Continuous Microwave Oven and Hot Air Line

The continuous microwave vulcanisation is one of the modern continuous vulcanisation processing methods. The microwave has an available power of 10kW. The microwave energy is generated by 4 magnetrons with a nominal rating of 3 kW each, but which are used at a maximum of 2.5 kW. The power can be infinitely adjusted up to 10 kW. The tunnel has a total of 6 cavities with the first and last cavities being empty or not fitted with magnetron. At the entry and exist of tunnel, adjustable metal gates are fitted as wave traps for blocking any possible remnants of radiation. The tunnel which is 8.5 m in length is also conditioned with hot air at a temperature which is adjustable up to 200 0C in order to ensure against possible radiation of heat generated with profile to the surrounding atmosphere.

Extruders

There are two types of rubber extruder namely warm-feed and cold-feed extruders. During extrusion, compounded rubber is forced to flow through a die to produce long section profile of constant cross-section such as hose and cable.

Twin screw extruder is a continuous processing technique of rubber or rubber/ thermoplastic blend from raw materials to extrudate of rubber compound or free flowing rubber/ thermoplastic granules. The Farrel FTZ Twin Screw Extruder (FTX80) in MRB has been designed to meet the needs of today’s compounders in TPR and TPNR compounding and polymer masterbatching. The equipment is fitted with automatic feeding system and a pelletiser.

Injection Moulding Machine

Rubber Injection Moulding (LWB VRE 1000)
The machine is designed for the injection of viscous-liquid uncured rubber into a closed mould under high pressure and suitable temperature in which vulcanisation will take place.

Plastic Injection Moulding (Toshiba 1580 EPN-2A)
This machine is compactly designed with newly improved functions and increased performance for production of high value added molded products. Stable molding is assured by the adoption of NCC (numerical closed-loop control), developed based on advanced numerical control technology used on machine tools. The granular plastics are fed into a heated barrel by gravity from a hopper, melted, mixed, and forced through a nozzle and enter the mold cavity through a gate and runner system. The melted material cools and hardens to the configuration of the mold cavity.

Internal Mixers (0.4kg to 50kg compounds)

One of the most important processes in controlling the quality in controlling the quality of finished product is the mixing process. The unit is well-equiped with mixing favilities capable of R&D work and supply of rubber compounds to customers. The Haake (0.3 liters) and BR1600 laboratory mixer (1.6 lters) are state-of the art technology in the R&D work for mixing. The bigger international mixers Francis Shaw (K2A) and Werner & Pfleiderer (GK 70) are capable for producing of 35 kg to 38 kg of coloured compound and 55 kg of black filled compound respectively.

Steam / Electrical Presses (80 tonnes to 450 tonnes clamping pressure)

The unit has two types of press. The steam and electrical presses range from 80 tonnes to 150 tonnes and 150 tonnes to 450 tonnes clamping pressure respectively.

Two-roll Mills (6in x 12in to 18in x 48in)

A two-roll mill is an equipment to masticate rubber as well as to perform mixing of rubber with compounding ingredients. It consists of two cylindrical rollers placed horizontally touching each other. The nip size between the two rolls is adjusted accordingly to grip and squeeze as the rubber passes through it. The UTGT unit has various sizes of two-roll mills ranging from 6 inches x 12 inches to 18 inches x 48 inches.

Capillary Rheometer (Rheograph 75)

The Rheograph 75 is High Pressure Capillary rheometer with enlarged shear rate range, higher test piston force (75 KN) and a huge variety of options. The main function of Capillary Rheometer is to measure rheological properties of polymer melt such as viscosity, die swell, thermal conductivity and melt fracture with temperature range up to 400 °C.

Filler disperGRADER

The filler disperGRADER instrument designed to measure filler dispersion in rubber compounds. The disperGRADER uses digital image processing by utilising the reflected light microscope method to automatically measure the size and proportion of undispersed agglomerates and provides quantitative results. The disperGRADER displays the sample image and reference image on a split screen and data is automatically compared to the standard dispersion scale of 1 to 10.

