Outlook 2016: Automation moves forward in rubber production

Global demand for natural rubber is projected to slow down through 2016 as consumption growth declines in China, the biggest importer.  Expansion will moderate to 3.5% in 2016 from 3.9% in 2015 and 4.1%in 2014, according to Hidde Smit, former secretary general of the International Rubber Study Group (IRSG). Estimates from the IRSG also indicate that China’s demand will rise 4.8% in 2016 from 6%  in 2015 and 7.1% in 2014.

Low prices of natural rubber, while cutting costs for major tyre manufacturers, compelled Thailand, Indonesia and Malaysia to limit exports of natural rubber. With global demand slowing down, production expansion is anticipated to post even slower rate to result in estimated shortage of 470,000 tonnes in 2016.  

Global consumption will reach 12.75 million tonnes in 2016, up from 12.32 million tonnes in 2015, while production output will hit 12.83 million tonnes from 12.25 million tonnes. The world’s biggest market for rubber, China is projected to increase consumption to 5 million tonnes in 2016 from 4.78 million tonnes in 2015 as a result of rising tyre production and higher requirements for rubber used in other applications.

Value and efficiency in production
Rubber production presents attractive opportunities for those engaged in developing advanced technologies in the production of rubber products. Innovative technologies with some very interesting process and automation solutions are gaining grounds as rubber products manufacturers see the need to improve their production process

Precision engineering, sensible applications, customer-orientated manufacturing examples are issues that have kept MAPLAN busy developing innovative technologies. “Practical and energy-efficient solutions offer great potential to improve value creation”, says Wolfgang Meyer, CEO of MAPLAN.

For instance, the company put three machines at work during the DKT. These included the newly developed 200kN “Top-Top“ C-frame machine, the ICM process (Injection Compression Moulding) with valve gate cold runner technology presented on an ergonomic, fully hydraulic 3,200kN machine, and the MHF horizontal machine range.

MAPLAN has developed the new C-frame generation that closes from the top down with the MTTF100/20C. The 200 kN machine is the first machine of this range. The 300 kN and 500 kN models will follow shortly. This range is very compact with an excellent footprint to match. Mr. Meyer commented: “The real attraction is the well thought-out design which combines both ergonomics with value analysis. In this case ergonomics stands for the user-friendly application of the concept.” The fully hydraulic clamping unit with a fixed lower plate has for example made it significantly easier to automate the insertion and removal process of profiles with corner moulding. Displacement of the profiles out of the tool is effectively prevented, resulting in a higher quality of the finished product. The optimised operation height of the range of machines, in connection with the C-frame design, ensures excellent accessibility to the mould area on all three sides. Conceived on the basis of value analysis, these machines offer a great deal of technology for a fair price. The C-frame which is optimised for stiffness guarantees a minimum of bending with a high degree of plate parallelism. Both effects result in low levels of mould wear when opening and closing and correspondingly low mould maintenance costs. Ideal applications for the new Top-Top range are corner moulding, the manufacture of small moulded parts and/or small batch sizes. Completing the range is a version with an injection unit for manufacturing with TPE.

Energy-saving is a primary concern nowadays and MAPLAN places great emphasis on energy efficiency even with the standard version, equipped with an energy-saving hydraulic pump with proportional pressure/volume control. Energy efficiency can be further enhanced by means of an optional CoolDrive®. This servo-controlled hydraulic pump offers extra power for rapid dry cycle times for even less energy consumption. This is both good for the environment and cuts production and unit costs. “CoolDrive® really is a success story for our customers: CoolDrive® reduces energy consumption of the drive by up to 50%, while simultaneously reducing dry cycle time and also cutting noise emissions by half. This potential is very attractive for production managers,” according to Mr. Meyer.

Compact operator-friendly and highly flexible machines with precision dosing and reproducibility are the hallmark attributes of all MAPLAN machines. The modular design enables the combination of machines with clamping forces from 1,000 kN to 8,000 kN with FIFO injection units from 130 ccm to 8,600 ccm, for the horizontal range. The horizontal MHF700/200editionS is an especially space-saving design that still exhibits excellent accessibility. This machine is ideal for the manufacture of flat seals, O-rings, contoured rings and similar rubber articles. Vertical machines are available with clamping forces ranging from 500 kN to 9,000 kN and a choice of FIFO injection units as well as screw/piston injection units from 20 ccm to 26,000 ccm. The spring pre-loaded short, cooled nozzles of the FIFO injection units ensure that only a very small pressure loss in the nozzle area occurs. Screw/piston injection units are deployed on vertical machines with injection from below where a low operating height and comparably large injection volumes are required. Both of these machine ranges are characterised by rapid reaction low-energy hydraulic pumps with position controlled proportional pressure/volume control. All machines are optionally available with particularly efficient servo-hydraulic CoolDrive® actuators.  

Automation is the way to go
The fully automatic extraction handling system by Robotix has been created using MAPLAN’s modular brush unit range and serves as the company’s response to the growing preference of manufacturers to automate their operations. Special features of the Robotix include the two servo-driven main axles. These ensure a rapid and constant cycle time. The servos are integrated in the control environment of the MAPLAN machine and can be accessed via the display of the PC5000 control system. All movement parameters including speed, acceleration etc. for the extraction process can be viewed on the display and altered if required. The extraction process has been developed in close co-operation with Elasmo Systems and MAPLAN. In order to make the complex extraction process possible, the bell-shaped pen holders are blown out with valve gate nozzles. The extractor system has to seal the parts to ensure the stability of this process. The finished parts are placed in-line on a conveyor belt which is integrated in a very space-saving way into the frame of the Maplan MHF700/200editionS machine.

 “The trend towards higher levels of automation in connection with sensor technology is steadily growing. Customer-specific requirements have considerably increased in the last three years”, according to Mr. Meyer. Due to the high degree of globalisation of elastomer processing, in particular in the automotive industry, this effect can be seen in every region of the world. With reference to automation and sensor components, MAPLAN estimates there is an average extra cost of up to 50% compared to conventional capital expenditure for machines. Particularly in the case of moulds for high volumes or with many cavities, there is, however, a significantly higher level of quality and considerably faster amortisation.

The integration of automation and sensor technology in elastomer processing facility, as what MAPLAN recently demonstrated, has a very long-term effect on profitability. This naturally also applies to the whole lifespan of a machine. Operating faults can be avoided or process deviations identified early on. By moving towards zero defect manufacturing, disturbance variables become more manageable. Whereas in the case of conventional machines quality has to be checked after the production process, i.e. offline, a fully automated machine can implement in-line QA controls, assuring quality during the ongoing production run. The reduced risk of faulty parts in part flow means a high degree of reliability and possible cost savings. A consistent flow of parts generates a “feel good factor” for all parties involved in the supply chain: parts producers, OEMs and users. IRNE

 
MAPLAN GmbH
Schoellergasse 9
A-2630 Ternitz
Austria
Tel: +43/2630/357 06-0
E-mail: office@maplan.at
Website: www.maplan.at