INDUCTION PROGRAM, LALRU PLANT

NAME- AmitKumar
COMPANY NAME- ALP Nishikawa Co.Ltd. Start date- 15-07-2013
DEPARTMENT- D&D End date- 25-08-2013
LOCATION- GURGAON
STAGE-1
RUBBER COMPOUNDING & TESTING
1. POLYMER
2. CARBON BLACK
3. WHITE FILLER CMB- carbon master batch
4. ACCELERATORS 28 grades of CMB in use
5. PROCESS OILS
6. PROCESS AID
7. RECLAIM
8. ACTIVATORS
9. CURING AGENT FMB- final master batch
10. BLOWING AGENT 28 grades of CMB in use
11. CaO
BASIC FORMULATION
CHEMICAL Phr Kg
1. Polymer 100 (100/323)*75= 23.2
2. A. zinc 05 (05/323)*75= 1.16
3. St. Acid 01 (01/323)*75= 0.232
4. PEG4000 01 (01/323)*75= 0.232
5. Process aids 01 (01/323)*75= 0.232
6. Carbon black 95 (95/323)*75= 22.05
7. Pr. Oil 70 (70/323)*75= 16.2
8. CaCo3 50 (50/323)*75= 11.6
TOTAL 323 76.4
Hence the batch weight comes out to be 76.4 for the above formulation.
HARDNESS:
Thermoplastic elastomer are measured in Shore A and Shore D according to ISO 868
Shore hardness is the measure of the resistance of a material to the penetration of a needle
under a define spring force. It is determined as a number from 0 to 100 on the scales A or D. the
higher is number, the higher the hardness. The letter A is used for flexible type and letter D for
rigid type.
E.g. hardness of a compound is calculated as:
Polymer= 40 ShA
Carbon= + Phr/2.2= 95/2.2= 43
Process Oil= - Phr/2= -35
Filler= + ((Phr/7 (CaCo3))/ Phr/5(Al.Si))
Accelerator= +2 to3
Hardness due to weather condition, or heating during process or due to some other reasons= +2
to 3
Hence final harness= 40+43-35+7+3+3= 61

HARDNESS TESTER
Factors effecting hardness- The hardness of compound will vary with respect to following
factors
Viscosity of oil
Mooney of polymer
Ethylene content of polymer
Carbon

1. Polymer- EPDM
EPDM is made-up of combination of Ethylene+Propylene+Diene. It is the most widely
used technical Elastomer covering a variety of applications such as automotive sealing,
hoses, window gaskets, roofing sheets, cable and wire.
Fast and uniform mixing can be achieved with narrow molecular weight distribution
(MWD).
Very high level of carbon black dispersion needed for an excellent surface finish of the
profile which can only be achieved with broad MWD EPDM grades at long mixing time.

Key Properties and Characteristics

Durometer (Shore A) 40-90ShAidely used technical

Tear Strength P

Specific Gravity (Polymer) 0.86

Flame Retardant Properties P

Tensile Strength Max-psi (Mpa) 2000
(13.8)
Weathering Characteristics E

Low Temperature Brittle Point (C/F) -58/ -70

Oxidation Resistance E

Resilience G to E

Ozone Resistance E

Compression Set G

Oil Resistance P

Heat Aging E

Acid Resistance E

Abrasion Resistance G

Resistance to Alkali Substances E

Key Characteristics

Good ozone resistance and extendibility.


Further Comments
Very good water resistant, and this resistance is maintained to high temperatures (up to 180C
in steam, for peroxide cures). The highest temperature resistance is achieved by using peroxide
cured grades. Has excellent resistance to atmospheric ageing, oxygen and ozone up to about
150C. It has good resistance to most water-based chemicals and to vegetable-based hydraulic
oils. It has poor resistance, however, to mineral oils and diester based lubricants.
Legend: P=Poor; F=Fair; G=Good; E=Excellent
List of supplier-
Major supplier
1. Keltan (Lanxess)-DSM- Netherland
2. Mitsui- Japan
These suppliers are under development. Only samples are received till now.
3. Dow
4. ExxonMobil
5. Kuhmo
6. Hardlia(India)- factory closed now and now it is known as Royalene
Grades used by ANCO from the different suppliers:
Keltan Mitsui
Solid
K-8340 M-3092
K-2340 Molding M-3090
K-312 M-3045
Sponge
K-4703 M3090
K-7341 M-9090
K-778Z Glass runs
Super sponge+ Molding
K-4551
Composition of different grades
1. Keltan
Code Type Ethylene Propylene Diene Mooney Viscosity
Wt% wt% wt% (1+4) 125c
K-21 E 60 6.3 25
K-520 E 58 4.5 46
K-8340 E 55 5.5 80
K-2340 E 53 6.0 25
K-312 E 49 4.3 33
K4703 E 48 9.0 65
K-7341 E 53 7.5 53**
K-778Z E 67 4.3 63
K-4551 E 64 8.7 48
C: copolymer, D: DCPD (Dicyclopentadiene) grade, E: ENB (Ethylidenenorbornene) grade,
CLCB: controlled long chain branching, *contains paraffinic oil, ** ML (1+4) 100C, *** ML
(1+8) 150C.
2. Mitsui
Material code Ethylene Propylene Diene Mooney Viscosity
M-3092 65.9 4.6 61
M-3090 48 4.7 59
M-3045 56 4.7 40
M-9090 40.4 10.9 62

Influence of Ethylene content or Ethylene/ Propylene ratio on main
performance characteristics.
Characteristics High Ethylene content Low Ethylene content
1. Aesthetics- surface Better Worse
Smoothness
2. Compression- deflection High particularly at low temp. constant over a wide
Force. temperature rate.
3. Tear strength Better Worse
4. Elasticity /stiffness Better Worse
5. Compression set at low Worse Better
Sub-zero temp.

GRADES OF POLYMER
K-21- Low Mooney polymer particularly suited for applications where the
use of plasticizers cannot be tolerated. Medium green strength ENB grade
with fast cure rate.
K-520 Normal curing amorphous grade, widely usable grade, particularly
suitable for peroxide cured profile in LCM.
K-8340 ultra fast curing, fast carbon black incorporation and relatively low
compound viscosity combines with very high cure rate and an excellent
collapse resistance make this grade especially suitable for extrusion
process. Because of Rheological properties, especially suited for high
quality solid sealing, particularly in sulfur curing.
K-2340 Ultra fast curing rate, amorphous grade with medium ENB
content. Low compound viscosity for high hardness applications. Its narrow
and broad MWD and low viscosity make it suitable for processing low/ non
oil extended compounds.
K-312- Amorphous, EPDM grade with medium/ high ENB.
Main Applications
1. Ultra low density sponge.
2. Automotive solid profile.
3. High hardness profile.
4. Brake parts.