Mooney Viscosity (MV 2000)

The Viscometer tests the viscosity and processability of raw or compounded polymers. It has a heated pressurised die cavity that contains a serrated rotor. The MV 2000 measures the viscosity at the preselected preheat and testing time and the minimum viscosity and scorch (induction) point of the sample: t5, t35 (large rotor); t3, t18 (small rotor). The MV 2000 can use any several output devices to produce a smooth, continuous curve that is proportionate to a sample’s viscosity and/or scorch characteristics.

Rheometer

Oscillating Disc Rheometer (ODR 2000)
The ODR 2000 Oscillating Disk Rheometer is an improved version of the popular oscillating disk rheometer technology. The R100 ODR curemeter from Monsanto has been a rubber industry standard test for more than 20 years, measuring rubber compound stiffness before, during and after vulcanisation in a single rapid test. The ODR 2000 reduces heat and mechanical losses typical of R100 tests and improves test precision with microprocessor temperature control, more rapid temperature response, and digital torque measurements. Conforming to international test standards, the ODR 2000 offers many benefits.

Moving Die Rheometer (MDR 2000)
The MDR 2000 has become the new standard for Rheometer testing. The MDR's unique design improves test productivity, repeatability and sensitivity to meet your ever increasing product quality demands. Increasingly in the future, less compound variation will be the key to meeting customer requirements and eliminating lost time and out of specification materials. The ability to reduce compound variation depends on both material variation and testing provision. The MDR 2000 improves not only cure testing precision but efficiency as well.

Moving Die Rheometer with Pressure Option (MDR 2000 P)
The MDR 2000P rheometer measures the pressure effect of blowing agents in cellular rubber compounds in addition to cure characteristics. The unique sealed cavity makes this the only system available that accurately measures full pressure development. A bi-functional pressure/torque transducer is attached to the upper die of the MDR 2000 to make precise and repeatable measurements of the chamber pressure produced by gas generation from precisely weighed samples.

By measuring both cure and pressure in a single test, the MDR 2000P efficiently tests cellular rubber compounds for compound development or process control applications.

Rubber Processing Analyser (RPA 2000)

It is latest-generation assay equipment for it analyses elastomeric polymer under processing conditions. It is considered to be one of the most advanced testing instruments for physical properties and has been especially developed by the rubber industry. With only one material sample, it assay, analyses, compares and makes complete graphics and report of the result obtained, thus supplying information on the mechanical, dynamic and rheological properties of the compound. The RPA2000 is the only rubber tester available today with the ability to completely measure uncured rubber processability, measure the cure reaction, and measure cured rubber properties on a single test specimen in a rapid test. Reduced scrap and improved product quality are among the many benefits users have already found with the RPA2000.

SERVICES PROVIDED BY ADVANCED RUBBER TECHNOLOGY UNIT

1. Rental of Machinery / Equipment

MACHINERY/ EQUIPMENT

Electrical curing press

Steam curing press

Autoclave (electrical & steam)

Kneader (2 litre)

Injection Moulding

Extrusion

2. Mixing

MACHINERY/ EQUIPMENT

Kneader (75 litre) - Non-black compound

Mastication - on 2 roll mill

Internal Mixer

Open Mill Mixing

Chungking/Granulator

BR 1600

3. Rheological Testing

TYPE OF TEST

Rheometer, ODR 2000, MDR 2000

Mooney Scorch, MV 2000

Viscosity, MV 2000

RPA 2000

Capillary Rheometer (Rheograph 75)

Reflective Light Microscope (disperGRADER)

4. Others

CHEMICAL/ PRODUCT

Material Supply e.g chemicals

RRIM Chem R - NR Base*

RRIM Chem R - NBR Base*

MRB Sealant*

Easy-to-process, good compatibility, colourable and electrically conductive (10-4-10-8 S/cm) vulcanised rubber blends (carbon blacks and heavy metallic fillers free), targeted for various electrostatic dissipative [ESD] products application (e.g. ESD table mats, ESD floor mats and ESD shoe soles). They are prepared by using a practical and environmentally friendly method, i.e. the high temperature-mechanical mixing (which does not involve the usage of any chemical solvents and has a shorter total mixing period).

