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Is Rubber Better Than Plastic ?
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Is Rubber Better Than Plastic ?
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Is Rubber Better Than Plastic ?

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In the past, people have seen the progress of technology. From the simple usage of wood and cement to the invention of metal, mankind has really made great progress to become what they are today. Along with this progress are some changes to their lifestyle. These changes were brought about by the materials surrounding them, and two materials that revolutionized man’s life today arerubber and plastic.

It is quite easy to differentiate between the two. By simply looking at each material, one can immediately tell that a particular thing, or object, is made of rubber and not plastic, or vice versa. The only confusion between the two is when the term polymer is used. Yes, a polymer as a term that greatly denotes plastics, but nonetheless, this term also describes the characteristic of rubbers. Although rubber is more of the specific elastomer (a viscous or elastic variation of polymers), it is still considered to be a polymer for example, CR (chloroprene rubber, neoprene); SBR (styrene butadiene rubber); NBR (nitrile butadiene rubber); and EPDM (ethylene propylene diene methylene).

Certain plastics such as PVC(poly vinyl chloride) and polyethylene can be compounded and cured to have properties that are considered rubber-like. PVC is commonly used in rubber flooring. Vulcanization is an irreversible chemical process which transforms the putty-like, dough-like, or chewing gum-like rubber into a product that has tensile, elongation and memory similar to a rubber band. This amazing transformation from one physical state to another is what makes rubber different from plastic.

Plastics are usually thought of as thermal plastic materials. In other words, when they get hot they soften, and when they get cold they harden similar to candle wax. Rubber, however, over a much higher and lower temperature range will maintain its original room temperature physical properties such as elongation, memory, tensile and hardness. Rubber is tough, holds shape once formed, even at high temperatures. It stretches, snaps back, has good tensile strength and is medically safe, soft, pliable, and pure. It is used to make Sealing products like o rings, washers, seals, grommets, bush etc., automobile tires, rubber bands, sealing gaskets for food boxes, stoppers for medical industry & various other products for a wide range of industrial applications.

Whereas, Plastic has no stretch, it is not pliable, is brittle, and cracks easily. Plastic does not typically have great strength, can’t withstand dishwasher heat. It does not have a good temperature range, does not stretch and is lightweight.

When it comes to choosing the right materials for our products, we always do our research. We want to make sure you’re getting the safest, highly durable, heat resistant, non-toxic & most eco-friendly options for your products. That’s why, when we were creating our leak-proof sealing solutions, we chose rubber over plastic.   

CHARACTERISTICS                                         

RUBBER                                                                                                                            

PLASTIC

ENVIRONMENT SAFETY

BiodegradableNon Biodegradable

DURABILITY

Highly DurableCracks Easily

RECYCLABLE

YesYes

HEAT RESISTANT

Highly heat resistantCan’t resist heat melts easily

HARDNESS

40- 9020-100

ELONGATION STRENGTH

High elongation StrengthDoes not Stretch

LEAK PROOF

Can be molded to any shape, can stretch & fit into any component.Cannot provide sealing as it is hard, cannot stretch & break easily
FDA COMPLAINTYesNo

Rubber is durable, and more eco-friendly than plastic. It lasts longer, and stands up better against heat and cold than plastics. It’s safer for your products, too, with no estrogen-mimicking toxins like BPA to worry about. It is odorless, stain-resistant, hypoallergenic, and has no open pores to harbor harmful bacteria. 

Rubber is recyclable, even though you might not be able to leave it with your curbside pick-up, and it can be incinerated safety without toxic off-gassing. When burned, silicone reverts back into its harmless ingredients: amorphous silica, carbon dioxide, and water vapor (unlike plastic which releases toxins when burned).

Thankfully, you won’t have to worry about rubber breaking or cracking for a long time! It’s super durable, resisting melting, breaking, and warping. Chances are our sealing products will outlast for a longer period of time. 

Blog-Post-14
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Do You Know The Ways To Prevent Failure Of Rubber Parts ???

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Rubber is probably one of humanity’s greatest inventions, it is a very useful & malleable material but chances are something made of rubber has let you down at some point in your life. Like most  elastomers rubber will also undergo significant changes over time when exposed to heat, light and ozone.These changes can have a dramatic effect on the service life and properties of the rubber products also can impair the functionality of critical rubber parts, like seals, O-rings, washers, gaskets etc. and could lead to machine failure which can of course have potentially catastrophic consequences. Read on to find out more about typical rubber deterioration causes and practical ways to prevent rubber deterioration.

What is Rubber Deterioration?

Natural rubber and synthetic elastomers deteriorate on aging as a result of the contribution of a number of factors. It has been generally recognized for many years that the changes in properties on aging are due primarily to the deteriorating effects of one or more of the following factors: heat, light, oxygen, and ozone. Some non oxidative thermal changes are involved but the effects of heat and light are for the most part a result of their effect upon the oxidation reaction. Oxidative and thermal ageing of rubber are accelerated by stress and reactive gases, like ozone, resulting in cracking, charring and color fading. However, the addition of antioxidants, UV stabilizers and antiozonants can slow or prevent these types of issues.

