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Advances and developments in NR.

Title Annotation: natural rubber


Comment: Advances and developments in NR.(natural rubber )
Author: Kadir, Abdul Aziz S.A.
Article Type: Statistical Data Included
Geographic Code: 9MALA
Date: Nov 1, 2000
Words: 4183
Publication: Rubber World
ISSN: 0035-9572
The Rubber Research Institute of Malaysia (RRIM) continues to fulfill its important objectives of
researching into all aspects of natural rubber cultivation, production and processing, and also
rubber product manufacture. Among these objectives, the emphasis is on reducing the cost of
production, increasing productivity, improving the quality and consistency of rubber and increasing
the usage of rubber in the local rubber manufacturing industries.
In the biological research areas, much progress has been achieved in breeding and selection of
hevea. The RRIM 2000 series clones, in particular, have been recommended for planting of latex
timber clones (LTCs). These clones are characterized by high latex yield and high wood volume.
Twelve clones of this series have been vigorously promoted for planting in the monitored
development projects (MDPs) at various locations throughout Peninsular Malaysia.
In the biotechnological research areas, hevea tissue culture has found a new application in the
genetic transformation of the rubber tree. The transgenic tree would serve as a `green' factory for
the production of high-value proteins such as pharmaceuticals, e.g., insulin, tumor necrosis
factors and blood coagulating factors.
In chemistry and technology, considerable achievements have been attained in the processing and
product sectors. Important topics of concern to the rubber products manufacturers are being
studied, such as low protein latex, deproteinized NR (DPNR), NR without foul smell, chemical
derivatives from NR serum, blends from NR and the use of NR in engineering applications.
Latex timber clones
LTCs are characterized by high latex yield and high wood volume. The RRIM, through breeding
and selection, introduced latex timber clones belonging to the RRIM 2000 series in 1995. Eight
clones of RRIM 2000 series were launched during the period of 1995 to 1997. Wide scale planting
of these clones is found in MDPs throughout Malaysia.
The planting of LTCs will help sustain the future supply of rubberwood, an important component in
the furniture industry. From recent selection, an additional four clones derived from the RRIM 2000
series were added to the Planting Recommendations. The availability of more LTCs allows
flexibility in choice of clones and suitability of various agro-climatic conditions. LTCs are also the
preferred planting materials for rubber forest plantation. Altogether there are 14 LTCs, inclusive
of two from the RRIM 900 Series, and these are currently being recommended for planting.
The mean yield from the twelve clones ranged from 2,007 to 2,850 kg/ha/yr. (table 1) (ref. 1).
These yields are much higher than the yield of the control clones, RRIM 600 and PB 260. In
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addition, these clones also produce high timber yield. The estimated mean total wood volume
ranged between 0.68 to 1.87 [m.sup.3] per tree at 14 years old.
Table 1 - RRIM 2000 series clones
Clone Yield(*) Total wood
(kg/ha/yr.) volume ([m.sup.3]/tree)
RRIM 2001 2,850 1.23
RRIM 2002 2,348 1.10
RRIM 2008 2,686 1.32
RRIM 2009 2,277 0.68
RRIM 2014 2,007 1.33
RRIM 2015 2,760 1.30
RRIM 2016 2,582 1.28
RRIM 2020 2,232 1.00
RRIM 2023 2,822 0.81
RRIM 2024 2,685 1.26
RRIM 2025 2,700 1.87
RRIM 2026 2,204 1.11
(*) Extrapolated yield from small scale clone trial
The NR industry has become an increasingly important supplier of raw material for the furniture
industry. With the world becoming more environmentally conscious and rubberwood being a
renewable resource and environmentally friendly, it is not surprising that spectacular growth in
export earnings from rubberwood furniture has been recorded. Rubberwood furniture accounts for
about 80% of Malaysian annual exports of wooden furniture.
Low labor input latex exploitation systems
The competing demands for labor among various sectors in Malaysia is an impeding factor in
rubber cultivation and production in both the estate and smallholder sectors. Reliance on foreign
labor is only a short-term measure, but given the current rubber price, even family labor is hard to
come by. The interest in rubber cultivation is slowly fading.