    

The reclaimed rubber gloves were blended with a suitable thermoplastic material and chemicals. Selection of suitable chemicals and appropriate blending procedure are important to create an effective reactive mixing conditions in ensuring the finished blend has a suitable Melt Flow Rate (MFR).The blended material can either be granulated into crumbs or pelletised into pellets to produce Thermoplastic Vulcanisate (TPV) products. The unique property of TPV is that can be processed through heat treatment like thermoplastic and yet the finished product behaves like rubber. The main advantages are its cost and its ability to recycle

  

Epoxidised palm oil is a new environmentally friendly renewable plasticiser in rubber compound. Epoxidised palm oil is the alternative to the highly aromatic processing oil that has high content of polycyclic aromatic hydrocarbon (PAH) and are classified as carcinogenic. The use of epoxidised palm oil in rubber compound improves the dispersion of filler and mixing characteristics.

Starch is a potentially useful filler in rubber compounds due to its low cost, availability, renewability and environmental friendliness. Good mechanical properties of rubber compounds can be obtained by appropriate mixing of starch and rubber. This can be achieved by increasing the chemical compatibility and reduction of starch particle size. The compound could then be applied in tyre, engine mounting and other rubber goods applications.

The Thermoplastic Vulcanisate (TPV) blends comprise of partially crosslinked Ethylene Propylene Rubber (EPR), Polypropylene (PP) and phosphorescent material, offers excellent weather resistance, good mechanical properties at elevated temperatures with “Glow-in-the-dark” characteristic. It is capable to absorb light and gradually re-emits the light over time within the dark environment. Therefore, the “Glow-in-the-dark” EPR TPV is recommended to be used as a material for safety based application products such as emergency signs, light switch cover, automotive panels and others.

1. MAZLINA, M.K., CLARKE, J. AND MD. ARIS, A. (2009) Comparison of Properties of Natural Rubber Compounds with Various Fillers. J. Rubber Res., 12(1), 27-45.
2. YONG, K.C. AND CHE SU, MT.S. (2009) Novel Peroxide Vulcanized NBR-PAni.DBSA Blends, Part 1: Preparation and Characterisation. J. Appl. Polym. Sci., 112(6), 3199-3208.
3. YONG K. C. AND CHE SU, MT.S. (2009) Novel Peroxide-Vulcanized Electrically Conductive Rubber Blends, Proceedings for 4th International Conference of Recent Advances in Materials (RAMM & ASMP 2009), Penang, Malaysia, 1st-3rd June 2009.
4. DAYANG HABIBAH, A.I.H, DR MAZLINA MUSTAFA KAMAL AND ROHAIDAH ABD RAHIM (2009), Thermoplastics Vulcanisates based on Reclaimed Nitrile Rubber Gloves (r-NBRG), Proceedings for 4th International Conference of Recent Advances in Materials (RAMM & ASMP 2009), Penang, Malaysia, 1st-3rd June 2009.
5. SITI SALINA S., AND CHE SU, MT.S (2009), The Effect of Humidity on Silica-Filled Natural Rubber Compound, Proceedings for 4th International Conference of Recent Advances in Materials (RAMM & ASMP 2009), Penang, Malaysia, 1st-3rd June 2009.
6. M. N. RAMZIAH, N.S. M. EL-TAYEB, SITI SALINA S., AND A. YUSOF, On the Surface Morphology, Mechanical and Tribological Properties of Blended DPNR/IR2200, Proceedings for 4th International Conference of Recent Advances in Materials (RAMM & ASMP 2009), Penang, Malaysia, 1st-3rd June 2009.

