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COMPRESSION MOULDING

OPERATION
(Rubber)
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ELYSIUM TECHNOLOGIES

Rubber
Industry

Need of Rubber
• Rubber in one of the source for global
economic.
• The need of the rubber in increase in
world wide.
• It is use many application in regular use
• things.

About Rubber Industry • Around 25 million tones of rubber is produced each year. • About 48% of the global demand for natural rubber comes from China. India and Malaysia which are three major natural rubber consuming countries within (Association the ANRPC of Natural Rubber Producing Countries) .

Market Capitalization India's Rubber production varies between 6 and 7 lakh tons annually which amounts to Rs. Output per annum Today Indian Rubber Industry consists of turnover of Rs 12000 crores. Percentage In World Market India is the world's largest producer and the third largest consumer of natural rubber. followed by Punjab and Maharashtra. 300 medium scale and around 5600 small scale and tiny sector units Geographical distribution Kerala is the leading producer of rubber. 3000 crores.Rubber Industry in India • India is the third largest producer Size of the Industry 6000 unit comprising 30 large scale. . with the world India's production of rubber is consistent at the rate of 6% per annum • India is the world's largest manufacturer of reclaim rubber. • Comparatively. of rubber in die world It is the fourth largest consumer of natural rubber.

In 1990. around 5. .4 million metric tons in 2013.Rubber Consumption • This statistic shows the global consumption of natural and synthetic rubber from 1990 to 2014.18 million metric tons of natural rubber were consumed worldwide. This amount increased to almost 11.

• Remaining large amount is used in medical goods and commercial purpose. .Rubber Consumption in Different industrial sectors • Around 70 percent of the world's natural rubber is used in tires.

Rubber Consumption in India • Kerala is the leading consumer of rubber. . followed by Punjab and Maharashtra.

which Percentage Of include tyres. exceeded Rs.Rubber Consumption in India Different industrial sectors • India's exports of rubber products.2000 cores Consumption according to a recent estimate. cots and aprons • Belts and beltings • Sheeting   Industrial Sectors 4 Belts and hoses 5 Camelback latex products 6 (Win Products 6% and 7% 10% . Products 1 Automotive tyre 50% consumption of all sector kinds of rubbers exported are as follows: J Bicycles tyres and 15% • Automotive tyres and tubes tubes 3 Footwear 12% • Rubber and canvas footwear • Cycle tyres • Pharmaceutical goods • Rubber hoses.

Industry/Secti on .

Industry/Secti on .

Rubber manufacturing .

Rubbers and elastomers will be considered to be synonymous in this work. Such materials are generally long chain molecules known as "polymers" and the combination of elastic and polymers has led to the alternative name of "elastomers".dimensional chemical structure and are able to withstand under force large deformations • Based on the source of raw material. . there are two kinds of rubber natural rubber (NR) and synthetic rubber (SR).Rubber • Rubbers are loosely described as materials which show "elastic" properties. Products made from rubber have a flexible and stable 3 .

milky white liquid called latex that oozes from certain plants when you cut into them. though we'd need an awful lot of them. (Common dandelions. you can see the latex dripping out from them. for example. if you snap off their stems.) Although there are something like 200 plants in the world that produce latex.Natural Rubber • Natural rubber is made from a runny. widely known as the rubber tree . there's no reason why we couldn't make rubber by growing dandelions. In theory. produce latex. over 99 percent of the world's natural rubber is made from the latex that comes from a tree species called Hevea brasiliensis.

mechanical. chloroprene (2chloro-1. The monomers can be produced pure and the addition of impurities or additives can be controlled by design to give optimal properties.3-butadiene). and chemical properties. .3-butadiene). and isobutylene (methylpropene) with a small percentage of isoprene for cross-linking.Synthetic Rubber • Synthetic rubber is made by the polymerization of a variety of petroleum-based precursors called monomers.3-butadiene. These and other monomers can be mixed in various proportions to be copolymerized to produce products with a range of physical. Polymerization of pure monomers can be better controlled to give a desired proportion of cis and trans double bonds. Other synthetic rubbers are prepared from isoprene (2-methyl-1. The most prevalent synthetic rubbers are styrene-butadiene rubbers (SBR) derived from the copolymerization of styrene and 1.