Oxidative rubberdegradation can cause hardening or softening, depending on the structure of the elastomer. Hardening is more common because free radicals produced due to heat, oxygen and light combine to form new crosslinks, which reduces the flexibility of the rubber. Although the general mechanism of autoxidation is well understood, the actual chain scission and crosslinking steps are often unknown. They depend on the composition of the rubber including concentration of accelerators, activators, and fillers as well as on the temperature and composition of the atmosphere. 

How does Rubber Products deteriorate?

Natural rubber and synthetic elastomers deteriorate on aging as a result of the contribution of a number of factors. It has been generally recognized for many years that the changes in properties on aging are due primarily to the deteriorating effects of one or more of the following factors: heat, light, oxygen, and ozone. Some non oxidative thermal changes are involved but the effects of heat and light are for the most part a result of their effect upon the oxidation reaction. Thus oxygen in the form of O2 or O3 is the primary cause of deterioration of elastomers. Rapid combination with ozone is a characteristic reaction of unsaturated organic compounds. 

Also Read: Causes of Rubber Parts Deterioration

The two main forms of rubber degradation are: hardening (or embrittlement) and softening. From a molecular perspective, these chemical processes are known as “chain hardening” and “chain scission” respectively. The chemical makeup of the polymer will determine which type of deterioration will ultimately occur. For instance, the polymer polybutadiene and its copolymer derivatives – such as styrene-butadiene-styrene (SBS) and nitrile rubber (NBR) – is developed using a process called cross-linking, which involves joining polymer chains together to form one single molecule. Free radicals produced by heat, oxygen and light combine to form new crosslinks, which reduces flexibility and leads to hardening. This is chain hardening.

Natural rubber (polyisoprene) and other isoprene polymers, on the other hand, are susceptible to chain scission. These types of rubber are developed using polymerization, which entails bonding multiple identical molecules – or monomers – to form a polymer. As such, their polymer main chain is liable to degrade, which is the act of chain scission, and leads to the softening of the rubber material.

How can we prevent rubber products from deterioration ?

DMA Analysis:

Even before a rubber product is manufactured, a technique known as DMA (Dynamic Mechanical Analysis) can be used to predict a rubber material’s response to stress-strain conditions. DMA stress analysis illustrates whether a proposed design will function to design specifications prior to manufacturing a mould tool.

After Ageing Properties:

Apart from DMA Ageing properties were tested according to the ASTM D573-99 Standard Test Method for Rubber – Deterioration in an Air Oven. The tensile and physical properties namely hardness, tensile strength, elongation at break, modulus 300%, tear strength were measured before and after ageing for each aging time. This can help to prevent rubber deterioration in the long-term and provide significant cost-savings.

Ozone Testing:

When ozone comes in contact with rubber, the double and triple chemical bonds are attacked causing the cracking that is commonly seen on the surface of some rubber products. Conducting controlled, laboratory Ozone Testing of material samples against industry standards also provide us critical information needed to make formulation decisions.

Compound Designing:

Rubber compounds are complex mixtures of polymers, reinforcing fillers, oils / plasticizers, curatives, stabilizers, and other additives that are combined in relatively quick mixing processes. Durability is impacted by all these ingredients, their interactions, and the quality of the mixing. By Compounding  Designing we are able to find out the correct proportion & composition of mixing various compounds in order to prevent the deterioration of our sealing products such as O Rings, Gaskets, Washers, Grommets, Bellows, etc.

Related Post: 5 Essential Considerations Before Designing Rubber Products !!!

Addition Of Antiozonants & Other Additives:

Apart from above methods & techniques the problem can be prevented by adding antiozonants to the rubber before vulcanization. With the help of additives rubber deterioration can be prevented. A common and low cost antiozonant is a wax which bleeds to the surface and forms a protective layer, but other specialist chemicals are also widely used.

On the other hand, the problem does recur in unprotected products such as rubber tubing and seals, where ozone attack is thought to be impossible. Unfortunately, traces of ozone can turn up in the most unexpected situations. Using ozone-resistant rubbers is another way of inhibiting cracking. EPDM rubber and butyl rubber are ozone resistant, for example. For high value equipment where loss of function can cause serious problems, low cost seals may be replaced at frequent intervals so as to preclude failure.

With the right rubber restoring techniques, and a sufficient level of care and maintenance, rubber seals or products of certain polymer types can often be brought back from the brink of failure and restored to functionality. 

To know more in depth about how to improve service life of rubber parts read our another blog

High-Temperature Sealing Applications
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5 Most Suitable Materials For High-Temperature Sealing Applications !!!

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Industrial Rubber Seals are designed to prevent leakage, while helping to combine systems or mechanisms together. While seals created for ambient and low temperatures are not extremely difficult, creating seals for high temperature applications is a challenge. This is because standard sealing materials cannot perform well in such conditions for long periods of time. As excessive heat can gradually degrade rubber materials, leading to deteriorating performance and premature failure. This can result in leakage & high-temperature applications require high-temperature-resistant rubber products that offer dependable performance no matter what. Hence, it is important to choose the right manufacturing materials to ensure prolonged seal performance in high temperature applications.