Polymer characteristics
1. Excellent mixing behavior and easy mixing
2. Collapse resistance
3. Robust extrusion properties
4. Efficient vulcanization
5. Very good low temperature characteristics

K-4703- Ultra fast curing, amorphous grade with high ENB content.
Relatively high viscosity because of narrow MWD. Good low temperature
flexibility on account of the low C2 content. Because of the rheological
properties especially suitable for sponge applications and high quality solid
sealing, particularly in sulfur curing.
K-7341- This grade is especially suitable for sponge profiles requiring
excellent surface quality, shape retention and resistance to compression set
along with excellent tensile strength.
K- 509/ 4551- Ultra fast curing, medium green strength grade with high
ENB content and 100 part Paraffinic oil. Very good physical properties and
high mechanical strength. High filler and plasticizer acceptance, especially
recommended for low hardness applications and highly filled compounds.
K-778Z- it gives good stiffness value. As in case of glass run, fairly good
stiffness is required due to presence of flocks, hence this grade is best
suited for Glass run.

Effect of different Ingredients on final Properties of a compound.
1. Ethylene: The quantity of ethylene is directly proportional to the Stiffness of the final
product i.e. higher the quantity of Ethylene in a compound higher is the Stiffness
(Elasticity). E.g. The grade K-778Z having higher % of ethylene is used in Glass run as it
contain flocks which required high stiffness value. With high ethylene content the CLD
value is also high. As in case of sponge the CLD value should be low hence low Ethylene
content Polymer should be used. High ethylene content polymer is used in Solid profiles.
2. Diene: The quantity of Diene decide the final chemical structure of the product like
Solid, Sponge etc. higher quantity of Diene more the open structure of the final polymer
i.e. Sponge. Its presence also control the compression set properties. In case of solid
profile high Ts2 value is required and as Ts2 value is inversely proportional to the Diene
content e.g. ENB hence low Diene content is required in solid and high Diene content in
case of Sponge. Ts2 value also affects the scorch value. It can retrieve with acceleration
system.
3. Mooney Viscosity: This test performed to know the flow property of a polymer as
well as the S.G of the polymer. More the Mooney Viscosity more compact structure of
the polymer. E.g. in case of solid the Mooney viscosity value is high where as in case of
Molding it is low.

4. Specific Gravity (S.G): Specific gravity is defined as the Weight of a compound in air
divided by weight of compound in water.
S.G= (weight in air)/ (weight in water)
For solid its value ranges from 1.1 to 1.3
For sponge its value ranges from 0.5 to 0.7
For Rubber Pad its value is 0.40.05
For Super Sponge its value ranges from 0.30.05

Some Definitions:
Phr: Parts per hundred of rubber. This gives the composition ratio of a chemical as well
as polymer in the final compound.
Shelf Life: It is the life of the compound up to which it retains its properties as required.
Sometimes if raw materials are stored too long in the plant under adverse condition
before use, they may impart poor properties to the mixed stock.
E.g.
Polymer- 3yrs
Carbon- 6months
CMB- 6 months
FMB- 3 days
Die swell: Die swell is commonly associated with the elastic behavior of polymer. It can
be expected to increase with increasing polymer chain length, especially when high MW
long chain branched molecules are present.

Test perform in incoming inspection of EPDM
MOONEY VISCOSITY ( ML(1+4), 125 deg C
This property is commonly used to characterize and monitor the quality of both natural
and synthetic rubber. It measures the resistance to flow of the rubber at relatively low
shear rate of about 1.3 s
-1
. When designating a mooney test, one must specify the
following condition.
1. Massed or non-massed
2. Test temperature
3. Pre-heat time
4. Test running time
5. Size of rotor
When performing a mooney viscosity test a standard test temperature should be
specified, as it decreases with rise in test temperature. Standard test temperature for the
mooney is 100degree C.
This test is performed to know the flow properties of a polymer as well as the S.G value.
Specification:
ML (1+4)@125C
Here
ML- this is the torque value.
The letter follow the M tells the rotor size.
L- Large rotor size
M- Small rotor size
(1+4)- Here it shows that the sample is pre-heated for 1min. when rotor is stopped
and 4min. is the actual testing time when rotor is in movement.
125C- this is the testing temperature.
On the graph we see that
Vm- This is the minimum viscosity of the polymer.
T5- This is the scorch safety time i.e. it is the time up to which scorch will not take
place and after this time curing will start.
T5= Vm+5 sec.
T35= this is the time at which mooney viscosity reached to a value of 35 torque units
i.e. Mu.



Procedure:
1. Sample weight of 253 is prepared (cut from the supply received)
2. Set parameters on apparatus Mooney- line viscometer.
3. Now place the sample in between the dies of the machine
Note: make sure the die temperature should be as per the specification sheet.
4. Machine will give the result against the set parameters i.e. (1+4)@125C.
5. Open the lab-line software in computer to get the results.


VOLATILE TEST- determination of volatile content of Polymer.
Equipments:
1. Oven- to heat the sample
2. Desiccator- this apparatus used to cool the sample.
3. Weighing balance
4. Baby mill- to mesh the sample
5. Petri dish
Note: For picture of equipments refer Lab equipment file.
Procedure:
1. Make crump of polymer sample in baby mill.
2. Weigh the polymer sample, 5gm sample.
3. Put the polymer sample in oven @ 70 degree C for 2hrs.
4. After that put the sample in Desiccator for few minutes.
5. Than weigh the polymer sample again, after & before weigh will give us the
volatile content.
6. Calculation: (Before weight- after weight)/( sample weight*100)

2. CARBON BLACK
Carbon Black is made of fine particles of amorphous carbon and is produced by partial
combustion of petroleum or natural gas.
The modification of an elastomer by carbon black reinforcement and vulcanization transforms the
soft elastomer into a strong, elastic product. A rubber compounder must select the right polymer,
the right carbon black grade/loading level combination, and the right vulcanization system to give
a rubber compound with the desired properties at the lowest possible cost.
Compound should have specific optimal loading for carbon black for optimal smoothness.
Compound loaded with carbon black with higher structure tends to have better smoothness than
compound loaded with carbon black of lower structure.

Effect of carbon black on different properties:

1. Hardness- hardness is directly proportional to the carbon content.
2. Tensile Strength- tensile strength is inversely proportional to the Carbon black particle
size. As the size of the particle decreases the T.S value increases for a compound.