Engineering. commercial and industrial . • Medical.Use of Rubber • Majorly used in tyers.

Manufacturing Process .

Rubber Manufacturing Sequence .

performing the extrusion operation using the Extruder and it is his responsibility to follow correct procedures as per the SOP of the company List of the activities that are performed by the extruder operator: .Role of Extruder Operator • The extruder operator is responsible for feeding the rubber compound to the extruder.

safety and health .Hazards.

property.Hazards • A hazard is a situation that poses a level of threat to life. once a hazard becomes "active". ii. . Most hazards are dormant or potential. or environment. Symbols • Types of Hazards: i. Chemical hazard. A hazardous situation that has come to pass is called an incident. it can create an emergency situation. Ergonomic hazard. health. Hazard and possibility interact together to create risk. with only a theoretical risk of harm: however. Physical hazard iii.

Chemical Symbols Explosive Corrosive Flammable Toxic Oxidizing Environmental Irritant Human-health Gas-bottles .

Physical Symbols .

Ergonomic Symbols .

Safety measures PPE .Personal protective equipment (PPE).

iii. clean and maintain PPE. ii. Care for. Properly wear PPE. Inform a supervisor of the need to repair or replace PPE. In general. . Attend training sessions on PPE.The Requirement for PPE • To ensure the greatest possible protection for employees in the workplace. and iv. employees should: i. the cooperative efforts of bom employers and employees will help in establishing and maintaining a safe and healthful work environment.

Types of PPE • Eye and Face Protection • Head Protection • Foot and Leg Protection • Hand and Arm Protection .

Read and follow the manufacturer's operating instructions and safety precautions for each piece of equipment. Providing local fire department a list of products stored in the premises . The Extruder Machine has moving parts and hot areas. including general site safety rules. 2. Training of staff in the correct selection in the use and maintenance of PPE.Safety Measures 1. 4. when using any of the equipment. Observing all equipment special safety rules (for your individual pieces of equipment). Training of staff in the correct use of machinery and safety devices. 3. DO NOT PERMIT HOT CONCENTRATE TO CONTACT ANY PART OF THE BODY AS A SERIOUS BURN WILL RESULT. 6. Wear gloves while handling warm/hot concentrate. Good standard of lighting 7. Redesign manual processes to avoid heavy lifting/ slash repetitive activities. 5. Installing automatic alarms and shutoff systems 8.

Housekeeping .

Housekeeping • Workplace Housekeeping is fundamental to maintain a clean. • Effective housekeeping can eliminate some workplace hazards and help get a job done safely and properly • Poor housekeeping can be a cause of accidents . tidy and safe working environment.

5’S Concept Japanese's Translation English 'S' Seiri Organization Sorting Seiton Neatness Seiso Cleaning Simplifying Access Sweeping Seitetsu Standardization Standardization Shitsuke Discipline Self-Discipline .

Workplace skills • Oral communication. • Reading and comprehension skills • Writing skills • Work ethics and professionalism .

Sample question .

• How much rubber is produced per year in the world? • What is the place of natural rubber consumption in India? • Which country produce the highest amount of NR in the year 2010? • What is the percentage of rubber used in tyer industries? • What is the percentage of rubber used in the footwear in Indian industrial sector? • What is the types of rubber? • What is the roll of Extruder operator? • Why the extruder wear the Personal protective equipment ? • Type of PPE(Personal protective equipment) ? • What is the need of 5’s concepts? .

Material Provide .

• Document about the theory .• Power point slides.

Session plan .

S.3 Introduction to housekeeping 3.3 Rubber manufacturing 1.3 Writing skills Work ethics and professionalism Total Duration Theory Practical 30min 0 15min 45min 15min 0 1hour and 45 min .2 PPE .2 Reading and comprehension skills 3.1 Introduction to rubber industry 1.NO Topics 1.1 Hazards 2. safety measurement and legal issues 2.2 Introduction to factory and section 1.1 Oral communication 3.4 Role of extruder operator 2.