Latex exploitation technologies are now being geared towards approaches that require fewer
tappers and that optimize tapper productivity. There are two main approaches that have been
shown to be practicable; (a) a reduction in the frequency of tapping, and (b) an increment in task
size (i.e., the number of trees that a tapper has to complete tapping). Not only do these schemes
require fewer tappers, but significantly higher wages that come with higher productivity per tapper,
but the significantly higher wages that come with higher productivity per tapper serve as incentive
for the tapper to remain on the job.
While the aforementioned latex exploitation systems employ the conventional excision method of
tapping, new systems of tapping, RRIMflow (ref. 2) and ReactoRRIM (ref. 3) offer the most effective
systems in increasing both tapper and land productivity. In these systems the rubber trees are
subjected to gaseous ethylene stimulation. Latex is extracted through open puncture, rather than
excision tapping in the conventional method. The exuded latex is collected in sealed receptacles
that are impervious to rain. Latex flow by this method of exploitation is sustained at a slow but
steady rate over two to three days as compared with two or three hours with conventional tapping.
Biotechnology: Foreign protein production by the transgenic rubber tree
Besides planting hevea for its conventional rubber crop, the rubber tree can also be genetically
engineered for novel applications. The rubber tree produces voluminous latex which can be
extracted non-destructively through the process of tapping. By transforming hevea with genes that
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control the production of high-value proteins (e.g. pharmaceuticals), transgenic rubber plants could
serve as efficient, low cost, low maintenance and environmentally-friendly production lines for the
production of the targeted protein. The system would enable continual harvesting of the protein
exuded in the latex.
The closest parallel to the transgenic rubber tree concept is the production of pharmaceuticals in
the milk of transgenic animals, such as cows and sheep. Progress in this area has taken the
research to a status far beyond that of a mere laboratory curiosity. Instead of producing
pharmaceuticals in the milk of animals, transgenic rubber trees can serve as living `factories' to
produce pharmaceuticals in the latex it exudes. Principally among the advantages of using a plant
system over an animal system are the relative cost efficiency of growing plants versus raising
animals and the fact that plants do not harbor animal viruses (an important consideration in
pharmaceuticals for human use). Using this approach, a recombinant antibody has been
successfully produced in the latex of the transgenic rubber plant.
New types of latex concentrate
In view of the health related issues confronting the NR latex industry, the RRIM has developed
several new types of latex concentrate to address the protein allergy problems at their source.
Several cost effective processes for the reduction of extractable protein (EP) of gloves have been
developed by the RRIM (refs. 4-9). These include the use of two types of low protein latices,
namely LPPL (low protein prevulcanized latex) produced by re-centrifugation of a prevulcanized
latex (refs. 6) and LOPROL (low protein latex), produced by a partial enzymatic deproteinization of
latex (refs. 7 and 8). The use of LOPROL is capable of producing gloves with a much reduced level
of residual EP, and the reduction becomes more effective when used with proper leaching protocol
during processing. The allergenicity of the gloves produced from these latices was found to be
negligible by skin prick testing on sensitized individuals. This is in consonance with the EP
contents, which are of the order of 0.1 mg/g as measured by RRIM Lowry against bovine serum
albumin (figure 1) (ref. 9).
[GRAPH OMITTED]
Standard Malaysian glove
Malaysia is fully committed to addressing the protein allergy issue. Great effort has been made to
ensure glove users are provided with the best and safest protective device available in the market
whereby the Standard Malaysian Glove (SMG) Scheme provides a mark of quality assurance (ref.
10).
Table 2 shows some of the technical requirements for NR examination gloves made in Malaysia to
be certified as SMG. Tensile properties shall be measured in accordance with ISO 37, taking a
minimum of three pieces from each glove and using the median value as the test result. The
determination of extractable protein shall be conducted following the modified Lowry method.