Grades used of Carbon Black are as follow:
ISAF (N220)
SAF (N110)
HAF(N330)
EF(N440) (extrusion furnace)
FEF (N550) (fast extrusion furnace) SOLID+SPONGE, this grade gives
better relaxation curve hence good for extrusion.
GPF (N660) SPONGE, but due to some quality issues we have stop
using this grade.
SRF(N774) this grade used in Molding
MT(N990)


Suppliers for Carbon Black
1. Continental- Ghaziabad (keep it as second source)
2. Himadri- Kolkata
Influence of particle size of carbon black
As the particle size decreases the dispersion of carbon in the compound
decreases, as a result of which the mooney viscosity decreases. It is also found
that particle size play an important role in Tensile strength of the compound.
Smaller the size of the particle more is the tensile strength of compound.




Test perform
DBP absorption CC/100 GMS: determination of DBP of carbon black.
Equipments:
1. Burette- 2 ml capacity
2. Stand
3. Mirror
4. Spatula
5. DBP solution
Procedure:
1. First measure accurate 1gm carbon.
2. Then crush it properly using spatula,
3. Fill the DBP solution in the burette.
4. Start testing; slightly open the burette valve at 1.0 ml.
5. Appearance of ball is the DBP No.
6. DBP value *91
It is found that if DBP absorption value is high the mooney viscosity is also high, hence
high flow/ S.G/ CLD and vice versa.
This test tells the carbon/ oil ratio which changes according to the test results.
DBP absorption= value at which carbon ball formation take place * 91
Sieve residue 325 mesh:
This test is performed to find out the impurities in a given weight sample of the carbon.
Procedure:
1. Take 100 gm sample in the mesh.
2. Add water in to it.
3. Sieving of carbon with water in mesh with the help of brush.
4. The residue should not be more than 0.01% of total weight.
5. The residue should not be metallic.
Due to the presence of the foreign particles the problem of blister will arise in the
extrusion.
OAN: This oil absorption number.
This value can be finding out in the DPB absorption test. This gives the oil absorption by
the carbon.
Metallic flakes- This test is perform along with Sieve test.

Iodine Absorption. Test reports provided by supplier.
Moisture content %: Determination of moisture content of chemical.
Equipments:
1. Oven
2. Desiccators
3. Weighing balance
4. Petri dish
Procedure:
1. First weigh the 5 gm sample.
2. Put the sample in oven @705C for 1 hr.
3. After that put the sample in desiccators for 10 min.
4. Then again weigh the sample, after& before weigh will give us the moisture content.
5. Calculation: (Before weight- After weight)/ sample*100.
Pour Density: this is the weight of 1000ml of carbon i.e. if we fill a beaker up to
1000ml mark with carbon and then weight the same carbon; it gives its pour density.
It is found that the Pour density is inversely proportional to the Mooney viscosity.
PH value (10%soln): Determination of PH value.
Equipments:
1. PH meter
2. Distilled water
Procedure:
1. Set temperature control at buffer solution temp.
2. Clean electrode with distilled water.
3. Dip the electrode in a 7PH buffer solution.
4. Switch on the instrument.
5. Adjust CAL button for reading in 7 PH buffer solutions.
6. Remove the electrode from 7PH buffer solution and clean it with distilled water.
7. Dip the combined electrode in any other buffer solution i.e. 4PH.
8. Set the temperature control at the temp of selected buffer solution.
9. Adjust, if necessary, slope control for correct reading in selected buffer solution.
10. Check that the correct reading is obtained from both solutions without further
adjustments.
11. Clean the electrode with distilled water.
12. Dip the electrode in solution under test.
13. Switch on the instrument.
14. Set the temperature control at the test solution temp.
15. The instrument will display the PH value of the test solution.
16. Between measurements leave the electrode immersed in distilled water.
17. Switch off the instrument when not in use, to conserve battery.
It is found that in the compound if Basic nature increases the curing time decrease i.e.
cure rate will be fast as the Ts2 value decrease. Due to which scorch problem will arries.
If it is of Acidic nature the curing rate will decrease and problem of large curing time will
arise.
Ash content: To determine the Ash content.
Ref standard: ASTM D 1506
Equipments:
1. Muffle furnace
2. Crucible
3. Desiccators
4. Analytical weighing machine
Procedure:
1. Ignite the crucible in the muffle furnace at 55010C for 30 min.
2. Transfer the crucible to the desiccators, cool the room temp. And weigh.
3. Put the 5gm sample to be tested in crucible carefully, again measure the weight &
write down the measurement.
4. Transfer the crucible to the muffle furnace at 55010C (As a precaution for ensuring
compound combustion) and ignite for 8 hrs.
5. Do the process carefully as it is extremely hot.
6. Take out the crucible from the furnace after 8hrs and put it in desiccators for half an
hour & weigh the sample.
7. Measure the weight of crucible, note it down & calculate the ash percent as follow:
A= (D-B)/ ((C-B)*100)
Where,
A= Ash %
B= mass of crucible
C= mass of crucible plus sample weight
D= mass of crucible plus the ash.
e.g. if we take 5gm initial sample and after the test the residue founds to be 2gms
then Ash content= (2/5)*100
Ash comes due to the presence of impurities in a compound and its value should be
as low as possible. It is found that its value increases with the increased quantity of
fillers in the compound.
Toluene discoloration: this is to find out the contamination chemical presence in
the carbon, which leave a yellow color precipitation on the body of the vehicle.
Procedure:
1. Weight the 3 to 4 gm sample of the carbon and fill it in a tube.
2. Now add some quantity of toluene in to it.
3. Stir the two and put the two in a stand for sufficient time so that chemical reaction will
take place.
4. Change of color of toluene to yellow show the presence of the foreign chemical in it.
This is important to perform this test as sometimes we see a yellow color precipitation on
the body of the vehicle on the areas where weather seals are present.
3. WHITE FILLER
These are the stones which mixed with primary polymer to reduce the cost of the rubber. As the
quantity of the white filler is directly proportional to the Ash content, hence these filler should be
use in such a proportion so that there is a balance between the Ash content as well as the cost
of the product.
Type of white filler use
1. Calcium carbonates CaCo3- This is used to improve the surface appearance and
smoothness.
2. Aluminum silicate.
3. Talc- This is used when surface appearance and smoothness is critical.
Test Perform:
Moisture content%- Procedure is same as described earlier.
Loss of calcination%- This is reverse of ash content test. E.g. if in a 100gm sample
the ash content is 70gm then remaining 30gm is the weight of Moisture, volatile content
etc which evaporate from the sample i.e. loss of calcination.
Loss of calcination: ((Initial weight- final weight)/ initial weight)*100
Sieve residue on 150% micron%- procedure is same as described earlier. Only
the mesh size varies.
Fineness through 240 mesh%
PH value 10% solution- procedure is same as described earlier.