Applications with high temperatures can include ethylene production, steam and gas turbines, solid oxide fuel cells, and industrial exhaust systems. Such applications comprise immense levels of heat, aggressive chemicals, and strong transfer fluids. Due to these elements, the temperatures can be of at least 400⁰F or above. Traditional sealing materials like mica or graphite lose their physical integrity, and their performance diminishes quickly in such environments. This can result in total leakage, which can lead to a shutdown, and downtime.

Silicone Rubber

A rubber-like polymer, Silicone Rubber has a high temperature resistance up to 230⁰. It offers outstanding high-temperature resistance, with some compounds able to withstand temperatures up to 305 °C. The material is resistant to UV rays, ozone, and oxygen. It has great electrical insulation properties, and high gas permeability. It is mainly used to manufacture aerospace seals, and automobile gaskets.

Silicone is not a high strength material and tears easily. Having said that, we have special compound grades that deliver better tear resistance than standard silicone. Fluorosilicone elastomer material combines high liquid resistance of fluorocarbon, and extreme temperature stability of silicone. With a temperature above 400⁰F, fluorosilicone O-rings can be exposed to sunlight, and will not degrade due to air, ozone, aromatic, or chlorinated hydrocarbons.

PTFE

Polytetrafluoroethylene is one of the reliable polymer materials. It can resist strong industrial chemicals, and maintain its integrity in temperatures above 500⁰F for long time periods.PTFE provides the least amount of friction when compared to other options. In addition, PTFE is tremendously nonwetting and acts as an excellent electrical insulator. PTFE is also unfazed by the majority of chemicals. It is extremely resistant to high temperatures, contain outstanding electrical properties, have excellent release surfaces and superior chemical resistance. PTFE is widely used across various industrial applications like Plumbing, HVAC, Electronic Appliances, Pharmaceutical, Automotive & many more.

FKM (Viton)

FKM is a family of fluoroelastomers commonly referred to by DuPont’s Viton® brand name. FKM is an excellent high-temperature-resistant rubber that can resist the temperature above, which retains its good mechanical properties and chemical resistance (oils, fuels, lubricants and most mineral acids), even at extremely high temperature up to 225⁰F. Due to its wide temperature range, chemical compatibility, low compression set, and excellent aging characteristics, fluorocarbon elastomers (FPM, Viton®) have grown to major importance in the seal industry. Fluorocarbon elastomers are highly fluorinated carbon-based polymers used in applications to resist harsh chemical and ozone attack. Fluorocarbon O-ringsshould be considered for use in aircraft, automobile and other mechanical devices requiring maximum resistance to elevated temperatures and to many fluids such as mineral oils and greases,  non-flammable hydraulic fluids, silicone oil, fuels etc. Whilst not recommended for use with brake fluids, ammonia solvents, strong acids or superheated steam.

EPDM

EPDM – also known as ethylene propylene diene monomer – is an extremely versatile material used in a variety of applications, from automotive products to HVAC parts. This type of rubber also acts as a less expensive alternative to silicone, as it can endure weather conditions, abrasion, and other challenges for long periods of time with proper use. EPDMis a copolymer of ethylene, propylene and diene monomers. This synthetic high-temperature-resistant rubber offers excellent heat resistance, performing optimally up to +150°C. It has good resistance to UV exposure, ozone, aging, weathering, and many chemicals – great for outdoor applications. Can be fabricated in a variety of ways, which includes custom molded and extruded partsLong-term part lifespan allows for fewer replacement parts, saving money in the long run. 

Also Read: What Are The Advantages Of EPDM O Rings?

HNBR

HNBR elastomers are changing the game for sealing and manufacturing companies. Made from hydrogenated acrylonitrile butadiene rubber (NBR), the compound meets higher temperatures, retains better resistance and has become widely known for its physical strength. It is a unique elastomer that is derived from conventional nitrile rubber through the hydrogenation of unsaturated bonds in the butadiene. HNBR is an exceptionally high-temperature-resistant rubber that can withstand much higher temperatures than conventional nitrile up to +150 °C. It also offers good abrasion resistance. It is resistant to mineral oil-based hydraulic fluids, animal and vegetable fats, diesel fuel, ozone, sour gas, dilute acids and bases. HNBR also resists new bio-oils (biological oils). Typical applications include gaskets and seals, especially for the oil and gas industry, and accumulator bladders, and diaphragms. It is compatible with automotive oils, gases and fuels such as aliphatic hydrocarbons, hydraulic fluids and dilute acids. However, HNBR is not recommended for use with chlorinated hydrocarbons, polar solvents or strong acids. Also note that it has limited resistance to brake fluids.

How To Check The Material Grade
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How To Check The Material Grade/ Impurities/ Quality etc. !!!

