OPTIMIZATION OF PRODUCTION PROCESSES AND INCREASING PRODUCTIVITY
Recommendations will be provided on selecting the right processes and equipment suitable for these processes according to product and formulation requirements for the optimization of production processes. It should not be forgotten that even if you have the right formulation, an unsuitable process, machine, or equipment will negatively affect product quality and may even result in products being out of specification.
A quality product is possible not only with the right formulation but also with the right process.
We review all your processes, from the weighing stage through to vulcanization and finishing, and provide recommendations for the necessary improvements.
Automatic weighing and dosing lines that minimize weighing errors,
Mixing lines that will provide the best compound,
Surface preparation and coating units that will provide maximum adhesion strength,
Pre-forming processes such as calendering and extrusion,
Vulcanization systems such as continuous vulcanization, compression presses, injection presses, and autoclave vulcanization,
We review all process steps, such as post-vulcanization finishing operations, report the points where improvements can be made, and follow up on their implementation.
MartConsulting®
DETERMINATION OF PROCESS PARAMETERS
- The right production parameters are just as important as the right processes. As part of this study, the results will serve as a long-term guide for you in correctly selecting the parameters that need to be controlled from start to finish on your planned or existing production line, as well as in determining the limits of these parameters and ensuring they are kept under control.
MartConsulting®
REDUCING SCRAP AND WASTE, INCREASING PRODUCTIVITY
- Unfortunately, for most rubber products and in most facilities, recovery after vulcanization is often not possible. Therefore, an increase in scrap and waste costs at every stage leads to a decrease in efficiency and, consequently, a decline in profitability. The necessary steps to minimize scrap and waste at every stage will be outlined. While implementing these measures, the technical training required to ensure that current and planned production personnel fully understand and grasp these issues will be identified and reported.
MartConsulting®
SPEED OPTIMIZATION ON PROFILE LINES
- The analysis of your profile lines within the “line speed–temperature–rheometer curve” triangle, along with efforts to optimize their speed, is a task that must be carried out by professional staff—both to improve production efficiency and to reduce costs.
- Additionally, implementing measurement control systems to prevent dimensional deviations and making process improvements to ensure your extruded profiles remain within tolerances are critical steps for reducing profile scrap. Profile dimensional tolerances are particularly critical if the extruded profiles are to be used in subsequent applications. In this regard, integrating dimensional control systems into your extrusion lines will ensure a rapid return on your investment, and our team of experts is here to assist you in this area.
MartConsulting®
STABILITY IN PRODUCTION AND STANDARDIZATION OF QUALITY
One of the biggest problems in rubber operations is production stability. For example, your dimensions may change frequently during extrusion. Imagine being able to produce a 0.5 mm thick hose throughout the entire day with a deviation of only +/- 0.03 mm, remaining within tolerances with just minor adjustments. We can provide this for you.
First, after determining the parameters and limits in your process, we identify Control Points and Critical Control Points to ensure that your production continues within these limits. If necessary, we prepare instructions and monitoring forms together and ensure the traceability of these parameters.
In this way, your production parameters are brought under control, ensuring stable production.
Our expert teams will professionally examine your entire production, starting from compound production through to the final process point, and provide you with professional solutions for stability and quality standardization.
Minimizing batch-to-batch variations in your compounds
Standardization of processes such as extrusion, calendering, and pre-forming
Consistency in operations such as surface preparation and coating
Standardization of curing processes such as autoclaves, presses, and continuous vulcanization lines, etc.
MartConsulting®
INCREASING PRODUCTIVITY IN PRESSES
- Similar issues arise when working with injection molds. In particular, with injection molding machines, it is possible to increase production volumes by analyzing rheometer curves, understanding the flow properties of the material, and ensuring proper mold design. Ensuring the compound has good flow properties through recipe design guarantees complete mold filling, and when combined with a curing system that provides the optimal curing rate, maximum yield is achieved. Through on-site analyses, our team of experts provides you with optimization and productivity improvements in press efficiency.
