Optimizing Anti-Tack Applications
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The document presents an overview of an optimized anti-tack application process for tire technology, focusing on challenges faced in plants and the components necessary for success, including equipment, belting, and chemistry. Key recommendations for belt selection and design considerations are discussed, emphasizing the importance of overall cost of use rather than just purchase cost for anti-tack solutions. The document concludes with an invitation for questions and further discussion at specified booth locations.
Optimizing Anti-Tack Applications
- 1. intralox.comintralox.com Optimized Anti-tack application Jointly presented by Intralox and the Polymer Solutions Group Tire Technology Expo, 21 February 2018 Hannover, Germany
- 2. intralox.comintralox.com Agenda • Welcome and introductions • Challenges currently facing in your plants • 3 components of a successful anti-tack application process • Intralox solutions – overview • Polymer Solutions Group – overview • Questions and Answers
- 3. intralox.comintralox.com • Paul Timmer, Application Engineer, Intralox Member of Intralox Tire Team with technical focus on tire applications, 10 years with Intralox • Ed Juline, EMEA Sales Director, Polymer Solutions Group 8 years with SASCO/PSG Introductions
- 4. intralox.comintralox.com • What current challenges are you facing in your anti-tack application process? • What upcoming initiatives or objectives are you focusing on? Let’s Hear From You
- 5. intralox.comintralox.com • Personnel training and problem solving • Mixing inconsistencies • Porosity Issues • New challenges with stickier, softer compounds • Line cleanliness • Inconsistent application • Backside coverage • Foam • Solids / concentration • Sedimentation / separation • Blisters • Stuck rubber • Downstream process issues • Impact to production • Product quality • Scrap • Unscheduled downtime • Cost incurred to reprocess rejected rubber – Line time, labor, energy, health and safety Challenges
- 6. intralox.comintralox.com Controlled and CONSISTENT process. Even application, good backside coverage, consistent quality, limited downtime, limited waste / reprocessing Chemistry Belting Equipment Optimized Anti-Tack Application Components
- 7. intralox.comintralox.com Optimized Anti-Tack Application Components • Equipment • Belting • Chemistry
- 8. intralox.comintralox.com Belt recommendation Considerations for belt choice: • Abrasive anti-tack solution (wear) • Hot rubber slab, 110-140°C (230-284°F) • Small contact surface for optimal backside coverage • Open surface required for drainage • Strong belt to handle ball-ups • Belt speeds: 10-40 m/min (32-130 ft/min) • Typical belt width: 1000-1400 mm (40-56 inch)
- 9. intralox.comintralox.com Belt recommendation Belt and sprocket recommendations: • S1700 FG NT Nylon with Nylon rods (dual rod system) • S1700 FG Nylon with Nylon rods (dual rod system) • S1700 Ultra Abrasion Resistant (Split) Sprockets - 16T, 14T or 12T • Other options available… S1700 FG NT
- 10. intralox.comintralox.com Belt recommendation Advantages S1700 FG NT: • Increased belt and sprocket life • Improved backside coverage • Decreased liquid carry-over • Better clean-ability • Reduced and easier maintenance 37% open area and nub pattern: easier flow of liquid through the belt 8% contact area between rubber slab and belt: More contact of liquid with rubber Rubber slab
- 11. intralox.comintralox.com Conveyor Design Gravity Take-up Min. Ø 6 inch / Ø 150 mm Stroke: Min. 2 %, ideally 4% of total belt lengthReturnway rollers Min. Ø 6 inch / Ø150 mm Belt edge guides (both sides) Carryway support: Stainless Steel wearstrips in chevron configuration Sufficient space for ball-ups to pass Dunk roller with position limiter Ensure sufficient back-tension (avoid sprocket disengagement) and storage capacity for belt elongation (minimal maintenance) Hugger strips designed such that it can deal with possible ball-ups
- 12. intralox.comintralox.com We suggest looking at the cost of using anti-tack in terms of total cost of use. What it costs to USE, not what it costs to BUY. 1. Rubber producers typically consume 20-50% more anti-tack than the optimal amount needed 2. Actual product purchase cost of anti-tack is a small percentage per ton of rubber (<$4 per ton of rubber) 3. The improper use of anti-tack causes extrusion, calendaring and molding problems that are often unjustly blamed on the downstream processes 4. Rubber producers modify their processes to adapt to their anti-tack instead of finding the best anti-tack for the compound and optimizing the equipment Total Cost of Use of Anti-Tack
- 13. intralox.comintralox.com • Depletion or Take-Up Rate: Amount of anti-tack solution used per ton of rubber • All anti-tacks deplete at different rates • Field Study – Competitor’s powder anti-tack and SASCO PolyCoat RLS-40 diluted to 4% solids (500 gallons) – 500 gallons of PolyCoat RLS-40 covered twice as much rubber as the competitors dip Not All Anti-Tacks Are the Same
- 14. intralox.comintralox.com Not All Anti-Tacks Are the Same Powder with Calcium Stearate Low-Shear Dispersed into Water Slurry with Calcium Stearate Prepared Under High-Shear Mixing
- 15. intralox.comintralox.com Objective • Cost per pound • Preparation – Mix time/hot water • Activity – Take-up or depletion rate • Drying • Dispersion – Down stream effects • Hazards Subjective • Coating – Back side coverage – Slip – Tack • Foam • Settling – Phase separation – Hard packing • Flaking/dusting Multiple complex evaluation criteria
- 16. intralox.comintralox.com “Hope for the best” strategy Suppliers Customers
- 17. intralox.comintralox.com PSG Automated Mixing System Layout H2O Air
- 18. intralox.comintralox.com You can do better…MUCH BETTER!
- 19. intralox.comintralox.com Controlled and CONSISTENT process. Even application, good backside coverage, consistent quality, limited downtime, limited waste / reprocessing Chemistry Belting Equipment Optimized Anti-Tack Application Components
- 20. intralox.comintralox.com Questions & Answers Intralox Booth 9020 Hall 21 Polymer Solutions Group Booth C238 Hall 19 Come and see us at our booths