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When it comes to predicting the durability or performance of a given material for use in a specific application, it’s crucial to evaluate chemical and physical properties as well as environmental compliance and quality control. At Kesaria Rubber we understand the real-world service-life and environmental challenges polymer materials face. Our experts can help you predict, manage and improve the performance of your polymer-based material or product whilst ensuring its safety and compliance. We provide independent rubber material analysis to clients operating in a wide range of industries.

We help clients understand, manage and improve the performance of their materials and products using a range of analytical techniques together with expert interpretation of results, guidance and advice. We go through a comprehensive range of chemistry, physical testing, and technical consulting stages to support the development of polymer based materials and end products. 

  • Chemical Characterization

When working with new compounds and sustainable, recyclate-based material formulations – gaining full confidence in their performance requires accurate assessment of not only physical and mechanical properties but also the identification and mitigation of any contaminants.

How we check the Material grade/Polymer Identification

Proper material selection is at the heart of any product or development project. Material characteristics and performance can determine the success or failure of the productand consistency of the rubber materials from lot to lot plays a significant role. Below are a few tests by which we can check the material/ identify the material and check the consistency of the quality of the rubber material. Following are the methods we use for chemical testing-

1.0Chemical methods ( ASTM D 297 )

  1. Burning Test: The piece of sample is heated in a flame and the odor and the color of the flame is noted.
  2. Acid degradation test:
  • Action of 80% H2SO4 and heated slowly in the flame.  The change in sample condition is observed.
  • Action of Concentrated Nitric Acid:  A small piece of width approximately 2-3 mm is taken in the test tube containing 1-2 ml of concentrated HNO3 and heated slowly in the flame.  The change in sample condition is observed.

      3. Beilsten test (Cu Wire test): The copper wire is heated till red hot; the sample is taken on the red-hot wire and heated in the flame. The color of the fame is then noted.

2.0 Instrumentation methods

    1. FTIR:     Fourier Transform Infrared Spectroscopy (FTIR)
    2. GCMS:   Gas Chromatography Mass Spectrometry (GCMS)

  • Physical Testing

Rubber material formulations can be greatly affected by a wide range of environmental conditions and physical forces. From adhesives to a variety of rubber compounds, Kesarias’ physical testing experts can provide guidance and test data to support your material evaluation needs. Our environmental exposure capabilities include variables such as temperature, humidity & UV Arc chambers to test in the harshest of lab conditions. Physical properties can be studied extensively through a myriad of internationally recognized standard test protocols. While data from any combination of these material property tests can provide you with a good picture of a given material’s expected performance.In addition, Kesarias’ laboratories are able to not only excise samples from most whole products, but our internal small batch mixing and molding capabilities can assist you in providing the most appropriate samples for your testing purpose.

How we check impurities and quality of rubber

  • Density: ASTM D297

The specific gravity of any elastomer is important for its identification and providing an approximate measurement of its physical properties. Rubber density determines the specific gravity of the material and Generally the S.G. of rubber is used in place of density which is measured with respect to water. Specific Gravity is normally abbreviated to SG and is the ratio of the weight of a given substance to the weight of an equal volume of water at a specified temperature. If the Specific Gravity increases from its standardized value then it seems that rubber material has impurities or fillers which will affect material properties.

Procedure:

The most common method of determining the density of a rubber material is to weigh a test piece in air and water. Weighing in air provides the actual weight and weighing in water provides the volume. The density is then calculated by dividing the weight by the volume.

 

  • Ash content (ASTM D297_Filler Analysis)

The quality of rubber varies widely due to the percentage of ash content into it. Rubber materials having Inorganic impurities like Silica, Zinc Oxide, Clay etc. and high concentration of these impurities or high ash content % may initiate the oxidative degradation of rubber and may affect the quality of the final product. The percentage of these impurities can be found out by an ash content test. This test method is used by the rubber industry to ensure purity of the ingredient as per standard specification.

Lower Ash Content 

(Virgin Materials/Lower Impurities)

Longer service life.

 

Higher durability.

Lower after sales services.

 Procedure:

Ash % is determined by taking an accurately weighed sample in a properly cleaned porcelain crucible and heating   in a muffle furnace at 550 + / 25 °C for 1 hrs. The crucible is then cooled to room temperature and final weight is taken after getting constant weight. The mass of residue in the crucible represents the Ash Content. The ash content is calculated as per given formula i.e.

Ash content % =   Weight of the ash

                            _________________        x 100

                            Weight of sample taken 

 

  • Life Prediction & Accelerated Ageing

Life prediction and accelerated aging studies to help you make significant, safe and effective material choices, supported by material analysis for your intended end-use application. Life prediction and accelerated aging can be assessed throughout the product cycle from material evaluation, product development, and material qualification through to prototype design and final product stages. As service conditions become increasingly more demanding there is a need to demonstrate material durability and ensure a material is fit for purpose. Testing materials and products exposed to accelerated high temperature aging enables product service life predictions to be evaluated.

