Rubber Vulcanization Lines

Rubber vulcanization has been a vastly popular application of Microwave Heating. The Bulk heating property of Microwaves combined with the rapid heating phenomenon makes Microwave Heating an ideal choice for rubber and rubber like materials. Rubber being a bad conductor of heat, any method of heating rubber relying on the conductivity of it scores a point lower compared to Microwave heating because Microwaves penetrate the rubber and heat the material from core to surface simultaneously. Most common and widely proven application of Microwave Heating is for the vulcanization of Automotive and Construction rubber profiles. Microwave Heating has been proven to be equally suited for Sponge, Solid and Co-extruded profiles. Since this is one of the well proven applications, there is rarely a need for any labscale or prototypes. Enerzi offers a range of Continuous Microwave Rubber vulcanization ovens for a range of rubber profiles.

We take pride in providing these lines with full support on Tool development, compounding and formulation development.

Rubber Profile Extruder

Being a one stop solution provider for variety of rubber extruders (screw dia ranging from 40 mm to 145 mm), Enerzi delivers compact and reliable extruders as well as machines equipped with the latest development in control systems and designs. Our extruders provide high screw torques just as variable screw speed ranges. We thus guarantee a wide production range without compromising quality. Enerzi rubber extruders possess the latest extrusion unit design and control system for all machine parameters. Excellent design of systems to achieve the best dimensional stability at highest productivity, makes our products unique.

Infrared Shock Oven

Enerzi Infrared Shock tunnel is highly efficient for the pre-vulcanization of profiles and hoses. Arranged between the rubber extruder and the continuous vulcanization line, the high power infrared radiation pre-cures the surface of the rubber products. This is related to a better dimensional stability and an excellent surface quality. This process is ideally suited for Sponge profiles, but solid profiles derive an equally useful advantage as well. Typically these systems are about one meter long and have got a heating capacity of about 30 kW.

Microwave Vulcanization Ovens

Microwave radiation penetrates the rubber and heat the material from core to surface simultaneously and hence microwave curing is very fast. Microwave heating has proved suitable equally for sponge, solid and co-extruded profiles. These ovens are available in 4 different capacities namely 4, 6, 8 and 10 station ovens, where the stations indicate number of microwave generators each having 1.45 kW. Our microwave generators are designed with state-of-the-art features and are well proven in the rubber industry since 2005. These ovens are designed with utmost care to minimise microwave leakage.

Hot Air Ovens

Hot air tunnels are used especially for curing or rather post curing of rubber profiles, insulation hoses and other special products. Hot Air Tunnels unlike their counterparts i.e. Microwave Ovens or Shock oven, do not have any high frequency heating. Rather these ovens have a heated air circulation with the help of a blower. These Ovens are similar in design to the Microwave Tunnel Ovens and serve the purpose of final curing / Post curing of rubber profile after initial curing in Microwave Oven / IR oven.

Caterpillars

Caterpillars form an essential subsystem in the scheme of the complete lines. This unit helps in retaining the tension of rubber profile along the line. Depending on the speed of production and profile sizes, the Caterpillars are designed from 36” to 100” belt length and even higher. Enerzi specializes in providing unique designs of Caterpillars to suit a variety of Rubber Profile manufacturing lines.

Cooling Tunnels

Cooling tunnels are primarily used in the commercial processing of rubber. Cooling tunnels use a conveyor system, mostly rollers to pull the product through the refrigerated tunnel. There are continuous as well as discontinuous cooling systems, depending on what is required. Continuous cooling involves moving the product until the required temperature is achieved, whereas discontinuous cooling is when the tunnel provides different cooling down periods through pallet and tray forms. Chilled DM Water is usually used for cooling Rubber Profiles and the system length varies from 3 to 10 meters depending on the throughput of the production line.

On special requests we also supply a variety of other customised line configurations as per your product specifications. We take pride in providing these lines with full support on Tool development, compounding and formulation development.

Rubber Vulcanization Lines