1. DAYANG HABIBAH A.I.H. (2008) A Study on the Potential Utilisation of Reclaimed Nitrile Rubber Gloves (r-NBRG) in blend with Virgin Nitrile Rubber (NBR). Malaysian Rubber Technology Developments, 8(2), 11-16.
2. DAYANG HABIBAH, A.I.H., HARPER, J.F. AND ANSARIFAR, A. (2008) Influence of Flame Retardant Additives on the Flammability Behaviour of Natural Rubber (NR). J. Rubber. Res., 11(4), 223-236.
3. DAYANG HABIBAH, A.I.H AND ROHAIDAH, A.R. (2008) Potential Utilisation of Reclaimed Nitrile Rubber Gloves (r-NBRG) in Thermoplastics Vulcanisates. The 11th International Conference on Thermoplastic Elastomers, Prague, Czech Republic, 12-13 November 2008.
4. MAZLINA, M.K. (2008) Starch-Rubber Blending’ International Conference & Exhibition on Composites Materials and Nano Structure, Melaka, 5 August 2008.
5. MAZLINA, M.K. (2008) A Renewable Filler For Rubber Compounds’ (Poster Presentation) International Rubber Conference & Exhibition, Kuala Lumpur, 21-23 October 2008.
6. CLARKE, J. AND MAZLINA, M.K (2008) Starch as a Filler for Rubber : Compounding and Processing for Optimum Properties. Polym. Pro. Society 24th Annual Meeting, Saolerno, Italy, S12(718), 279, 15th June 2008.
7. YONG, K.C., FOOT, P.J.S., COOK, S., TINKER, A.J. AND MD. ARIS, A. (2008) Electrically Conductive Epoxidised Natural Rubber-Polyaniline Dodecylbenzenesulfonate Blends Prepared by Solution Mixing. J. Rubb. Research, (2), 59-77.
8. YONG, K.C. AND CHE SU, MT.S. (2008) Electrical Conductive NBR-Polyaniline Blends: Preparation & Characteristics. International Rubber Conference & Exhibition 2008, Kuala Lumpur, 21-23 October 2008.
9. YONG, K.C. AND CHE SU, MT.S. (2008) Novel Electrical Conductive Material Based On Natural Rubber. Rubber Chemistry International Conference, Prague, Czech Republic, 2-4 December 2008.
10. NIK INTAN, N.I., ASRUL, M. AND MD. ARIS, A. (2008) Preliminary Investigation of Carbon Nanotube-Filled Natural Rubber Using Rubber Latex Masterbatch Technique. 6th International Materials Technology Conference & Exhibition Kuala Lumpur, 26-27 August 2008.
11. NIK INTAN, N.I., MANROSHAN, S., ASRUL, M. AND MD. ARIS, A. (2008) Some Properties of Carbon Nanotube Filled Natural Rubber Using Rubber Latex Masterbatch Technique. Malaysian Rubber Technology Developments, 8(1), 30-34.
12. ROHAIDAH, A.R., CLARKE, J., COOK, S. AND TINKER, A. J. (2008) Thermoplastic Vulcanizate based on Natural Rubber: Co-continuous Phase Morphology. 8th. National Symposium on Polymeric Materials, Penang, 26-27 November 2008.
13. MOHAMAD ASRI, A., SHAMSUL, K., ASRUL, M. AND MD. ARIS, A. (2008). Natural Rubber Insulator for Noise and Vibration Control in Automotive Application. Malaysian Rubber Technology Developments, 8(2), 37-40.
14. SITI SALINA, S., CHE SU, MT.S., DAYANG HABIBAH, ABG.I. (2008) Potential of Epoxidised Palm Oil as Plasticiser in Rubber Compound (Poster Presentation). International Rubber Conference & Exhibition 2008, Kuala Lumpur, 21-23 October 2008.
15. LOH, P.C., NGEOW, Y.W. AND AHMAD NAZIR, K. (2008) Improving Retread Quality to Meet MS 149, MS 1394 and MS 224 Requirements. Seminar on Tyre Regulatory Requirement, Selangor, 28 July 2008.
16. LOH, P.C., SITI SALINA, S. AND NGEOW, Y.W. (2008) Malaysian Regulatory Requirements for Retread Tyres. Malaysian Rubber Technology Developments, 8(1), 10-13.

