1
In-Plant-MaterialsOptimization
Presented BySpecialty Elastomer Recovery, Inc. (SERI)
SERI
2
PRESENTATION Guiding Principals Process Polymers Processed Quality Assurance Additional Capabilities & Process
Development Suggested Procedure for In “In Process
Materials” (IPM) Optimization Practice Summary
3
Who is SERI? Leader in Fine Elastomeric Powder
Technology Process Recovered FKM and High-end
elastomeric Materials to a 325 Mesh Powder
ISO Certified Excellent R&D, Pilot Plant, Laboratory and
Customer Support Unique and Proven Technology Continual Process and Product
Improvements
4
SERI Manufacturing Facility
5
SERI
6
SERI FKM Procesing Line
7
SERI Warehouse
8
Guiding Principles Assist Material Approval Process Assist In Collection, Optimization and
Implementation Demonstrate Economic and Value Successful Long Term Relationship
9
Objective Objective is
to Recover, Reduce, Reuse, and fully Recycle IPM Materials in a cost
effective, viable, and environmentally sound manner.
10
CAPABILITIES Process many cured polymers into precise gradations
and surface morphologies. Strict adherence to QC measures which insure zero
contamination. Includes both virgin and recyclable elastomers. Finished particle size tailored to customers specific
needs. Finished powder down to a minus 325 mesh particle. Process is energy efficient, environmentally sound. Produces highly uniform products with high yields.
11
The Process1
Receive
Sample(s)
2Process
to aGradation(s)
3 Lab
Evaluations
4Make Process Adjustments
If Necessary
5Feasibility
Finalize Parameters At Mfg. Facilities
6Begin Collection
&Processing
7Continue ongoingProduct/serviceimprovements
12
Process Quality Assurance– Multi Elastomer Processing Two manufacturing lines.
Line 1 – Strictly FKM Materials (Black and Colors) Line 2 – Other High-end Elastomer Materials
Specialized high-pressure rotating steam cleaning system for all pipes in system.
Water flush through grinding and dewatering system. Optimal equipment engineering design to
accommodate thorough and efficient cleanout between every material produced.
Line 1 and Line 2 are contained in separate areas divided by a concrete wall with individual packaging systems.
13
“In Process Material” (IPM) Optimization
Closed Loop IPM
Methodology
Materials Products
Manufacturing Operations
IPM Loop
Manufacturing
Plant Site
14
Merits of an “IPM” Practice
Waste streams become resources No Chemistry Changes No Process Modification No Material Alterations Utilization of Existing Resources & Procedures Internal Cost Savings Competitive Cost Advantage Improved Production Performance Eliminate landfill burdens (cost & liability)
15
Goal → Recapture “In Process Materials”
Present Practice
Landfill
> In ↓ Out $ IPM Practice
IPM Optimization
< In ↑ Out $
16
THE PROCESS
The basic grinding process is called – UltraFineTM
The uniqueness is grinding in fluids, preferably water, with or without additives to achieve precision gradations, uniform chemistry, and surface morphologies
The process when used as a compounding system then becomes an IPMTM process
17
The UltraFine “IPM” Process
Feed Hopper
MillingRare EarthMagnets
Conveying
Conveying
Rare EarthMagnets
Slurry Hopper
Filtration
Conveyor
Conveying
Packaging
Rare EarthMagnets
Screening
SHIPPINGCustomersCustomFine GroundElastomericPowders
Feed Hopper
RECEIVINGCustomers“IPM”
Drying
Pollution Control
Water Make-up
PumpPump
Wet Grinding
Note: Heavies & Light Contaminate Ends Removed
Conveying
Conveying
18
Nature of UltraFineTM PowdersHigh Surface AreasUniform ChemistryUniform GradationsClean FlowableReplaces Costly Polymer EquivalentsHigh YieldsEnergy & Environmentally Sound
19
Rubber Material: FKM Compound with 25% SERI 170 mesh Regrind Material
PROPERTIES: Unit Results Results
Test Pieces 214 Orings No Regrind 25% FKM Regrind
Original Hardness, Shore A (ASTM Slab) point 75 75
Properties Hardness, I.R.H.D. point 70 71
Tensile Strength MPa 14.0 13.9
Ultimate Elongation % 251 236
Modulus @ 100% Elongation,Mpa % 6.3 7.2
Heat Aging Change in Hardness, Shore A point 0 +1
Change in Tensile Strength % +39.9 +40
250°C x 70 hrs. Change in Ultimate Elongation % -19.1 -21.8
Immersion in Liquid Change in Hardness point -2 -1
Fuel C Tensile Strength % -7.7 -9.6
Ultimate Elongation % +1.9 -1.8
23°C x 70 hrs. Change in Volume % +2.8 +2.2
Immersion in Liquid
Methanol Change in Volume % +3.7 +3.0
23°C x 24 hrs.