4. ACTIVATORS
These are the chemicals which are added in a compound to activate the accelerators. The quantity
of activators in a compound play an important role as low quantity will not activate the accelerator on
a required rate and hence due to which the curing time will increase. If the quantity of activator is
high problem of poor Scorch safety and very fast curing rate will arise in compound.
Type of Activators
A.ZnO (Primary activator) - The most important usage for A. zinc oxide is as an
activator in rubber industry. Properties of A. zinc are as follow:
1. Low specific gravity.
2. Larger surface area, hence the cross-linking density is higher.
3. Less harmful impurities.
4. It contains very low lead content and hence color of vulcanization or rubber is much
clean.
Advantages:
1. A. zinc oxide improves the degree of cross-linking and this improves the modulus,
tear resistance and abrasion resistance. It also improves the ageing properties and
gives good protection against flex cracking.
2. Use of active zinc results to good dimensional stability to extruded profile.
3. With correct composition of A. zinc in a compound saving can be done on account of
lower input such as M/c time, power consumption, accelerator and blowing agents
etc.
4. A.zinc has less lead content ( SOC requirement).
Steric Acid (Secondary activator)
Test performs:
Moisture content%
Loss of calcination
Sieve residue on 63 micron %
PH value (10% solution)
Melting point- this gives the temperature at which solid activator melt.
Equipments:
1. Capillary tube
2. Thermometer
3. Melting point apparatuses
Procedure:
1. Take a sample in capillary tube.
2. Now melt the sample in melting point apparatus.
3. Note down the temperature at which the sample melts with the help of thermometer
attached with the apparatus.
ASH content
5. ACCELERATORS
These are the chemicals which when added to the CMB accelerate the chemical reaction in a
compound during vulcanization, and responsible for reducing the time for vulcanization process.
It is found that the quantity of accelerator in a compound play an important role i.e.
If quantity is high low scorch safety, fast curing rate and blooming problem will arise.
If quantity is low under curing will be found, due to which a white film comes on the surface
of the part.
Type of Accelerators
MBT- MERCAPTO BENZOTHIAZOLE Primary Accelerators
MBTS- DIABENZOTHIAZOLE DISULFIDE
TMTD- TETRAMETHYLE THIURAM DISULFIDE Sulfur donor
DPTT- DIPENTA METHYLENE THIURAM TERASULFIDE
TDEC- TELLURIUM DIETHYL DITHIOCARBAMATE
ZDEC- ZINC DIETHYL DITHIOCARBAMATE Ultra fast Sec. Accelerator
ZDBC- ZINC DIBUTYL DITHIOCARBAMATE
ETU- ETHYLENE THIOUREA
CBS- CYCLOHEXYL BENZOTHIAZYL SULFENAMIDE



Test performs:
Moisture content at 70, 80C%
ASH content%
Melting point C
Sieve residue on 150, 63, 63(wet), 45,micron %
Contamination: This test is similar to the sieve test i.e. presence of foreign particles in
the sample.




6. PROCESS OIL
These are the oils which added in to the compound to improve the flow properties as well as
maintain the hardness of the compound.
As we add carbon black in to the compound, its hardness increases which further decrease its
flow properties, hence to improve the flow properties we add process oil in compound.
High carbon black + low process oil = High hardness
Low carbon black + high process oil = high flow ability
Type of Process Oil
NAPHTHANIC OIL
PARAFFINIC OIL (EPDM)
AROMATIC OIL
TEST PERFORM
ANILINE POINT- The aniline point of oil is defines as the minimum temperature at which
equal volume of Aniline (C6H5NH2) and the oil are miscible, i.e. form a single phase
upon mixing. The value gives an approximation for the content of aromatic compounds in
the oil, since the miscibility of aniline, which is also an aromatic compound, suggests the
presence of similar (i.e. aromatic) compounds in the oil. The lower the aniline point, the
greater is the content of aromatic compounds in the oil as obviously a lower temperature
is needed to ensure miscibility.
Procedure:
1. Take 20 ml sample of process oil.
2. Add same quantity of aniline oil.
3. First heat the tube so that both oil will properly mixed.
4. Remove from burner and put at room temperature to cool down.
5. Note down the temperature at which both the oil separate again with the help of
thermometer.
It is found that the aniline point range for
Naphthenic oil is 65-80C
Paraffinic oil it is 110-130



FLASH POINT- This is the test to find out the temperature at which oil catches the flash
(spark). Generally the temperature range is from 220 to 250C.
Procedure:
1. Fill the flash point apparatus with the oil.
2. Heat the oil in apparatus.
3. Give fire at the small exit in apparatus in an interval of temperature range of 220 to
250C.
4. Note that if oil catches the fire before 250C or not.
Note: the oil should not catch the fire before 250C, as most of the oven in the company having
processing temperature up to 250C.
SAYBOLTS VISCOSITY (SEC)@100C SUS- This test is perform to check the
viscosity of the oil. It is found that if the viscosity of oil is high, higher will be the viscosity
of the CMB as a result of which its mooney will decrease and hence that of rheo
properties of FMB.
The range of viscosity is 90sec to 150sec for better performance.
Procedure:
1. Fill oil in the beaker inside the apparatus SAYBOLT VISCOMETER.
2. Now switch on the apparatus and start the lamp-stir.
3. Now when temperature reading reached at 100C switch off the apparatus.
4. Now pour the oil from the beaker in the other beaker and start stop watch.
5. Note down the time at which beaker gets empty, this is our viscosity.
DENSITY- Density of the oil also play an important role in the compounding as with
increase of density the weight of oil will increase and volume of oil in CMB decrease,
hence change the properties of CMB.
Procedure:
1. Fill oil in measuring cylinder.
2. Now insert the hydrometer in the cylinder.
3. Note the density value on hydrometer at which it stopped.
KINEMATIC VISCOSITY- supplier responsible
7. RECLAIM- This is the polymer made-up of scrap rubber by converting the scrap in to
powder form and then making the polymer by mixing it with some chemicals. This play an
important role when cost reduction of the compound is required. A calculated quantity of Reclaim
is mixed with the virgin polymer. This will reduce the Phr of virgin polymer in the compound.
Test perform
Mooney viscosity
Ash content
8. PROCESS AID
These are used to improve the flow properties of the material during Mixing.
Flow rate, homogeneity, tackiness etc; this product range includes lubricants, tackifiers,
homogenizers, chemicals dispersing agents, peptisizers, plasticizers, flow promoter and oil.
Type of process aids
Ul-250- To improve the flow in case of mixing.
PEG4000- PEG (poly ethylene glycol) 4000 overcomes the retarding effects caused by
various mineral pigments, improving both cure rate and state of cure.
It also gives polarity in compound along with carbon black which is needed for Microwave
curing.
PEG 4000 also acts as a process aid in rubber compounds, which may otherwise difficult
to process. Lubrication and release of EPDM extrusion is much improved. It is also act
like the magnetic agent for proper bonding between the different chemicals along with the
base polymer during the mixing process.
Typical Properties:
Appearance- white micro-granules
Melting point- 138F
Specific gravity- 1.20
Solubility in water- very soluble
Test perform
Ash content
Melting point