1. DAYANG HABIBAH, A.I.H, NIK INTAN, N.I., SITI SALINA, S. (2007) Studies on Reclaimed Nitrile Rubber Gloves (r-NBRG)/Virgin NBR Blends. Proceedings of 7th National Symposium on Polymeric Materials 2007, UniKL City Campus.
2. NIK INTAN, N.I. AND MD. ARIS, A. (2007) Ethylene Propylene Rubber/Polypropylene Blends: Effect of Blend Ratio and Dynamic Vulcanisation on Morphology and Mechanical Properties. Proceeding of International Conrference on Advancement of Materials and Nanotechnology, Langkawi, Kedah.
3. SITI SALINA, S., CHE SU, MT.S. AND DAYANG HABIBAH, A.I.H (2007) Epoxidised Palm Oil as Plasticiser in Rubber Compound, roceeding of 7th National Symposium On Polymeric Materials 2007, UniKL City Campus, Bandar Wawasan, Kuala Lumpur.
4. SITI SALINA, S. AND MD. ARIS, A. (2007) Tambah Nilai Bagi Sisa-sisa Getah Tervulkan, Seminar Pengurusan Sisa dan Singkiran Produck Getah – Sisa Getah Sumber Tambah Nilai, Johor Bahru, Malaysia, 4 September 2007.
5. LOH, P.C., SITI SALINA, S. AND NGEOW, Y.W. (2007) Performance Tests on Retreaded Tyres. Product Knowledge Training Session with Special Reference to MS 224, Selangor, 21 August 2007.
6. LOH, P.C., SITI SALINA, S. AND NGEOW, Y.W. (2007) Improving Product Quality Performance to meet MS 224:2005 Requirements. Seminar / Workshop On Tyre Retreading, Kuching, Sarawak, 21 November 2007.
7. ROHAIDAH, A.R. (2007) Deformation and Recovery Behaviour of Thermoplastic Vulcanisates. M.Phil. Thesis, University of Loughborough, Loughborough, United Kingdom.
8. MAZLINA, M.K. (2007) Starch as a Filler for Rubber Compounds, PhD Thesis, University of Loughborough, Loughborough, United Kingdom.
9. MOHAMAD ASRI, A. (2007) Rheological and Processing Behaviour of Black Filled Rubbers, PhD Thesis, London Metropolitan University, United Kingdom.
10. YONG, K. C. (2007) Conductive Elastomer Blends. PhD Thesis, Kingston University London, United Kingdom.

Gold Medal (ITEX 2009)

1. YONG, K.C. (2009) Novel Electrically Conductive Vulcanised Rubber Blends for Electrostatic Dissipative [ESD] Application. 20th International Invention Innovation and Technology Exhibition, Kuala Lumpur, 15-17 May 2009.

Silver Medal (ITEX 2008)

1. ASRUL, M., NIK INTAN, N.I., SHAMSUL, K., AZIANA, A. H., KARTINI, A. R. AND AMIR HASHIM, MD. Y. (2008) Natural Rubber Composite with Enhanced Environmental Decomposition Features. Silver Award, 19th International Invention Innovation and Technology Exhibition, Kuala Lumpur, 9-11 May 2008.

Bronze Medal (ITEX 2008)

1. NIK INTAN, N.I., MD. ARIS, A., DAYANG HABIBAH, ABG. I. AND AHMAD NAZIR, K. (2008) A New High Performance Glow in the Dark TPV Blends’, 19th International Invention Innovation and Technology Exhibition, Kuala Lumpur, 9-11 May 2008.
2. MOHAMAD ASRI, A., SHAMSUL, K., ASRUL, M. AND MD. ARIS, A. (2008) Natural Rubber Composite for Noise and Vibration Insulator. 19th International Invention Innovation and Technology Exhibition, Kuala Lumpur, 9-11 May 2008.

Silver Medal (ITEX 2007)

1. DAYANG HABIBAH, A.I.H. AND ABU AMU (2007) Value Addition of Waste Rubber Gloves. 18th International Invention Innovation and Technology Exhibition, Kuala Lumpur,18-20 May 2007.

Silver Medal (ITEX 2006)

1. SITI SALINA, S., AHMAD NAZIR, K. (2006) Treated Carbon Black for Rubber Industry. 17th International Invention Innovation and Technology Exhibition, Kuala Lumpur, 19-21 May 2006.