About HS Materials India Pvt Ltd

Certified Company ISO 9001-2008

HS Materials India Pvt Ltd

On the footsteps of HS Materials Korea and China the concept is transmittable in India. Opening HSMI is a land mark in state of the art compounding facility is one of its kind having capacity of 24000 MT/Yr will be expanded to 30000 MT/yr in 2020 under one roof. The facilities spread over 14.7 Acres of land with covered area of 14,500 Sq M with fully own backup power.

The Supplies are made in Carbon Master Batch with accelerators chemicals for making FMB at customers end. There is flexibility of making compound as per Specifications provided Customer or as per the Recipe (Formulation) given by Customer.

The Size (Width and Thickness) of the Rubber Compound are Maintained to meet as per the Customer Specification and Processabiity.

The supplies are made in standard packing’s on Plastic / Steel / Corrugated Box wooden pallets for domestic supplies and in Sea Worthy packing for Export Deliveries. The compounds generally in Wigwag Rough Sheets/ Endless Strips or Granules in case of PVC / TPE.

Milestones of HSMI

Compounding Information

Compound production usually comprises two steps, CMB (Carbon Master Batch) typically containing rubber, filler, softener, antioxidants, processing aids and other additives. The second step is called FMB (Final Master Batch) adding accelerators and cross-linking agents in the CMB (Carbon Master Batch).

Every batch has complete traceability records and test buttons and slab for verification. The Company also supplies CMB and accelerators are mixed at customers end.

Compounding Technology

The state of the art compounding technology of intermeshing intermixers ensures more homogeneous mixing compound as comparison to conventional kneader technology and open mills most Indian Rubber Companies have in house.

The production is totally computerized and automated including chemical weighing ensuring the consistency in compound properties in and between batches. Material flow is automated to a high degree too. The major part of the raw materials is transferred to hoppers at delivery. The material is weighed and transported directly to the kneader computer-controlled. Other raw materials, e.g. rubber, are weighed at the mixer. Mixing Mills are having stock Blenders as standard for heterogeneous compounding and Batch Off to ensure the online cooling and maturation.

Significance of Master Batch & Final Batch in Rubber Compounding

Rubber compound:

Rubber compound consists of a Polymer (selected for the specific properties), Activator, Process Aid, Anti Oxidants, Anti Ozonants, Flow Promoters, Reinforcing Fillers, Extenders, Plasticizers, Resins, Accelerators & curatives.

MASTER BATCH:

A good rubber compound is one in which all the ingredients are very well dispersed. All the above mentioned ingredients are dispersed well with low shear stress and in a short time except Reinforcing fillers like Carbon Black and Precipitated silica which require a higher energy in terms of higher shear stress for a longer time. This is due to the small particle size and large surface area and high Structure.

In order to effect High Shear Stress, low shear strain and shorter Mixing Cycles, Internal Mixers are used to produce large volumes of well dispersed Master batches in short time.

Master batches are made in order to get good dispersion of Fillers in the rubber compound.

Since the heat generated during the internal mixing is very high, the dumping temperature is also very high, close to125*C to 150*C. Since this dump temperature is above the threshold temperature of "Activation" of the accelerators, the Master batch is always mixed with out Accelerators and curatives. The master batches are sheeted out and cooled to room temperature and allowed to mature for 24 Hours.

FINAL BATCH:

The Final Batch is prepared by mixing the Accelerators and the Curatives with The Master batch on a KNEADER along with TWO ROLL MIXING Mill (provided with a stock blender) and good cooling arrangement for the Rolls. After the initial band formation on the rolls, The Compound stock is passed over the blender rolls and reversed and rolled until thorough distribution is achieved. The purpose of mixing the Accelerators & Curative on a Mill is to get even DISTRIBUTION of the chemicals which is possible only in a mixing mill which gives a low shear Stress and high Shear rate.

Summary: A good Rubber compound is made in two stages: 1. Master batch 2. Final Batch.

Distinct Technology Advantages

  • More Homogeneous Compound - Conventional Kneaders - Intermeshing type Intermixers
  • Consistence Quality/ Less Variation - Individual System - Centralized Controlling System (Time, Electricity, Temp, Inputs, pressure, RPM)
  • Economical Running Intermixer - Efficient on line Mixing.
  • ERP controlled System with PDA Scanning Bar Code Identification in all Process Identification and Traceability.
  • Fully Computerized SPC management and data analysis for Better Process Control.

Manufacturing Facilities

  • Line 1: Intermixer 190 liters Capacity - 1 No; Production of CMB.
  • Line 2: Intermixer 190 liters Capacity - 1 No; Production of CMB & FMB with 2 Roll Mills Capacity of 26" and 22" with AC Batch of Machines for Cooling.
  • Kneader 125L Liters Capacity - 1 No.Production of  FMB with 2 Roll Mills Capacity of 22" and 18" with AC Batch of Machines for Cooling
  • Kneader 75L Liters Capacity - 1 No.Production of  FMB with 2 Roll Mills Capacity of 22" and 18" with AC Batch of Machines for Cooling
  • Strainers 150 Dia - 3 Nos
  • Strainers 120 Dia - 1 No.
  • Sheet Cutting Machine.- 1 No.
  • Computerized weighing Dispensing System
Testing Facilities

As per Company HSMI Presentation
Mixing Method

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