9. CURING AGENT
It promotes the cross-linking of the rubber matrix. Addition of accelerators and activators is
necessary in sulfur curing to enhance the cross-linking process at an optimum level.
Type of curing Agents
Sulpher- Discovered by Charles Goodyear in 1839, USA. Molecular sulfur S8 is the most
customary cross-linking agent, which combines the micro molecules with X=1 to 8 as Sx.
2R-H + S8 (RH) 2 Sx + S8-x
Following dialkene rubber can be cross-linked with sulfur-
NR, IR, BR, EPDM, NBR, SBR etc.
Basic Sulpher cure system for EPDM consist of-
1. Cross-linking agent
Sulpher
Sulpher donor
2. Primary accelerator
3. Secondary accelerator
Peroxide- these are excellent curing agents, but due to high cost they are not use in ANCO.
Test perform
Melting point
ASH content
Moisture content
Solubility test- This test is performed to find out if the grade of sulfur is as per the
requirements or not.
Procedure:
1. Dissolve sulfur in Cs
2. Check for 100% solubility.
3. If solubility is not 100% then the grade of sulfur is not as per the requirement.
10. BLOWING AGENT
The role of blowing agent is to form gases at curing temperature to create cells in the rubber
compound. The factors which should consider while selecting a blowing agent are:
1. The chemical composition
2. The amount of gas generated per gram.
3. The decomposition temperature.
4. The rate of gas evolution.
5. Uniformity of cell structure produced in successive batches.
6. Price.
Type of Blowing agent
OBSH- OXY-BIS BENZENE SULPHONYL HYDRAZIDE
ADCK- AZODICARBONAMIDE


Test perform
Moisture content%
Ash content%
Decomposing temp- This is similar to the melting point test only difference is
in spite of melting the solid; it is a temperature at which fumes start.
Sieve residue (wet) on 200BSS
PH(5% solution)
Gas evolution test- This is the test performs to find out the amount of gases
in the blowing agent. Cell size is directly proportional to it and surface
smoothness is inversely proportional to it.
11. MOISTURE REMOVAL AGENT
Cao- This is added during the FMB formation to soak all the moisture content
present in CMB.
Kazadel-

Stage-2
MIXING
The mixing operation is one of the most important stage through which raw material must pass
in manufacturing elastomer. The processing stages subsequence to the mixing depends on the
dispersion and homogeneity of the mixed compound; also the economical manufacturing of the
quality product is directly affected by the mixing.
Mixing of rubber involves several additives, such as reinforcing fillers, non-reinforcing fillers,
process oils, vulcanization chemicals, stabilizers etc. Mixing of rubber and carbon black is not
done by one step. In general four unit processes are involved, each required separate
consideration. They are:
1. Mastication- this is a process of breaking of the long chain structure of the polymer in to
small particles, to make a free surface for the further bonding between the polymer and
the chemicals.
2. Incorporation- this is a process where the filler particles become included inside the
rubber.
3. Dispersion- it is a process where carbon black pellets and their fragments are broken
down to the primary unit called aggregate.
4. Distribution- it corresponds the mixing in the usual sense, except that it is
homogenization on the macro scale.
The primary objective of mixing is to:
1. Attain a uniform blend of all the constituents in the mix; each portion of the mixed
compound is of uniform composition.
2. Attain an adequate dispersion of filler.
3. Produce consecutive batches which are uniform both in degree of dispersion and
viscosity.
Batch weight= Fill factor X chamber volume X S.G
= 0.7 X 91 X 1.2
= 76.4 Kg
Note: For the better dispersion we generally take a batch weight of 74 to 75 kg, in case if
mixer is old and 72 if the mixer is new.
Normal fill factor for EPDM ranges from 0.65-0.75.
Type of mixing operations:
1. Single stage mixing- This is popular for productivity reasons, but is only feasible to
certain compounds and where mixing time is not limited by temperature rise. In this
method the batch of compound is processed through the internal mixer only one time.
The accelerators and sulfur are charged along with the synthetic rubber manufactured
master batch and other ingredients required producing a final mixed compound. The
compound after discharge from the mixer is blended on a mill, slabbed, cooled and
stored.
2. Two or Multi stage mixing- This will always give a better dispersion of filler particles in
mixer and used for compounding tougher compounds. The choice of how many stages
of mixing are used is often controlled by compound viscosity consideration, as well as
filler dispersion.
Two stage mixing- In this two internal mixing operations or cycles are involved.
The first is making CMB (carbon master batch) after which the compound is
milled, slabbed, cooled, stocked and aged. The master batch is then returned to
the internal mixer and the curatives added. The final mix is then milled, slabbed,
cooled and stacked.
Three stage mixing- This is same as two stages mixing except the process oil are
added in two equal parts. This will give much better dispersion then two stages
mixing.
Comparison sheet for Single stage and multi stage mixing
S.no. Single stage mixing Multi Stage Mixing
1
Mixing time is less hence high
productivity
Mixing time is more hence less
productivity in comparison to
Single stage
2
Poor Dispersion of Fillers and
chemicals
Good Dispersion of Fillers and
Chemicals
3
Limited to some Low hardness
compounds
Can use for all type of
compounds
4 Cost of processing is low High cost of processing


3. Upside down mixing

Master batch mixing
During the master batch mixing stage, filler, plasticizers and chemicals are incorporated in
the rubber to enhance final performance and/ or to improve handling and process ability of
the compound in the stages.
The two major objective of the master batch mixing stage are maximum carbon black
dispersion and proper final viscosity.

Mixing process at Larlu
In our plant we are using two stage mixing process which includes formation or CMB
(carbon master batch) then formation of FMB (final master batch).
1. CMB
The mixing process consists of following steps:
1. Weighing the Polymer and other chemicals (chemical auto weighing) according to the recipe
of the compound.