Prediction of expected product life time

Kesaria Rubber Industries helps generate data to drive product improvements. Polymer material performance is dependent on time, temperature, stress and environmental factors which can all be investigated with the following testing:

  • Mechanical (creep, fatigue, stress relaxation, impact, environmental stress cracking (ESC) and wear)
  • Thermal (degradation, dimensional stability, fire)
  • Oxidative (oxygen, ozone and metal catalyst)
  • Chemical (fluids, gases, water and steam)
  • Radiation (sunlight, ultraviolet light and atomic radiation)
  • Biological (microorganisms)
  • Electrical (arcing, electrostatic build up, dielectric breakdown)
essential considerations before designing
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5 Essential Considerations Before Designing Rubber Products !!!

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Designing rubber parts means taking multiple requirements into consideration. A design engineer wants to get the part that will work in their assembly. Purchasing Managers want to make sure they can meet the timetable and get the most cost-effective part. The quality engineer needs all the documentation to satisfy quality standards and information to pass regulatory reviews. Designing the ideal rubber part for all the industrial applications, there are several rubber product design features worth bearing in mind.Here are five ways to make sure that part will meet those requirements and get to market on time.

1. Using The Right Material

With new material regulations being introduced, making sure you have the right material is critical. Many design engineers use common rubber sealing material in prototype concept work. It’s the easiest to get and they may believe all rubber materials are the same. Before the product goes to market, a company’s regulatory department may find the material not acceptable or requires a high level of testing to determine if the material is qualified for use. 

Letting a rubber molder know about what material is going to be used in a particular application will allow the molder to select the correct material. This will help streamline compliance and may eliminate future testing if the material is already tested. Rubber compounds are typically made up of 20 or so individual ingredients, compared with plastic compounds that might only have three or fewer. Formulating rubber products requires an extensive review of these ingredients, including the purity level of each. To know more about choosing the right material check our material selection guide-

https://www.kesaria.com/blog/how-to-choose-which-rubber-is-best-for-my-application/

2. Evaluation Of Chemical Compatibility

No rubber material is perfect. When designing the perfect sealing product It’s important to use the right material to match the application & the environment in which it will operate. When working with chemical substances we majorly face challenges in handling & processing of various chemical substances. Hence, it is very important to check the chemical compatibility of these substances & select the most appropriate elastomeric material that can withstand any type of environment & media therefore we would recommend a range of chemical resistant materials such as NR, SBR, NBR, CR, EPDM, HNBR, ACM, CSM, Silicone & FKM (Viton) with our technical experts to guide you in selecting the right material as per your application.

3. Review Of Hardness In Rubber Compound  

Shore Hardness measures the resistance a material has to indentation. The Shore durometer is used to compare & measure the hardness of a material, typically of polymers, elastomers & rubbers using a spring-loaded steel rod by compressing the surface of the material. A shore hardness of 0 equates to the maximum amount of indentation possible, while A shore hardness of 100 is indicative of an extremely high resistance to indentation. To know more about hardness of your product check out our hardness comparison chart-

https://www.kesaria.com/products/o-rings/

4. Observe The Permissible Tolerances

It is essential to observe the rubber tolerance in your design process as almost all the elastomers undergo a certain degree of shrinkage. The ingredients in a rubber formulation are mixed at a given tolerance. This can cause variations in the amount of shrinkage from batch to batch. In addition, molds are heated. The tolerance on a mold temperature profile can also cause shrinkage variations apart from these other factors are like tool design, geometry, hardness etc. are also responsible for shrinkage hence considering all these factors it is important to get a guidance at the earliest stage from our technical experts to ensure the most optimum solution for your particular application requirement. 

5. Review The Geometry To Avoid Stress / Strain

Determining the geometry is very essential to check viscoelastic properties, stress-strain properties, rebound resilience & tear strength of rubber raw materials as it includes essential chemical-analytic and physical structure of carbon atom also called geometric factor i.e. highest possible level to bear stress. The simpler and more symmetrical the geometry of your design, the easier it will be to produce. It is worth bearing in mind that complicated geometries can often cause stress to the product that in turn could decrease it’s durability hence causing the product to be less durable & only for a shorter period of time.

With a little work during the design phase, rubber parts can have a smooth sailing right through production. We make sure our customers get the perfect product as per their application requirement to achieve their business goals.

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Is There Any Need For Biodegradable Rubber Products?

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In recent years, the waste disposal problem has spurred mounting interest in the biodegradability of polymers & elastomers, especially when the public is voicing greater concern about protecting human health and preserving the quality of our environment. Concerns regarding the environmental impact of solid wastes, recycling and composting options are expected to increase as landfill capacity decreases. Managing waste is thus a challenge facing the global community. With reference to a research rubber waste make up approximately 8 percent of the total waste generated yearly, the tremendous amount of waste produced in general is a significant burden on the environment when considered in measurements more equitable to the impact tons of rubber discarded into landfills yearly.

Given the unique properties of rubber materials, the overall use of rubber for a large number of applications is constantly on the rise and becoming an ever increasing focus of concern. Rubber materials are also of increasing concern, not only in industrialized countries but also in less developed nations, rubber products are everywhere to be found, though few people recognize rubber in all of its applications. Since 1920, demand for rubber manufacturing has been largely dependent on the automobile industry, the biggest consumer of rubber products. With the increase in demands, the manufacturing and use of rubber and the rubber products has increased tremendously both in the developed and less developed countries. The use of rubber in so many applications results in a growing volume of rubber waste.

