cutter
3. Collecting rubber slabs
4. Switching “ON” Pre-breaker

machine
5. Feeding the collected rubber slabs

into the Pre-Breaker Machine
6. Collecting the rubber
7. Switching "ON" the Creper Machine
8. Feeding the rubber chips into the

creping Machine in five stages. In
every stage it should be passed in the
roller 6-7 times.
9. Switching "OFF" the processing
machines
10. Recording the produced rubber
blankets
11. Storing the rubber blankets
12. Preparing the production
operation report
13. Proper waste disposal; where in it
should pass 6 silting pans before
disposing to the river, for
environment protection.
Rating
Note: Rating is Passed/Failed. Task with NO mark means repeat the
task in order to pass.
_________________________________
Name
__________________________________
Rater/Trainer/Supervisor
34
Operation Reports
(Sample Only)
Any incidence occurring in the factory should be reported to the
higher officials of the company. It may be manpower, machineries,
process, operation and others. An incident report is to be made and
submitted.
Sample Incident Report Form
Date: March 21, 2015
Nature of Incident Cause/Observation Remarks
Breakdown of creper Creper machine 1 not Needed electrical

machine 1 operational technician to
Electrical connections inspect
burned Needs immediate
Current overload repair
Machine operation Electrical parts
straight 24 hrs needed
2-3 pax needed for
the work
Prepared by:
ROBERTO PENASO
__________________________________
Name
Submitted to :
JAMES PATRICK LIM

_________________________________
35
Activity 2.1
Prepare Incident Report
I.Materials:
Ball pen
Incident Report Form
II.Procedure:
.1. Observe for any incident around.

2. Write an incident report using the incident report form
3. Observe safety
4. Submit report
36
Incident Report Form
__________________________
Date:
Nature of Incident Cause/Observation Remarks
Prepared by:
__________________________________
Name
Submitted to :
_________________________________
37
RUBRIC
Incident Report
Task Score Remark

Scoring is
Observe for any incident around. 1-5
Write an incident report using the 1 being lowest

incident report form 5 being highest
Observe safety Scoring 3& below

means repeat the
Submit report activity
Rating
_________________________
Name
_________________________
38
Production Report
Every enterprise has a product to produce. Production is the basis for

the existence of the certain company. All product must be recorded
and reported. In rubber industry one of the product produce is the
rubber sheet/crumb rubber and needed to be reported.
Weighing the Product
The total rubber sheets production/crumb rubber production in the

factory is determined through weighing using heavy duty weighing
scale. Weighing scale must be functional. Defective weighing scale give
erroneous data. Recording is very important in this aspect.
Dry Rubber Content (DRC) Determination
DRC determination is usually based on the quality of lumps delivered

in the factory. Visual Approach is usually practiced in the field in
comparison with the texture of the lumps. Lumps that are more than
15 days old with formic acid has higher DRC. Soft lumps contains
more water are expected to have less DRC content. Harder lumps with
formic acid have approximate DRC of 50% and above. Soft lumps has
approximate DRC of 40% and below.
39
ACTIVITY 2.2
Determination of Weight of Lumps and DRC
Purpose: Determine the weight of Rubber Lumps Production
Supplies & Materials: Tools/Equipment:
1. Sheet Rubber/Bale 1. Weighing scale

2. Record Book/Form 2. Trolley (if any)
3. Ball Pen 3. Pallet/storage area
4. Calculator
5. Label
Sheet Rubber/Bale Production Report

Batch Weight DRC Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Prepared by;
________________________________
Checked by:
________________________________
Supervisor
40
RUBRIC/Scoring Sheet
Tasks Score Range in

Scoring
Tools & equipment are prepared
Supplies & Materials are prepared
Rubber lumps placed on weighing scale
Weight of rubber lumps determined and Scoring is

recorded. 1-5
1 being
Rubber lumps removed and placed in the lowest
storage area 5 being
highest
Process repeated until the remaining rubber Scoring 3&
lump is finished below
means
repeat the
Cleanliness & safety observed activity
Total productions determined
Record submitted to the office (reporting)
Total Score
Average Score
____________________________________
Name
___________________________________
If you have questions, ask 41

42
Post Assessment
How much have you Learned?

1.Mill brakes can be either mechanical or electrical, but they must be

checked each shift and the distance checked weekly
a. morning
b. day
c. shift
d. closing time
a. mill height
d. safety measure
3. When rubber lumps are fed into the slab machine and is turned to
rubber strips the process is called _____?
a. creping
b. pre-breaking
c. Repairing
d. Slabbing
a. creping
b. pre-breaking
c. slabbing
d. repairing
5.Getting caught in the rotating rolls are major safety hazards during
operation of milling machines. Which ones best describes this
condition?
b. falling accident
d. milling
a. manager
b. machine operator
c. supervisor
d. technician
43
machinery is __.
b. planning
c. repairing.
d. tasking
the _____.
c. simple machines
d. all of the above
one priority.
a. supplies
b. worker
c. safety
d. safety measure
needed repair and maintenance on a regular basis.
a. be changed
b. not be changed
c. always change
d. all of the above
work?
c. creper machine
d. crane
rubber.
c. creper machine
d. rotary press
a. cuplump
b. crepe
c. bale
d. latex
b. creper machine
c. bale cutter
d. rotary press
44
a. milling machine
b. rotary press
c. latex
d. crane
45
Congratulations! You did a great job!
Rest and relax a while then move on to
the next module. Good luck!
GENERALIZATION:
This module gave opportunity to the students to develop their

skills in Producing Blanketed Rubber Sheets according to
standard operating procedures, techniques and knowledge of
RUBBER PROCESSING NCII.
This prepares them to move on to the next important skills for