Table 2 - tensile properties and extractable
protein
Property Unit Requirement
Minimum tensile strength before
aging MPa 21
Minimum elongation at break before
aging % 700
Minimum tensile strength after aging
7d/70 [degrees] C MPa 16
Minimum elongation at break after
aging 7d/70 [degrees] C % 500
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EP (prepowdered glove) [micro]g/g 300
EP (powder free glove) [micro]g/g 50
Quebrachitol from NR serum
Natural rubber serum (NRS) is the aqueous portion of NR latex which is separated from the rubber
after the coagulation process, and is usually discarded by depositing into large ponds for a period
of time. The RRIM, in collaboration with Yokohama Rubber, has explored an approach in
recovering the non-rubber substances from NRS and developed useful applications from them. The
most useful substance extracted from NRS is quebrachitol (or 2-O-methyl-L-inositol). It has
attracted much attention because of its optical properties and also because of recent investigations
which show that certain inositol derivatives are connected to the mechanisms for the transmission
of information between living cells, a process which is referred to as "cell-signaling." For example, it
has been disclosed recently that inositol-1,4,5-triphosphate, which is a decomposition product from
inositol phospholipid and diacyglycerol, plays an important role as "second messengers" in the
cell-signaling mechanism. It is thought, therefore, that by suitable chemical modifications, some
inositol derivatives might be able to function as an anti-cancer drag, antibiotic or as an enzyme-
inhibitor (ref. 11).
Specialty natural rubber grades
In addition to Technically Specified Rubber, Standard Malaysian Rubber (SMR), the Malaysian
Rubber Board has developed several types of specialty NR. These specialty rubbers cater to the
needs of specific areas of application. The most recent commercially available grades are
deproteinized natural rubber (DPNR), NR without foul smell (SUMAR) and epoxidized natural
rubber (ENR), while the most established grades are methacrylate-grafted natural rubber (MG) and
superior processing natural rubber (SP). New rubbers currently in the development pipeline are
liquid natural rubber (LNR), thermoplastic natural rubber (TPNR) and thermoplastic epoxidized
natural rubber (TPENR).
Deproteinized natural rubber
Deproteinized natural rubber has low protein and ash content. It is produced by treating NR latex
with an enzyme which breaks down the naturally occurring protein and other nonrubber materials
into soluble residues that are subsequently washed away during coagulation and washing (ref. 12).
By removing these non-rubber materials, its water sensitivity is reduced, resulting in NR with low
affinity to water. Formulating DPNR with rubber soluble curative produces vulcanizate that is low in
compression set and creep and has good dynamic properties. These properties inherent in DPNR
make it the most suitable rubber for use in automotive engineering applications. For such
applications, the rubber components function as vibration, noise and shock absorbers, dampers,
flexible transmission couplers, seals and bushes.
The physical properties of DPNR CV are comparable to the properties of SMR CV, as shown in
table 3 for vulcanizates based on a typical black-filled formulation. In addition to good dynamic
properties, DPNR has low volume swell in water and low compression set. A combination of these
properties had made DPNR the rubber suitable for hydromount for automotive engines. In this
component, the rubber would isolate vibration at high frequency while the fluid (hydro) enhances
damping, thus reducing transmissibility peaks at low frequency.
Table 3 - typical vulcanizates properties of DPNR-CV
Property SMR CV DPNR-CV
Mooney scorch time, t5 @ 120 [degrees] C, min. >60.0 46.7
Optimum cure time, t95 @ 150 [degrees] C, min. 18.8 18.3
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Tensile strength, MPa 27.4 27.3
Elongation at break, % 482 520
Modulus at 100%, MPa 2.35 2.01
Modulus at 300%, MPa 13.5 11.34
MR 100, MPa 1.41 1.25
Hardness, IRHD 55 52
Lupke resilience, 23 [degrees] C, % 66.9 63.0
Compression set, 1d/70 [degrees] C, % 23.7 20.2
Volume swell in water, %
7d/23 [degrees] C 1.30 0.94
3d/100 [degrees] C 8.0 5.70
Compression stress relaxation, 25% strain
7d/23 [degrees] C, % 11.7 8.60
Air aging, 7d/100 [degrees] C, % retention
Tensile strength 84 81
Elongation at break 73 72
Modulus at 300% 140 149
Natural rubber without foul smell
This new grade of NR which does not have a foul smell is called SUMAR (standard uniprocess
natural rubber) and it has provided further avenues for consumers to select the grade of NR
preferred for their process (ref. 13). The development of this new grade is considered timely to
address the malodor problem which is one of the global environmental issues. The typical physical
properties of SUMAR in comparison to SMR 20 and RSS 1 are shown in table 4. SUMAR exhibits
better tear properties and abrasion characteristics than RSS 1. The heat build-up is also lower than
RSS 1.
