MANUFACTURING PROCESS

All incoming raw materials are tested for the required specification. If all materials meet the required specification the same will be accepted and if not, rejected and returned back to party.

Rubber Compounding

Rubber Compounding is prepared by internal mixer (kneader machine) is used to make master batch of the Nitrile Rubber Compound, Activators, Process aids, fillers, (White & black), Processing oils are added in the Kneader Machine as per the order of addition and specified time and temperature are being given for the particular rubber compound. The Temperature of kneader machine is controlled by water circulation. Final batch are prepared in two roll mill, the master batch is loaded in two roll mill and curing agents, accelerators, retarders are added in the given time. The mill temperature is also controlled by water circulation.

Laboratory Testing

The sample of final batch form Mill room are tested as per specification. If any problem observed all properties of rubber compound are tested and necessary precautionary measures (rectification) are taken.

Extrusion 1st (Tube)

Before sending for extrusion, rubber compound is warmed up on two roll mill and Strips (70mm/5mm) are cut. These Strips are fed into extruder M/c & Temperature of different zones are control by heating and cooling process. Cooling is done by water circulation and water coming out of machine goes to water tank re-circulated.
Nylon Mandrels are lubricated with silicone oil and are passed through cross head fitted with die of required size. The Thickness of tube is maintains through these dies. Tube are extruded on mandrels and then pass through cooling conveyer and are coiled either on drums or trays. The tubes extruded are given rest for at least 8hrs. For further processing of wire braiding.

Wire Braiding

Tubes after rest period are sent to braiding machines & are braided with high tensile steel wire (0.3mm dia). The wires are filled on Bobbins by help of wire winder where fixed tension is set for filling wire and 3 ends of wires are filled on bobbins (16 Nos.) which are put on braiding M/c and are coiled either on drums or trays.

Extrusion (2nd layer i.e. outer cover)

After braiding is done, outer cover is extruded which is normally orange colour nitrile rubber by help of cross head fixed with dies to maintain the outer dia of hose within limited dimension.

Wrapping

After outer cover is done, hoses are wrapped with Nylon tape (75mm wide) by help of wrapping machine which wound the tape on hose with high speed at controlled pitch

Unwrapping

After curing, Hoses are unwrapped by Unwrapping M/c, this machine is same which is used for wrapping operation also. Nylon tape is remove form hose and the tape removed is re-used for wrapping other hoses.

Demandreling

After Unwrapping the hoses, Nylon mandrels are remove from the hose by Hydraulic Pressure which is done by Hydraulic Pump. The mandrels removed are cleaned and Coiled on drums for re-use.

Cutting Washing

After mandrels are removed from the hose, hoses are cut to size i.e. required length by high speed cutter, after cutting, these are washed by soap solutions and go for inspection.

'

Inspection

After Pcs are cut and washed, they are inspected for visual examination for any defects etc and also they are sent to laboratory for performance tests like bonding, pressure testing and leakage testing etc.

Packing

After inspection, hoses are packed individually in poly then and then in bags or cartoon and sent to customers.