We need to integrate rubber materials into the natural cycle of biodegradation, an important aspect of any environmental approach to waste disposal as it is becoming more critical to address our solid waste as society grows and our use of rubber products expand. There are three methods considered appropriate, in the environmental sense, to dispose of various rubber wastes; Recycling, Incineration and Biodegradation.

Ultimately, the most interesting avenue of disposal is in landfill disposal and biodegradation of unwanted rubber materials; the ability to effectively biodegrade the wasted material is of paramount importance. Microbial degradation is a natural process by which organic compounds, including rubber polymers are converted by the action of bacteria to simpler compounds, mineralized and redistributed through the elemental cycles. Biodegradation is the biological breakdown of organic compounds by microorganisms into cell biomass and less complex compounds, and ultimately to water, and either carbon dioxide (aerobically) or methane (anaerobically).

Anaerobically biodegradable waste materials offer a unique value proposition when assessing waste management of landfilled materials and most rubbers are either landfilled or incinerated. The biodegrading material reduces in mass – freeing up valuable space in overflowing landfills. The resulting products of biodegradation, (water, carbon dioxide, methane, inert humus, etc.) are non-toxic and revert to the natural cycle. And, the methane produced is a highly valuable energy resource that is quickly gaining favor globally. There is tremendous push from waste management companies as well as municipalities to increase the use of methane to energy. Many companies and municipalities are utilizing the energy produced from methane created by biodegrading landfill waste as a green energy proposition in their overall environmental portfolio.

In conclusion, there is a tremendous need to address the ever growing issue of rubber waste and focus must be put on remediation of these wastes. Complete biodegradation of these materials may be the suitable answer, provided we are able to control the biodegradation in such a way that it does not impact the service life of rubber products. There has been substantial focus in the past as to the inherent biodegradation of natural rubber; and the focus here was to create synthetic biodegradable rubber materials. Testing clearly shows drastic increases in the rate of biodegradation in various synthetic rubbers when treated with the biodegradation being in anaerobic environments offers a unique waste disposal solution.

Additionally, the resulting methane production during the anaerobic biodegradation of these materials is commonly used for energy production to offset traditional energy sources, such as coal burning. This provides a method for reducing waste volume through biodegradation as well as benefiting environmentally for the byproduct of that biodegradation. For manufacturers and brands utilizing rubber materials, this presents an opportunity to provide environmentally focused waste management for the foreseeable future, in a way that requires very little direct action or input other than a slight change in materials.

coatings
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How Special Coatings Can Increase The Performance of Rubber O Rings & Seals?

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Rubber seal products, or Coated O-Rings, are used in a multitude of different industries. A large percentage of these are used in static seal applications where the O-ring is held in place and where elasticity and resistance to abrasion or friction are not as important. However, many O-rings are also used in dynamic applications where the product surface moves in relation to the seal. These dynamic applications are much harder on O-rings and, without proper prevention, can cause them to fail. O-ring failure can lead to catastrophic results in many products, and as such, manufacturers must be very attentive to the ways in which they can extend the life of their O-rings to ensure that their products have the best chance at maintaining required rates of performance.

Benefits Of Rubber Coatings:

  • Reduce Surface Friction
  • Reduce Corrosion
  • Reduce Insertion Force
  • Provide Wear Resistance
  • Prevent Surface Adhesion
  • Improve Chemical Resistance
  • Easier Identification Of Parts
  • Easier Installation Of Parts
  • Reduce Substrate Ageing

Types Of Coatings & Their Advantages:

1. Powder Coatings-Dry (powder) coatings are commonly used to inexpensively treat automatic assembly equipment parts. These coatings reduce the tendency of parts to stick together, forming clumps or masses. Dry powder coatings such as talc, powdered PTFE, mica, graphite and molybdenum disulfide are widely used. Each is similar in function, but can offer different performances depending upon application specifics, such as fluid compatibility or temperature. Over time these coatings may foul assembly equipment, requiring downtime for cleaning, especially with sensitive automatic assembly equipment that utilizes photoelectric sensors.

2. Wet Film Coatings-Like dry coatings, wet coatings are an inexpensive way to increase the part installation efficiency of automatic assembly equipment. While wet coatings can be applied to all part sizes, they typically are for larger, hand installed parts with greater surface contact areas. The Primary wet film coatings are:

  • Silicone emulsions (mixture of silicone and water)
  • Soap and soap/water mixtures
  • Vegetable oils or any other customer specified coatings.

Wet film coatings generally offer superior lubricity over dry coatings, but can be messy. Take care to prevent migration across the shop floor.

3. PTFE RESIN Coatings- Not to be confused with PTFE powder coatings, PTFE resin coatings are aqueous colloids – acrylic resin binders mixed with PTFE powders and colorants. Heat dries off the water, leaving behind a PTFE/resin film on the part’s surface. These coatings reduce friction and are “semi” permanent as they will not rub off with contact, but can be removed over time. Primarily used for automatic assembly, these coatings offer the best combination of lubricity, cleanliness and cost. Also, high value materials can be different colors for easy identification.