Table 4 - typical vulcanizate properties of Sumar
Physical properties SUMAR SMR 20 RSS 3
Tensile strength, MPa 27 28 26
Elongation at break, % 540 550 510
M100, MPa 2.4 2.4 2.7
M330, MPa 10.8 10.9 11.9
Compression set %, 33 33 34
22h. @ 70 [degrees] C
DIN abrasion, ARI 103 110 94
Rebound resilience, 62 68 65
% @ 23 [degrees] C
Trouser tear, N/mm 16 17 11
Hardness, IRHD 64 63 67
Heat build-up (0.025"/24 lb.) 29 26 34
100 [degrees] C, temperature rise
@ 120 min., [degrees] C
Aged 7 days/70 [degrees] C
Tensile strength, MPa 25 27 26
Elongation at break, % 500 490 470
M100, MPa 2.9 2.9 3.0
M300, MPa 12.5 13.7 14.7
Hardness, IRHD 70 69 71
Thermoplastic natural rubber
The work on thermoplastic natural rubber (TPNR) has been carried out by various workers (refs.
14-20). The material is essentially prepared by blending NR with polyolefins such as polypropylene.
The properties of TPNR depend on the composition of the blend. At high rubber content, the
material behaves as a thermoplastic elastomer in which the rubber phase normally contains some
crosslinks. For the semi-rigid material in which the rubber content is low, the rubber phase is
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dispersed in the continuous matrix of the polypropylene phase and hence leads to improved
toughness, elongation at break and ductility.
The soft grades of TPNR blends, which can be classified as thermoplastic elastomers, have
hardnesses in the range of 55 to 80 Shore A. Typical properties of the blends covering this range
are given in table 5. The T-PNR blends are not oil-resistant materials and the oil-resistant types are
obtained from the blend of epoxidized NR (ENR) and polypropylene, i.e., TPENR.
Table 5 - typical properties of soft blends of TPNR
Hardness, Shore A 55 60 70 80
M100(MPa) 3.1 3.7 4.8 5.9
Tensile strength (MPa) 5.4 8.0 10.1 12.8
Elongation at break (%) 300 300 300 350
Tear strength (N/mm) 20 21 27 35
Compression set, 22hr./70 [degrees] C, % 42 40 40 50
Thermoplastic epoxidized natural rubber
Epoxidized natural rubber is a Modified form of NR in which a proportion of the double bonds is
converted to epoxide via reaction with peracetic acid (ref. 21). One important change is a marked
increase in resistance to swelling by oils. As a result of this, the thermoplastic rubber produced by
blending ENR with polypropylene is therefore oil resistant (ref. 22). Typical properties of TPENR
having hardness in the range of 65 to 85 Shore A are presented in table 6. The tensile and tear
strength are typical of dynamically vulcanized blends of elastomers and polypropylene such as
Santoprene. The compression set values are good within the context of thermoplastic elastomers,
particularly at elevated temperatures. The oil resistance of TPENR is close to that of
acrylonitrile butadiene rubber (NBR) containing medium acrylonitrile content.
Table 6 - typical properties of TPENR
Hardness, Shore A 65 75 85
M100, MPa 3.7 5.0 6.2
Tensile strength, MPa 6.5 8.8 9.6
Elongation at break, % 240 260 255
Tear strength, Die C, N/m 23 31 36
Compression set
24h./23 [degrees] C, % 24 29 33
24h./100 [degrees] C, % 36 39 45
168h./100 [degrees] C, % 44 49 55
72h./120 [degrees] C, % 49 55 55
Volume swelling, %
ASTM #2, 3d/125 [degrees] C 0 1 2
ASTM #3, 3d/125 [degrees] C 14 17 17
The aging resistance of TPENR is excellent, as illustrated by good retention of properties in
accelerated aging tests (table 7) and in long term tests (table 8). In addition to this, TPENR has
excellent resistance to ozone. There is no cracking after exposure to ozone at levels of up to 200
pphm for three days at 20% strain and 40 [degrees] C. This represents four times the severity, in
terms of ozone level, as used in the ISO test.