development… the Performing Drying Operation.
46
References
http://3.imimg.com/data3/IR/QC/MY-5246730/rubber-sheet-
cutting-machine-250x250.jpg,3:10PM, 9-5-2015
http://img.tradeindia.com/fp/1/001/201/917.jpg,3:18PM, 9-5-2015
http://img.dhstatics.com/pr-2013-04-16-68816-174440791333-
220x220/crumb-rubber-prebreaker-machine1.jpg, 3:27PM, 9-5-2015
http://img2.en.china.cn/0/2_393_33641_800_445.jpg, 3:29PM, 9-5-
2015
http://www.rubber-processing.org.cn/pro/creper.jpg, 3:32PM, 9-5-
2015
http://i00.i.aliimg.com/photo/v0/132605332/
Rubber_Creper_Machine_Small.jpg,3:34PM, 9-5-2015
http://www.alibaba.com/product-detail/2015-New-Designed-Rubber-
Sheet-cutting_60056227508.html
http://www.bouncing-balls.com/serendipity/pictale.htm, 12:25PM, 7-
12-2014
http://www.rubberandplasticmachinery.com/home/
used_rubber_machinery/used-rubber-cutters/used-goodman-35-
rubber-slab-cutter
http://weidajixie.en.alibaba.com/productshowimg/661725663-
801929268/Rubber_Slab_Cutter_Machine.html
http://i01.i.aliimg.com/photo/v1/1879104567_2/
Rubber_dry_pre_breaker_machine_in_Vietnam.jpg
http://www.bl-machinery.com/general-rubber-machine/rubber-
sheeting-mill/
http://www.commodityonline.com/images/
3156964414cee5a0eeeb50.jpg, 3:05PM. 7-11-2015
http://www.ilocis.org/documents/chpt80e.htm, 1:05AM, 8-24,2015
Sheetsp.9-10, 4:16PM,9-5-2015, Angelito Aballe..4:23PM, 9-5-2015)
The Philippine Recommends for Rubber, PCARRD Technical Bulletin
Series # 33A
DA-WESMIARC, Sanito, Ipil, Zamboanga Sibugay
47
ACKNOWLEDGMENT
The Department of Education (DepED), Central Office through the

Bureau of Secondary Education (BSE) wishes to extend its gratitude and
appreciation to all the Module Writers and those involved in the
Development of the Learner’s Manual for sharing their time and expertise.
Writer (Agriculture and Fishery Arts)
Valentino M. Navarrete
Master Teacher II
Iligan City National School of Fisheries
Division of Iligan City
Region X
Language/Content Editors
Reviewer/Validator
Angelito A. Aballe, Ph.D.
Senior Education Program Specialist
Division of Zamboanga Sibugay
Region IX
Lay-Out Artist/Illustrator
Management Team
Jocelyn DR. Andaya
Director III
OIC, BSE
Maria Cecilia O. Nayve Edna M. Bulan
Senior EPS EPS II
Clodualdo V. Paiton
Technical Specialist
Administrative Staff:
Pamela C. Loveria Criselda J. Reyes
Efren K. Darcera, Jr. Romeo L. King, Jr.
NOTE:
All Pictures and graphic illustrations taken from the internet are properties of the
original owners and are used only as supplemental materials for educational
purposes.
48

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RUBBER PROCESSING NC II

Module No: 5 Producing Blanketed Rubber

Welcome to the course of Rubber Processing NCII!

This Module covers the knowledge, skills, and attitude in Rubber

You need to complete and pass the self-check of this module

This module consists of two learning outcomes. Each learning

1. This Manual contains several Modules.

2. Begin by reading and understanding the Learning Outcome/s.

4. Do the required Learning Activities. They begin with one or

After reading the Lesson Information, test yourself on how

5. It is not enough that you acquire content or information. You

6. How well did you perform? Accomplish the Scoring Rubrics.

Each Lesson also provides you with references and definition of

LO1. Prepare machine for operation

What Do You Already Know?

Let us determine how much you already know about producing

Read and analyze the statement carefully. Choose the CORRECT

1 Mill brakes can be either mechanical or electrical, but they must be

 Machine is checked and adjusted

Is a machine with special grooving

Lesson Information 1.0

Machineries in Producing Blanketed Rubber Sheets

There are three kinds of machine used in producing rubber blankets:

Machine Image Description

Cuts rubber block by the

Rubber slab cutter machine has

There are rotating cutter and

The broken rubber blocks push

Fig.3 Slab Cutter machine

Used Goodman 35" rubber slab

Product Produced: Slabs

Fig.5 Slabs (Courtesy of Aballe,

is a high efficient machine for

Dry Pre-breaker Machine is

Small pieces of lumps

Fig.9 Rubber lumps ( Courtsesy:

rubber mixing mill/two roll

For sheeting of masticated

Rubber lump is passed through

Fig. 15 Mangle machine

Fig. 16 Mangle Machine

Fig. 18 Rubber Sheets (Courtesy:

Procedure in Checking and adjusting roller distance.

1. Read the manual

Small Scale Rubber Processing

A strict implementation of the procedures below must be adhered:

1. Ensure that during tapping, the latex collection cup must be

Fig. 20 (Courtesy: Aballe, A.)

Smoking @ Smoke House

Fig.21 (Courtesy: Aballe, A.)

If you have questions, ask your

How much did you

Read and analyze the statement carefully. Choose the CORRECT

1. Which machine is used to cut rubber block by the rotating cutters

Check and Adjust Rollers

Tools and Equipment:

1. Slab cutter machine

1. Read the manual

Regular equipment maintenance adds years to the life of machinery

1. Consult with machine operators and maintenance technicians to

4. Begin instituting the maintenance program. Shut down the

5. Use the date of the initial complete maintenance checkup to