4. Parylene Coatings-Parylene is a vapor deposition coating. Poly(p-xylene) based polymers are thermally deposited on the rubber part surface. The outer layer forms a composite structure with the rubber part as the core, and the parylene as the external jacket. Parylene coatings offer these advantages over other coatings: Permanent, FDA complaint coatings, Reduced friction on par with PTFE coatings, Added chemical resistance, Reduced vapor transmission & Hydrophobic.

Blog-post-8
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How To Improve Service Life Of Rubber Parts?

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Service Life Of Rubber Parts is it’s expected lifetime, or the acceptable period of use in service. It is the time that any manufactured item can be expected to be ‘serviceable’ or supported by its manufacturer. Since elastomers are used in many products, the service life would be dependent on the product manufactured. There are several primary factors that influence the service life of an elastomer in a finished product like – Heat, Corrosion, Wear and Cracking.

As they age, rubber seals and molded rubber products can undergo changes in physical properties and become unusable due to excessive hardening, softening, cracking, crazing, or other surface degradations. These changes may be the result of one particular factor or a combination of factors, such as the action of oxygen, ozone, light, heat, humidity, oils, water, or other solvents. The detrimental effects of these factors can, however, be minimized by proper storage conditions. 

There are three important factors involved in the determining the shelf life of rubber products: 

  1. The initial quality level of the rubber
  2. The quality assurance provisions of the specifications under which the product was procured 
  3. The age resistance of the rubber. The age resistance of the raw material may not always correspond to the age resistance of the finished product. 

6 Things To Take Care For Improving Service Life Of Rubber Parts ?

Elastomers are susceptible to deterioration by aging.  The rate of deterioration depends on a number of factors like –

  1. Temperature – Store between 15-25°C (59-77°F) and away from direct heat sources
  2. Light – Avoid exposure to direct sunlight, artificial light or UV
  3. Humidity – Below <65% recommended
  4. Ozone – Avoid placing near electric motors or high voltage electrical equipment
  5. Chemical Media – Avoid exposure to any liquids or vapours
  6. Deformation – Tension, Bending and Twisting should be avoided. Do not hang, fold or roll
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10 Things You Should Know About Your Rubber Parts Manufacturer ?

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With the globalization and open market numerous suppliers have emerged to lure customers with various offers and discounts. Finding and selecting the best supplier is an essential first step to managing product quality and limiting product defects in your orders. Choose the wrong supplier and you could face shipping delays, poor quality and product returns. But choose the right supplier and you’ll be on your way to quality products and satisfied customers. So, what makes a good supplier?

  1. Quality Standards– Never compromise with quality as it serves the critical function of your product. Kesaria Rubber is an ISO 9001:2018 and IATF 16949 certified company. To ensure quality of the Products manufactured & supplied KESARIA has well defined process flow and frequent quality monitoring system. Parts manufactured are of high quality and comply with International standards.
  2. Latest Technology – Always ensure products are developed from latest technology for best product finish. KESARIA has all the modern facilities, state of the art equipment & world class manufacturing facilities at its plant, which has sophisticated technology to produce 100% quality parts. It has in-house tooling facilities which include mould designing & mould development software along with High speed CNC & VMC machines. For more accurate inspection and speed, the latest Automated Online Inspection System is installed to avoid manual inspection errors.
  3. Research & Development – Intensive research and regular development will ensure upgraded quality. KESARIA is involved in R&D which means long-term support for our customers. Our teams are tasked with evaluating future technologies and bringing developments through to a production stage over a tight deadline. KESARIA works with our customers and offers them advanced products to meet their challenges & demands.
  4. Effective Design Inputs – Right Design will offer best fitment and enhance product performance. KESARIA offers services like drawing, sampling, manufacturing and testing to help steer clients from concept to actual product performance. Wherever industrial rubber sealing components are required, KESARIA’s highly skilled staff regularly provides extensive design input to customers. This involves the creation or modification of 3D files and the provision of 2D drawings for parts.
  5. In-House Facilities – 100% quality and in time delivery could only be achieved when complete production is under one roof. KESARIA has complete In-house manufacturing facilities with production capacity of more than 2.5 Million Parts Per Day and cater to a wide range of industrial applications. With this capacity we offer very rapid response lead times. Well equipped to manufacture any volume with our fast track facilities and deliver in a short time to meet our customers requirements and demand.
  6. Legally Compliant – Ethical business practice is the sign of sustainable business model. Buyers must be aware of the suppliers business practices and complying with government`s rules & regulations. This ensures a safe, long and healthy business. At KESARIA we follow every government norm, practice Social reforms, regularly engage in employee`s welfare, conduct CSR activities and monitor pollution control etc.
  7. Customer Service – Building relationships through delighted service and experience. At KESARIA we believe that our technical experience and superior quality rubber products would not be as valuable to our customers if they are not backed by a strong service ethics. Dedicated technically competent support team who are always ready to go an extra mile & create meaningful solutions.
  8. Customised Solutions – Your product is unique and requires unique rubber parts to fit well. KESARIA is specialized in offering customized products as per the drawing, sample and application. With an in-house development team and dedicated tooling department, we develop the exact products as per client`s concept and fitment. We understand that right fitment will enhance product performance and ensure 100% leak proof rubber solution.
  9. Continuous Improvement – Constant step towards innovation and next level of performance. We at KESARIA always demonstrate to our buyers that our organisation is committed to continual improvement by learning from the audit results and achieving better audit scores year after year. This shows our buyers that KESARIA is continually meeting the ever increasing buyer standards. KESARIA may not always be perfect but we ensure that we have action plans in place which help us go a long way.
  10. Past Experience – Finally experience makes the difference. With over 30 years of experience KESARIA is proud to have achieved a place amongst the top players in the Indian Rubber Industry. KESARIA has gained acceptance over so many years and across so many industries like Automotive, Electrical, Fluid Power, Home Appliances, Plumbing & Sanitary.
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Which Molding Process Is Right For Your Application?