Table 7 - percentage retention of properties on
aging TPENR (65 Shore A) in air
Aging condition 7 days at 15 days at 7 days at
125 125 135
[degrees] C [degrees] C [degrees] C
M100 109 128 130
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Tensile strength 104 146 132
Elongation at break 102 117 117
Table 8 - percentage retention of properties on
long aging of TPENR (65 Shore A) at 100 [degrees] C
Aging period, weeks 12 24 48
M100 112 115 130
Tensile strength 109 102 110
Elongation at break 96 86 76
Liquid natural rubber
Normal NR is of high molecular weight ([M.sub.W]) exceeding one million. The [M.sub.W] of NR
can be reduced by means of a depolymerization process. Dry NR in liquid form, termed as liquid
NR (LNR), may be produced if the [M.sub.W] is below about 20,000.
Several methods to produce LNR have been developed. The preparation of LNR involves reacting
NR latex with an oxidizing agent, as well as a reducing agent to depolymerize the latex to the
desired [M.sub.W]. The depolymerized latex can be further processed to LNR by coagulating the
latex and drying the latex coagulum or to depolymerize latex concentrate by the normal centrifuging
process. Depolymerized latex concentrate is unique as the concentrate may be available up to 80%
total solid content. The unconcentrated depolymerized latex can also be blended with normal latex
to produce special dry blends of NR and LNR.
LNR is now produced at a pilot plant at RRIM (ref. 23). It is intended for applications in adhesives,
binders, sealant, processing aids for polymers, etc. The latex concentrate can be directly used for
applications such as in aqueous based adhesives or as [M.sub.W] modifiers. The dry blends of NR
and LNR have improved processability characteristics such as ease of mixing during rubber
compounding and low mixing energy requirement. At suitable [M.sub.W], the LNR can also
co-vulcanize and hence contribute to the physical properties of the rubber vulcanizates. In this
case, LNR serves as a co-vulcanizable plasticizer in rubber processing.
NR/EPDM blends
NR vulcanizates have good elasticity and strength properties, but poor resistance to heat and
ozone. Ethylene-propylene-terpolymer rubber (EPDM) vulcanizates, on the other hand, have
excellent heat aging and ozone resistance. It has been a practice that NR is blended with EPDM in
order to obtain the best characteristics of each component or for cost consideration. However, this
practice often results in poor physical properties. This has partially been explained by migration of
curatives from the EPDM to the NR phase resulting in the EPDM being undercured and the NR
overcured.
A recent study, adopting a `reactive mixing' procedure for EPDM masterbatch mix, has shown that
improved cocurability and good black distribution throughout the NR/EPDM blends can be
obtained, resulting in improved physical properties. The reactive mixing procedure involves the use
of BAPD (bisalkylphenol disulfide) with DTDC (dithiodicaprolactam) for effective modification of the
EPDM phase in the blend to give improved crosslinking, morphology and good interaction with
carbon black (ref. 24). These blends have found useful applications such as automotive weather
seals and grommets.
NR impact absorbers
Natural rubber has been successfully used as shock cells to absorb the impact during the
installation of gas production platforms in the open sea (ref. 25). The gas production platforms were
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initially built onshore with the entire auxiliary equipment and substructures installed and
commissioned. The integrated platforms were floated-over into the open sea to a designated field
and were then mated with preinstalled fixed steel structures. NR absorbers preinstalled in each of
the steel structures would absorb the enormous amount of energy generated during the mating
process. Each integrated platform weighs between 8,000 to 8,500 metric tons.
Conclusions
The MRB, through its research units, RRIM and TARRC, has undertaken research activities
covering a very wide field embracing numerous scientific disciplines from biology to chemistry,
physics, rubber technology and manufacturing technology. The skills and expertise acquired over
the years have contributed significantly to the progress of the Malaysian rubber industry with
respect to innovation, technical advancement, production efficiency and impact on consumers. The
R&D activities will continue to be reviewed in order to achieve a high level of productivity in the
rubber industry. Some strengthening in the R&D efforts in certain directions is also desirable. It is
foreseeable that Malaysia will gradually shift from being primarily a provider of NR as an
agricultural material, to that of being a provider of NR as industrial materials and value-added
rubber products.
References
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Malaysia. 1991.
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(25.) Kamarul Baharain Basir, "Natural rubber impact absorbers for installation of offshore gas
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COPYRIGHT 2000 Lippincott & Peto, Inc.
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