Rubber Molding Business

1. Rubber Molding Business www.aatmnirbharsena.org

2. Introduction • Generically, the term rubber in use comprises Indian rubber(Also known as natural rubber), synthetic rubber, or a combination of both the rubbers. • Natural rubbers and Synthetic rubbers are elastomers. Most of the time, synthetic rubbers get tagged as artificial rubber. • It makes around two-third of rubber production all across the globe. www.aatmnirbharsena.org

3. The derivative source of synthetic rubber is crude oil whereas, the Hevea tree sap is considered as the source of derivation for Natural rubber. • The family of synthetic rubber also encompasses plastics, and they get sourced from natural gas and petroleum. • Intrinsic attributes of rubber cover superior tensile and elongational toughness, electrical insulation, wear and tear resistance, as well as resilience, make it a perfect choice to get employed in high volume preformed items for a diverse array of applications. www.aatmnirbharsena.org

4. Rubber Molding is a method of manufacturing a usable rubber product from uncured rubber/ elastomers. • Elastomer is a natural or synthetic polymer having elastic traits, which clearly implies that they return into their primary shape or size after applying pressure. So they are usually utilized in numerous businesses as they are flexible. • In addition to this, they can likewise have varied uses in homegrown and modern divisions like industries. www.aatmnirbharsena.org

5. India has proved its worth and emerged as the second-largest and third-biggest producer of rubber all over the world. • The rubber industry is amongst the most significant manufacturing industries in the category of the Small and Medium Enterprises (SME in the short) sector in India. • The rubber industry of India is responsible for manufacturing around more than 30,000 different products that are practiced in multiple fields like defense, automobiles, aviation, civil, railway, agriculture, medical, sports industries, steel plants, ports, and more. www.aatmnirbharsena.org

6. How to Initiate a Rubber Molding Business? • Those business enthusiasts and new players who are willing to commence the rubber molding business should acquire around 170sqm to 500 sqm to initiate the rubber molding business initially with some civil activity like constructing walls and shed for this unit. • In the initial stage of the rubber molding, the business workforce must revolve around 10 to 11 people, which depends on the unit's business and capacity producing. www.aatmnirbharsena.org

7. Having this much area and workforce under control, you can generate about 60,000 rubber products on a daily basis. • Aatmnirbhar Sena will be providing a supportive platform to nourish the capabilities of promising entrepreneurs and enhance their potential with a mission of making them well-to-do entrepreneurs and progressive corporate leaders. • Aatmnirbhar Sena will put its heart in assisting new startups and render them long term goals along with further support in different forms. www.aatmnirbharsena.org

8. License- what all is required to set up the rubber molding business? • Under the Rubber Act and Rules' present regulation, all rubber transactions are monitored by licensing through the Rubber Board in India. Hence license is a necessity to commence a rubber molding business. • You need to get a license- License to obtain a deal in rubber (dealer's license) or license to get the rubber for processing and to sell such concocted rubber (Processors license) or license in order to procure rubber for manufacturing rubber products (manufactures license). www.aatmnirbharsena.org

9. The dealers & processors license is issued from the office of the Board at Willingdon Island, Kochi- while the manufacturer's license would get issued from the Board's HQ at Kottayam. • Before giving a dream start to this business, one needs to seek the government's permission; first, you must look for a GST number for your business, fire safety certificate, pollution NOC, and commercial electricity connection. www.aatmnirbharsena.org

10. Process and investment • For example, if someone is going to tread the tyre rubber business, raw materials need to be settled in the mixing machine; in this step, the mixing machine incorporates all the raw materials, which takes about 20-25 minutes and delivers out in the form of a rubber sheet. • In the next step, the kneader machine creates a long thin strip of the rubber sheets, and then the thin rubber strips are embedded in the extruder machine in which thin rubber strips can be sliced into desired sheets. www.aatmnirbharsena.org

11. After size cutting, the rubber is now set in the cold press machine, where the rubber gets heated and transforms in the form of a tyre, and in the ultimate step, it is let to cool it down and, after cooling, is packed and is equipped to ship it to market. • Investment- If we discuss tread tyre rubber business, it takes about 50-60 lacs to begin it fully and make profits of up to 4-5 lacs per month. www.aatmnirbharsena.org

12. The industrial sector, which consumes most of the rubber products manufactured- • Automobile sector- tyres,50% of the total produced • Two-wheelers tyres-15% • shoe industry- 12% • latex products- 7% • other products- 10% www.aatmnirbharsena.org

13. Types of rubber molding process • Rubber Injection Molding- Through this process, the uncured rubber compound is ignited to a liquid state prior to getting injected into a mold. The product is released by unfolding the mold and closing it again to get the next injection. Injection molding is considered the best method for making rubber products. • Rubber Compression Molding- Fixing a predestined amount of rubber compound undeviatingly into the mold cavity and later compressing it into the cavity's appearance by closing the two sides of the mold. The pressure is sustained while heat is affixed to the mold to cure the product. The product is extracted from the mold on the process's fulfillment, and excess rubber (flash) is removed. www.aatmnirbharsena.org

14. Rubber Transfer Molding- Under this process's hat, the uncured rubber compound is set in a part of the mold termed as "pot" before being driven through an aperture into a cavity in the aspired product's shape. When cured, the mold is split, delivering the final product. www.aatmnirbharsena.org