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Rubber molding is a method in which a functional rubber product is manufactured. Rubber molded parts are produced by pressing a chunk of rubber into a rubber mold, then exposed to heat to activate the chemical reaction. While there are variations in specific methods, all rubber manufacturers use heat and pressure methods to form molded rubber products.

There are three common techniques used in rubber molding:

  1. Rubber Compression Molding
  2. Rubber Transfer Molding
  3. Rubber Injection molding

There are a number of factors to consider when determining the type of molding process required. Some of these include:

  • Size and geometry of your part
  • Weight of your part
  • Material required
  • Volume / number of parts required
  • Precision / Tolerance levels

Rubber Compression Molding

Compression Molding is the original production method for molding rubber. Compression molding involves taking rubber compounds or mixed raw material and making “pre-forms”that are close to the shape of the end product. These shapes are then loaded, typically by hand, into an open mold. The mold is closed, the rubber cured, and then de-molded. It is a useful molding process particularly for molding Gaskets, Seals, Rubber O-Rings, and large, bulky parts. It is a widely used, efficient and economical production method for many products, particularly low production volumes of medium to large parts and higher cost materials.

 

Advantages Of Compression Molding:

  • Short set up time
  • Least amount of waste
  • Is cost-effective for low quantities of parts requiring a long cure time
  • Ideal for parts with a very large cross section
  • Ease in processing high hardness materials
  • Tooling is simpler and more cost-effective
  • Disadvantages Of Compression Molding:
  • Parts can be less consistent
  • Coloured rubber can be easily contaminated
  • Longer cure times due to slow heat transfer through the rubber

Rubber Transfer Molding

Transfer Molding is a method permitting manufacturers to produce both rubber items and molded rubber parts. In this technique, manufacturers insert the molten substance into a cavity located above the pot and then use ram to force the mold through a runner and gate system as it melts upon the application of heat and pressure. Rubber transfer molding is related to injection molding since the rubber goes in the cavity after the mold is locked. Rubber products by this technique are less costly than a rubber product by compression molding.Transfer molding is an ideal process for molding parts that require multiple cavities, intricate parts that require a closed mold, bonding rubber to metal parts and if the geometry of the part might cause mold cavities to trap air.

 

Advantages Of Transfer Molding:

  • Fewer and simpler pre-forms because one pre-form can fill many of cavities
  • Tighter dimensional tolerance control because the mold is closed
  • Ease in processing Colored rubber parts
  • Disadvantages Of Transfer Molding:
  • Increased waste material rubber left in the pot has to be discarded
  • Designing and molding are complex hence process becoming costly

Rubber Injection Molding

Injection molding of rubber was originally an offshoot from the plastics industry in the early 1960s. After overcoming the initial issues of temperature (plastics are cooled when molding and rubber is heated) and pressure (rubber injection molding requires significantly more pressure per square inch of cavity surface), the process has become an efficient way to mold rubber in many cases. Rubber Injection Molding process begins with efficient preparation of material. First off, the material is mixed in bulk and immediately stripped off into continuous strips. The strips are fed into a screw with a predetermined amount of rubber into a barrel. When the mold is closed, the material in the barrel is injected into the mold cavities and cured.

 

Advantages Of Injection Molding:

  • Lower unit costs
  • Faster cycle times
  • Almost negligible flashes
  • Little scrap or waste material
  • Higher dimensional tolerances

Disadvantages Of Injection Molding:

  • Higher set-up costs
  • Small runs of parts can be costly
  • More expensive machinery and tooling

The choice of whether to go for Rubber Compression Moulding, Rubber Transfer Molding or Rubber Injection Moulding largely depends on cost, volume and time pressures. Neither technique is better than the other. It entirely depends on the requirements of your product and its application. At Kesaria Rubber, we have spent decades developing innovative techniques which can help you achieve your business goals. If you would like further assistance, please contact our Sealing Experts who will be happy to help, diagnose the problem and suggest possible solutions.

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