2. Set the parameter of the intermix as follow:
Set Time- 360 sec.
Set temperature- 140-160C in case of sponge and above 160 C to 200 C for solid. As at
high temperature the process oil get flashout from the mixture and hence reduce the flow of
compound.
Set energy- 450

3. Send all the Ingredients in the Intermix/ kneader type Extruder for mixing.
4. The carbon black and process oil will be added from the different lines connected with the
intermix/ in case of kneader type it is feed manually.
5. Run the intermix for the specified time and at set temperature.
6. Take the Meshed rubber to the Dump mill to make the sheets of the mixed compound.


7. Pass the rubber sheet to the strainer for the filtration process. The mesh sizes in use are
Sponge: 40/40, 40/60
Solid: 20/40
Here 20, 40, 60 is the mesh size of the metal filter.
It serves two purposes.
1. It removes all the foreign particles as well as impurities from the CMB.
2. It also performs secondary mixing operation for better results.



8. Store the CMB batch at the specified place for minimum 10 to 16 hrs for better performance.

The process can be seen with the help of below diagram.



Test performs:
1. Mooney viscosity (ML(1+4)@125C)
The procedure is the same as specified earlier. Now check the results for the batch, if found ok then
store the material and if not then add the ingredients to achieve the required property.
2. FMB
The mixing process consists of following steps.
1. Take the CMB from the store; make sure that the Aging of the CMB should be done.
2. Now warm-up the CMB on the Blender mill up to a temp. 40 to 45 C, this is the ambient
temperature when making FMB. The temperature should not exceed from 75 C.

Blender Mill

3. Now add the desiccant in to it and blend.
4. Now add the Sulfur, Activator and required chemicals in to it. Blend the mixture for 10 to 12
minutes.
5. After mixing pass the FMB to the Batch-off M/C which cool the FMB as well as cut it in to a strip of
size 85*9 mm
2
* length. Now store the FMB for minimum 4 to 8 hrs, so that all the chemical reaction
stop and uniform cross linking take place in the compound. Store Sponge in a cold room and solid
at room temperature for minimum 4 hours for better results.












Baby Mill
This is used for the small batch production such as in case of Trials for a batch as well as for testing
of the FMB. The rubber removed from the head of the extruder is converted in to sheet on this mill
and further tested for the scorch and other properties.


Test perform on CMB
1. Rheo-meter test.
2. Tensile strength
3. Elongation at break
4. Compression set
5. Aging
6. Tear strength
7. Ozone resistance
8. Ash content.

Rheo-graph: During the curing phase of the graph, the cross-linking process starts. The
shape and the slope of the curve are very important because the curing curve must be design
according to the thickness of the finished part to produce and to the kind of transformation process.
Typical data can be obtained from the cure:
T10: time corresponding to 10% curing
T50: time corresponding to 50% curing.
T90: time corresponding to 90% curing. After that there is self curing process start.
The result is considered the optimum vulcanization time.


Here,
ML- Signify the flow. It is found that ML value is inversely proportional to Flow of the compound.
Ts2- Scorch safety time. This is the time after which Curing of the compound starts.
T90- This is the 90% curing time. After which self curing will take place.
MH- Responsible for Product hardness.
The last part of the curve is an indication of physical properties.
The maximum value of torque obtained is related with:
1. The final level of cross-linked.
2. The quality of polymer used.
3. The filler used.
4. The compounding process.

Test procedure:
1. Take a 5.5 gm sample from the batch.
2. Now set the temperature of the Rheo-meter to 177C.
3. Pre-heat the sample for 1 mint in machine then do the testing for 4 minutes.
4. Provide a rotary motion to the sample at 1degree arc and examine the torque Vs time graph for
the performance.

Sponge density- The sponge density can be adjusted by the amount of blowing agent in
combination with the curing package to vary in between 0.2g/cm
3
till complete solid.
In order to achieve the best compromise between water/air tightness of the seal, noise
absorption, sufficient strength of the profile against tear when frozen to the car body, ease of
door closing and material consumption the density in actual practice ranges from 0.4 to 0.6
g/cm
3
.


Compounding for EPDM sponge:
Some requirements are:
1. Compound viscosity of such a level that the blowing agent can economically blow the
compound to the required density, before being arrested by the curing.
2. Compound viscosity variations within very narrow range to guarantee a reproducible and
constant amount of blowing and curing from batch to batch.
3. Smooth and very fine distribution of ingredients to safeguard homogeneous blowing.
Sponge Super Sponge
1. Medium quantity of white filler low quantity of white filler
2. Medium quantity of blowing agent high quantity of blowing agent.
Factors effecting Cell size
1. Quantity of blowing agent
2. Line speed
3. Mooney of the compound
4. Particle size of carbon and other filler
5. Cure characteristics ( high cure rate required less Ts2 and hence less blowing)
6. White filler presence (work as nucleating agent)
7. Polymer mooney
8. Ethylene content
Close Vs open cell structure
Closed cell means that all the cells are basically self-contained. Open cell means that the cell
walls are pierced and that air contact exists between neighboring cells. A closed cell structure is
the result of sufficient melt strength of the EPDM compound or rather sufficient elongation
before breakage occurs. The longer the blowing air bubble remain intact, the higher the level of
blowing, the lower the density, the more the sponge will tends to show the open cell structure.

Stage-3
Development Cycle-
Development time- This is the time period required for developing the first proto sample.
Depending on the type of profile it may vary as given below:
If need to submit any of our existing profile we take 2 to 3 weeks to check for all the
tools, drawings, Dies etc.
For a profile without secondary operation takes 4 to 6 weeks to get develop up to the
first sample.
For part having secondary operations like molding, notching, drilling etc the time frame
will be 5 to 6 weeks, & as in F1 & F2 line if pre-bending is also need to perform it will
take 8 to 10 weeks.
The detailed development cycle is as shown in diagram:

Note: In some cases customer demand for the proto samples made with soft tools. In such a
case we made soft tooling in case of corner joints only but with a limitation of that this type of
tool can only have life of 10 to 12 samples. Such kind of samples is made in some silicon
compound. Some of the parts made earlier include parts of W201, Versa, Zylo etc.
The design cycle consist of following steps:
1. Receiving of RFQ/SOR (Request for Quotation) from customer
2. Feasibility review and risk analysis.
3. Section/ technical proposal for quotation.
4. Quote submission(including VAVE if any)
5. LOI if RFQ is accepted
6. CIR( Customer input requirement)
7. Project planning as per customer timeline.
8. Designing/ part modeling
The design itself consist of following steps
If customer is design responsible the following data will receive from customer(White
box)
1. Part Drawing
2. Sample( if existing part is available or any existing model which will launch in India)
If supplier is design responsible(Black box)
BIW ( Body in white)
Note: in some cases Sash data will be received from customer such as in case of glass run
etc.
9. DVP&R
Standards, if in case we dont have the standards we follow JASO (Japan Association
Standard Organization.
10. Make the APQP time chart up to PPAP level.
11. Process flow chart for development.
12. DFME along with TGW (things goes wrong) & TGR (things goes right).
13. DVP&R