Compression Set Compression = 25% % 17 16
175°C x 22 hrs.
SERI
20
HNBR Compound with 25% SERI 170 Mesh Regrind Material
PROPERTIES: Unit Results Results
Test Pieces ASTM Dumbells No Regrind 25% HNBR Regrind
Original Hardness, Duro A point 73 73
Properties Tensile Strength MPa 29.30 29.4
Ultimate Elongation % 225 238
Tear Die B kN/m 21.43 25.06
Heat Aging Change in Hardness point +1 +1
Change in Tensile Strength % +7.4 +2.7
120°C x 70 hrs. Change in Ultimate Elongation % +1.3 -2.1
Immersion in Liquid Change in Hardness point -10 -11
Fuel C Tensile Strength % -70.3 -61.0
Ultimate Elongation % -47.6 -42.4
30°C x 48 hrs. Change in Volume % +37.7 +37.3
Immersion in Liquid Change in Hardness point -10 -12
Fuel C +M10 Tensile Strength % -71.3 -75.0
Ultimate Elongation % -52.4 -53.5
30°C x 48 hrs. Change in Volume % +56.7 +56.9
Immersion in Liquid Change in Hardness point -10 -11
Fuel C +E20 Tensile Strength % -71.6 -72.3
Ultimate Elongation % -51.1 -54.5
30°C x 48 hrs. Change in Volume % +53.9 +53.7
Immersion in Liquid Change in Hardness point -8 -9
Fuel C +MTBE15 Tensile Strength % -67.9 -66.7
Ultimate Elongation % -48.4 -47.2
30°C x 48 hrs. Change in Volume % +36.0 +36.4
Compression Set Compression = 25%% 10.6 11.0
120°C x 70 hrs. Plied Slabs
SERI
21
Dynamics of the UltraFineTM
Wet Grind System
Precision Intimate Grinding in a Fluid
System
Customer
Specialty Polymer(s)
Precision Tailored Ground
UltraFineTM Powder
Light End Contaminates Removed
Heavy End Contaminates Removed
22
Custom Tolling - UltraFine™ “IPM” Flow Loop
Customer –Facility1. Collecting Source Separated Materials2. Labeling3. Shipment
SERI RECEIVING4. Receiving5. Storage6. Production Scheduling
UltraFine PROCESSING7. Primary Reduction8. UltraFine Grinding9. Precision Screening
SERI PACKAGING10. Drying11. Packaging/pre-weigh12. Warehousing
SERI SHIPPING 13. Product Certification14. Final QA/QC15. Material Balance16. Shipment (Round-Robin)
23
Present to Future Practice
Customer IPMConverted to CG-
FKM-170 UltraFine Powder Back to High Quality
New Parts
24
The Benefit
Maintain Product Properties
Eco
nom
ic V
alue
, $
IPM Value, Time
Landfilling, $ Losses, Stop
Generally Improved Manufacturing Experiences and Significant Economic Benefit
Transition
25
Future Improvements
FKM
Teflon
AflasFQM
New Specialty
Development in Time
Savi
ngs/
Profi
t
26
SUMMARY OF SERI’S SERVICES TO CUSTOMERS Established Certified For Quality and Methodology Professional Staff and Services Confidentiality Precision Grinding to Produce
Specified High Quality UltraFineTM Powders
Partnering for Future Innovation and New Developments
27
Result Reduced Material Costs Capture Lost Opportunity Value Improve Production Leading Edge Opportunity Improve Product Margins Maintain Competitive Edge
28
Thank You
An “IPM” Partnership
SERI
29
Shipping Area
30
Receiving Area
31
Back of Manufacturing Facility
32
Manufacturing Facility
33
SERI Manufacturing Facility
34
Direct line to the power company
Top Related