15. Rubber molding materials A wide range of natural along with synthetic rubbers are available for molding purpose. The popular ones are listed below- • Ethylene Propylene Diene Monomer (EPDM) – generally used in rubber molded products for steam systems, braking systems, and vehicle panel seals due to its tremendous resistance. It’s easy to use in generating smooth, extruded products. Its low cost has established it a better choice. www.aatmnirbharsena.org

16. Nitrile or Buna-N – is the most widespread and low-cost solution in rubber molding. Attributes include resistance to water, oil, hydraulic fluid, and solvents. • Butyl – has excellent resistance to gas permeability. Therefore, it has emerged as the perfect solution in seals production for high-pressure gas and vacuum systems. It is cost-effective and also has useful sound damping features. • Natural Rubber – is a natural product fabricated from latex obtained from the rubber tree, which can also be generated synthetically. It has unusual tensile power with excellent abrasion and surface friction traits. Therefore, it has become a perfect material for the manufacture of vibration dampers, machinery, seals, o-rings, component mountings, bumpers, and diaphragms. www.aatmnirbharsena.org

17. Silicone- Resistant to exposure to high and low temperatures is very adaptable and has high-grade weather resistance. These attributes imply typical uses in medical devices and food processing. • Hydrogenated Nitrile – this is a more costly hydrogenated variation of Nitrile polymer, which extends its resistance to heat, petroleum products, and ozone nearly fivefold. It is now used widely in the automotive, marine, and aircraft industries. • Neoprene – as a robust multi-purpose material, it can be utilized in a considerable number of rubber molding solutions. It has excellent fire-resistant and abrasion properties. www.aatmnirbharsena.org

18. Mold Making Process in detail • Design –The mold's design must be harmonious with the accurate molding machinery that it will be fitted to. Managing this process in a business that produces high volumes of single or multiple rubber components can be elucidated using 3D (3 dimensional) modeling software. A 3D designer builds a digital model of the mold base, core, and cavity to resemble the component specification; • Materials – under a mass manufacturing process, the mold must replicate the segments perfectly with minimal material spillage and at a noble frequency. The size, weight, and curing temperature of the element will ascertain the mold's size and material. Molds for rubber molding can be gained from plaster or other rubbers but principally from various engineering-grade metal alloys in the event of reusable molds; www.aatmnirbharsena.org

19. Manufacture – this process requires the casting of the components and the application of high precision equipment that incorporates milling, drilling, grinding, and polishing machines to formulate the contours of mold components; • Testing – molds components are examined to ensure that they meet all features of the design specifications in terms of durability, surface coating, dimensional stability, and mechanical traits; www.aatmnirbharsena.org

20. Rubber molding machinery • Rubber Injection Molding Machinery • The wholly hydraulic mold clamping machine is the perfect rubber injection molding machine of choice for a significant chunk of manufacturers. • The injection molding process is suitable for the production of high-quality precision components on a massive scale. • It entails injecting fixed volumes of a rubber material beneath pressure into the closed mold before curing and releasing it. www.aatmnirbharsena.org

21. Rubber Compression Molding Machinery • Compression molding is the most well-known process, including applying pressure to a preset volume of molding material before and throughout the curing process. • This process is most fitting for low to medium volume production operates not requiring tight tolerances and smooth endings. • Compression molding is suggested to manufacture diaphragms, dampers, O-rings, valve parts, gaskets, seals, rubber wear parts, etc. www.aatmnirbharsena.org

22. Rubber Transfer Molding Machinery • In the matter of rubber transfer molding, a rubber material passes into the open mold until it closes. • It may drive to gas formation and shrinkage of the element that cannot be revised during the curing process. Rubber transfer molding machines are utilized for the precise molding of rubber, encapsulating electronic parts, medical products bonding rubber to metal parts, inserting electrical connectors, etc. • Transfer molding machines are comparatively inexpensive and have a simplistic manufacturing manner. www.aatmnirbharsena.org

23. Small Rubber molding business for startups • Ballon Manufacturing- ballons are rubber products and simple to manufacture, and also they are extensively used, a perfect product for startup on a small scale. • Hospital Consumables- In hospital doctors, nurses apply latex, rubber gloves daily; if one springs this on a small scale, it can generate a fair amount of profits. • Conveyor belt rubber- Conveyor belts are used nearly in all industries. And day-by-day industrialization advances and demand for conveyor belt is also increasing swiftly. www.aatmnirbharsena.org

24. Other examples for small scale startups are- rubber gaskets, rubber-based adhesive, auto tubes, radial tyres, waste tyrepyrolysis, water storage tanks, rubber floor mats, plastic containers, etc. • The world production of rubber was viewed as truly precarious during the last few years. www.aatmnirbharsena.org

25. To Wrap Up • Similarly, India's production of rubber is steady at a rate of 6% per annum. • The Rubber business in India is developing with its underlying foundations more profound. • India is the third-largest consumers while the largest maker of standard rubber products in the world. • The expansion of the rubber industry in India assumes a critical function in the worldwide economy. • For aspiring entrepreneurs in the rubber molding business, Aatmnirbhar Sena will provide them assistance and help them grow their startup to boost our economy. www.aatmnirbharsena.org