14. Tooling kickoff
15. Designing tools (which includes Dies, Corner molds, jigs etc.)
16. Tool Manufacturing
In-house
Outsource- Then quotation receiptapprovalP.O release along with advance
cheque-- Manufacturing.
17. Sample development as per customer build/ time line.
18. Sample submission and customer feedback.
19. Modifications (tooling, process, Design) if any.
20. PTR (production trial run)
21. PPAP submission.
22. SOP




Costing Involve following factors:
Raw material cost:
Length of the extrusion
Weight /meter= (CSA* S.G)
Weight/ part= Weight/meter *Length
Cost of section= Weight/ part * Rate
Flock, adhesive for glass run channel
Flock tape for TPE belts
Hard silicone for door mounting seals, extrusion, joints and for glass run seal only for
joints
Anabond / adhesive
Adhesive for Steel to TPE bonding
silicon emulsion (for solid wind shield)
Child part cost
Profile mounting clips for door rubber
Corner clips for door rubber
Molding inserts, ousters
End caps for outer belts
Processing cost:
Extrusion cost
Molding and secondary operation cost
Tooling cost:
Scrap Cost:
Packaging cost
Over head cost:
Inventory carrying cost
Freight cost
Profit cost

Calculation of CSA
From 2D drawing:
Steps involve
1. Open the AutoCAD drawing.
2. Select the section- type LI and enter.
Or
Select object- type AA- type O and enter.
From 3D model:
Steps involve
1. Go to startthen shapesthen generative shape design.
2. Open the operation blockselect boundary commandselect the profile boundary
enter.
OR
When we get IGES data from customer.
1. Open the IGES file in Catia.
2. Open the operation block.
3. Go to join command.
4. Now select the curve or right click on the selection menu, it will give much other option.
5. Go to fill command in surface & fill the selected close curve.
6. Go to measure inertia and click the surface. It will give the CSA of the profile.
Note: Weight of rubber is calculated after deduction of weight of inserts (metal, plastic etc.)
from the profile. Generally in case of a profile with metal strip insert the weight/ Meter is
calculated as.
For a profile below

The Parts include
1. EPDM Solid
2. EPDM Sponge
3. CRC Metal Strip
Hence,
Weight/meter for solid= CSA(mm2) (Solid)*S.G(g/cm3)
Weight/ meter for sponge= CSA (Sponge)*S.G
Weight/ meter for CRC strip= CSA (metal strip) * Density (7.85g/cm3)
= CSA (Metal strip) * Density*85
Hence Rubber weight for solid= (Weight/ meter solid- Weigh/ meter for metal strip) + 30% of
extra rubber weight in case of punch Strip.
1. Glass Run:


2. Door Rubber(Primary seal)

Body mounted Sash Mounted Clip Mounted

3. Tail gate/ Trunk lid Seal


Trunk Lid Tail Gate Seal
Stage-4

TOOL ROOM
In tool room unit we perform following Jobs.
1. Making Extrusion dies
2. Making tools like Adapters, Adapter holders, cutting tools, Jig & fixtures etc.
3. Repairing Old Extrusion Dies, moulds & other tooling.

Process flow chart for Tool Room.



List of machines available in tool room.
S.no. Name of Machine Quantity
01 Lath M/C 01
02 Milling M/C 01
03 Shaper M/C 01
04 Surface Grinder 01
05 Micro Drilling M/C 01
06 Pillar Type Drilling M/C 02
07 Welding M/C 01
08 pedestal Grinder 02
09 powers saw 01
10 CNC Wire cut M/C 01
11 CNC carving M/C 01

Type of Extrusion Dies:
1. Sponge + Solid (Co-extrude)
This is the die which is use for the extrusion of a profile which consists of solid as well as sponge
rubber with or without metal strip. This type of die mostly runs on Extrusion lines such as F1, F2,
and AA5 & GDX.


Die for F1 line (Glass bead line)
The die consists of following parts.
1. Mandrel- This is use when part consists of metal strip in to it. This is used to give guidance to
the metal strip from the die during the extrusion. There are mainly three type of mandrels
Straight type
Pre-bend type- this is used when the flap on the profile starts just at the corner of the
bend.
Glass cord type
Mandrel also aligns the die assembly center with the head center.



Following are some of the defects which found in the part.
Extrusion
1. Blooming: Blooming is the exudation of one or more compounding ingredients to the surface of the
compound stock after mixing and cooling. This separation of compounding ingredient is usually due to
chemical insolubility or incompatibility. Generally a Rainbow color is appearing on the surface of the part. It
can occur over a given time period for both uncured and cured rubber compounds. This defect is mainly due
to the excess quantity of sulfur and process oil. This defect can also due to the less curing temperature then
required. Accelerators exceeding limits especially MBT/MBTS, ZDEC, ZDBC.
Precautions:
Receiving the level of processing oil used in the recipe may reduce the tendency for bloom to occur. Oil
with lower VGC (viscosity gravity constant) tends to become more compatible with EPDM.
2. Blister: Blister is appearance of some hard insoluble particles or foreign particles on the surface of the
profile after extrusion.
Precautions:
Sieved material should be use.
Hard sulfur particles, white fillers, Cao etc should be sieved before use.
FMB should not be come in to contact of impurities, hence it should be stored properly.

3. Pin Hole: This is due to presence of some hard particles in the chemicals or additives as well as presence
of moisture, which melts/ evaporates during the curing of the profile and leave a hole on the surface.
Precautions:
Sieved material should be use.
Desiccant should be mixed with compound for moisture removal.

4. Cracks: This is due to over curing as well as aging of the product. Some cracks appear on the surface of the
product. This defect may also be due to the high hardness of the compound.
Precautions:
Curing temperature should be properly maintained.
Curing agents quantity in the FMB should be maintained.

5. Bubble: This defect appears due to presence of moisture in rubber.
Precautions:
Use of desiccant (Anti- moisture powder) during FMB formation.
Raw material should be dried and properly stored in a controlled atmosphere.

6. Deformation: This if the defect which appear on the profile in the form of Wrinkles or bends. Following
are the reasons for this defect.
Technique of storage of material.
If Ts2/ T90 value is high, there is a possibility of under cure and hence that of deformation.
Line speed is fast then profile may not be properly cured.
Oven temperature is low then also possibility of under cure.
7. Distortion: This is the change in the section of the profile during extrusion or molding. This defect is due
to following reasons:
Mooney changes- can be controlled by high mooney polymer.
Compound factor
Process parameter
Line speed & microwave oven temperature.
Selection of polymer.

8. Whitening: This is the appearance of white color powder on the surface of the profile. This defect is due
to following reasons:
Excess Phr of the chemicals.
Under curing due to the fast line speed i.e. the chemicals which are unable to make a link with the
polymer will appear on the surface.

9. Flock peel off: This is the defect of removal of flock from the surface of the extruded profile. This defect
may be appearing due to following reasons:
Under cured adhesive.
Surface is not buffed.
Adhesive is not properly applied.

10. Lip cut:
11. Lip stick:
12. Tear bit:
13. Dent marks:
14. Scratch:
15. Cure bit:

Molding
1. Joint Crack:
2. Press mark:
3.Under fill:
4.Over flow:
5. Joint twist:
6. Short/ over length:
7. Loose joint:
8. Mis-match:
9. Push back:
10. Profile cut:
11. Air hole miss/ torn:
12. Pad upset:
13. Notch misses/ not ok:
14 Bending offset:
15.Tube over/ small:
16. Clip miss:
17. Over trim:
18. Improper anabond:
19. Bad trim:
20. Wrong center mark:
Limit sample: The CFT sit together and prepare a limit sample for the maximum limit of a defect in the
product beyond which the sample should not be accepted and after the approval from the customer this
sample use for the Inspection.
TESTING
Test perform on the part
Water absorption test:
1. Weight the test piece.
2. Place the sample in Desiccator containing water.
3. Ensure that the test piece is completely immersed in water.
4. Switch ON the vacuum pump.
5. The vacuum pressure has to be lowered to 125mm mercury.
6. Retain in this condition for 3 min.
7. Raise the air pressure to atmospheric pressure.
8. Again retain in this condition for 3 min.
9. Remove the test piece from the water.
10. Dry the work piece with blotting paper and weight it.
11. Calculation
%water absorption= (V2-V1)/V1*100
V1- original weight
V2- weight after immersion in water

Abrasion resistance test: This test is performed on the flocked profile such as glass
run. This is performing to know the strength of the adhesive to hold the flock against the
continuous thru and fro movement of glass in profile.
Procedure:
Cut out 200mm long test piece from the product and insert one in to the jig and insert
one in to the jig installed on the surface abrasion tester. The surface abrasion tester
should be capable of reciprocating movement between two points 140mm apart from
each other at the rate of 60 t 66 cycle per mint, keeping 10n load applied to the ----------
. The jig shall be the vehicle door sash itself, to which the glass run attached, or be
prepared so that bottom whereon the glass slides is horizontal and is fastened with the
aid of the stay. The abraser should be a glass plate whose ends are ground in to the
shape. The test piece is checked after every 3000 cycle and peeling off of flock is
checked visually. It should not peel before 10000 cycles minimum.

Sliding resistance test: This test is performed to know the sliding resistance offered
by the glass run during the sliding of glass in to it.
Procedure:
Cut out 100mm long test piece from the product. Set two of them on the sliding
resistance measurement jig and insert a glass plate with its shape and ensure both ends
are ground as shown in picture bellow. Installed the apparatus on the tensile tester.
When drawing the glass plate from the test pieces at the rate of 200mm/min, measure
the sliding resistance (maximum load) on the glass plate. The sliding resistance shall be
calculated as follow:
W= F/2, where W= sliding resistance N/100mm & F= resistance per two test specimens.
Test piece= production part 100mm.
Pulling speed= 20010mm/min.
Glass thickness= 3 to 3.5 mm & glass length= 2505mm.

Coating thickness measurement with microscope:
Procedure:
1. Cut 100 mm sample from product.
2. Clean the blade with toluene.
3. Keep the sample on the cutting plate.
4. Cut approx. 5mm*10mm length from sample, during cutting keeps the coated area
in bottom side.
5. Cut approx. 3mm slice from the sample.
6. Keep the same slice on microscope glass plate.
7. Open JENOPTIC progress software.
8. Switch on the camera light.
9. See the picture on the desktop, adjust the knob left & right for clean picture, and
first select 5 X objective.
10. When picture appear then change the objective to 20 and see the coating area by
adjusting the fine knob.
11. Measure the coating thickness at four places, take the average value of min &max.
12. Coating thickness should be min. 4 micron and can be 8 micron max.
13. Save the reading.

CLD (Compressive load deflection) Test
This test is performed to know the load at a particular deflection on the bulb of the
profile in base of door seal.
The value affects the door closing effort as well as the strength or the bulb. Like if CLD
value is
High- Door closing effort will increase.
Low- Strength of sponge is low i.e. there is a possibility of cracks, damage and stickiness
of the bulb.
In this test the important parameters are;
D0- close condition door. Generally we take its value as 50mm.
D+2- More compressed condition then Closed condition.
D-2- Little bit open condition.


Insertion & retention force: Apparatus- Tensiometer
Insertion Force: This is the force comes when we insert the insertion plate (specified by
customer) in the lip of the seal.
Retention Effort: It is the opposite force should be applied to remove the seal from the
insertion plate.
These forces are depend on the profile of the lip and should be maintain by the design of
the lip.
This will help the fitter to fit the seal on the car body easily and reduce its effort.

Water absorption test (sponge):
Weathering Test:
Use specimen cut from finished product. Give an elongation of 20% and expose the
specimen for 200hrs in the sunshine carbon weather-ometer or 400hrs in the two bulb
ultraviolet carbon weather-ometer. Inspect for cracks.
Ozone Resistance Test:
The test involve following steps:
1. Cut a specimen of 50mm length and 10mm width from the sponge section of profile.
2. Give an elongation of 20% and allow to stay at room temperature for 24hrs.
3. Expose specimen cut from the finished profile in the ozone weather-ometer for 30hrs
at 401C and ozone concentration 505 pphm.
4. Inspect for cracks.

Final Inspection
Firewall checking- This is a second phase of Inspection which is performed
after the final gauge Inspection. The cost of inspection is beard by the ALP
Nishikawa itself. Part is 100% checked at this station to make sure that no
rejected part can send to the customer. It is further divided in to two stages
such as:
Firewall-1
Firewall-2