Manufacturing

Manufacturing

Saini Rubber Ltd is able to produce components from 1 gram to 4 kilos in weight from any rubber polymer, using any one of our comprehensive range of both Compression, Compression Transfer and Injection Presses.

Manufacturing is supported by many special processes for completion of final component such as Cryogenic Deflashing, Post Cure Ovens, Material Code Spotting, Grinding, Econo Cutting, Individual Packaging, Screen Printing, Engraving, Labelling and Barcoding.

Saini Rubber Ltd specialise in Custom Rubber Moulding, Thermoplastic and Rubber Injection Moulding, Compression and Transfer Rubber Moulding of all types of Precision Moulded Components, manufactured in any polymer with recognised approvals for specific industries. A leading independent UK company whose reputation is built around flexibility, technical ability, customer service and quality ISO 9001:2008 accreditation. In partnership with our sister companies in China to achieve low cost manufacturing of rubber mouldings abroad.

work process

Finishing Process

Saini Rubber is able to produce one off special parts or very high volume components in both solid and sponge rubber but we can also offer our customers a variety of finishing / post moulding processes.

Production is supported by many special processes for completion of final component such as cryogenic deflashing, post cure ovens, material code spotting, grinding, econo cutting, adhesive backing,individual packaging, screen printing, engraving, labelling and barcoding

  • Hand Trimming
  • Machine Trimming
  • Engraving/ Etching on bonded metal surfaces
  • Hole Punching
  • Hole Drilling
  • Econo Cut
  • Lathe Cut
  • Cutting/slitting
  • Buffing/Linishing
  • Cutting to Length and Joining – Vulcanised Joints and Cold Bonding
  • Cryogenic Deflashing
  • Paint Dots
  • Silicone Wash Coating
  • Silicone Grease Coating
  • Talc Coating
  • Washing
  • Gluing
  • Applying Self Adhesive Backings
  • Kitting
  • Assembly Work
  • Screen Printing
  • Bulk Packing, Individual Packing or Set Quantities in Bags/ Boxes or Sleeves

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part and can assist with tool design

Schedule Of Equipment

Saini Rubber has all the Plant and Equipment you would expect to find in a modern Rubber Manufacturing facility.

We have equipment to be able to cope with anything our Customers demand from us - one off special products or high volume components, from material development to finished product testing / validating.

Below listing illustrates the type of equipment we have to keep ahead of our game.

Mixing and Blank preparation

  • Rubber Mixing Mills
  • Performer Extruders
  • Screw Extruders
  • Clicker Presses

Moulding Presses

  • Compression Moulding Presses 25 tons to 500 tons
  • Injection Presses from 30 tons to 500 tons
  • C Frame Injection Presses from 5 tons to 40 tons
  • Sponge Moulding Presses from 25 tons to 150 tons

Finishing Equipment

  • Cryogenic deflashing - Freeze Trimming Machines
  • Buffing Machines
  • Trimming Machines
  • Spray Painting / Bonding Agent Application Equipment
  • Post Cure Ovens
  • SIC Marking Equipment (Engraving)

Cleaning Equipment

  • Washing Machines for finished product
  • Shot Blasting for mould cleaning and metal preparation

Laboratory / Test Equipment

  • Nikon INEXTV VMA 2520 Measuring Machine with EVJ 40100 VMA 3CCD Colour Scan Camera with Cell Equipment and Monitor
  • Shadowgraph - Non Contact Measurement
  • Various hand held Measuring Equipment
  • Micro Hardness Tester IRHD (International Rubber Hardness Degrees)
  • Hand held Hardness Meters IRHD and Shore
  • Hardness – Dead load IRHD
  • Electrical Resistivity
  • Specific Gravity
  • Magnifying Lights

Technical / Sales

  • Cad - to be able to view / review customer data
  • We are able to accept in various formats e.g., IGS, STP, DXF, DWG, x_t

Maintenance / Engineering Department

  • We have all the necessary skills and the equipment to both maintain our plant and equipment in top condition as well as developing production engineering solutions.

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part

Corner Shot Mouldings

Saini Rubber has comprehensive facilities for specialist Extruded Seals and Gaskets with Shot Moulded and Vulcanised Corners/ Joints.

Using these techniques we can manufacture very large seals and gaskets for a variety of applications.

Saini Rubber has developed jointing techniques to make extruded profiles into seals and gaskets and this technique applies to solid and sponge extrusions as well as a variety of polymers.

Our capabilities include production of Large Diameter Rings and Picture Frame Gaskets for a wide range of applications:

  • Train and Bus Doors and Windows
  • Large Window Seals
  • Large Industrial Seals

Saini Rubber’s vulcanised jointing technique allows the same extrusion material to be used for the joint. It is also for joining together two different rubber extrusions with the changes in section occurring in the moulded section.

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part and can assist with tool design

Moulded Sponge

Saini Rubber manufacture and supply a wide range of Sponge Rubber products including Seals, Gaskets, Extrusions, Mouldings and Die Cut Gaskets in a range of polymers.

Our largest sponge moulding press is 2250mm X 1250mm where we are able to manufacture large seals and gaskets.

Saini Rubber can help with both material and processes selection for the manufacture of sponge rubber components.

Is sponge the right choice for your application?

Sponge is used in applications where the Seal has to cope with large tolerances such as Ceramic pipes. It is also used where there are low compression forces available to effect a seal eg. Plastic boxes and closures, automotive doors/ hoods/ boot seals.

Some Sponge rubbers have the ability to be compressed and reduce in volume so it is used in applications where large deformations are required when fitted. Solid rubbers require large loads to deflect them and behave hydraulically and bulging out when compressed.

Sponge Rubber can also be used where Thermal or Sound insulation is required.

Various types of sponge are available:

  • Open Cell Sponge
  • Closed Cell Sponge
  • Moulded Sponge
  • Extruded Sponge
  • Die Cut Sponge with and without adhesive backing

Saini Rubber can supply a wide range of foam and cellular materials, including, neoprene, pvc, nitrile, silicone, epdm etc.

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part and can assist with tool design.

Moulded Rubber

Saini Rubber utilises various Moulding Techniques for the manufacture of Rubber Components. The moulding process selected will depend on many things – for example the number, size and shape of the parts and the dimensional tolerances required of the finished part.

Below is a very brief summary of the type of moulding process Saini Rubber can offer.

RUBBER MOULDING – FROM COMPOUND TO FINISHED PRODUCT

Most rubber compounds are a mixture of a base polymer to which has been added various ingredients that modify its properties and allow it to be made into the material we recognise as rubber.

The rubber compound needs to be prepared for the moulding process and preparation varies depending on the moulding method to be used.

Compression Moulding:

This method uses a heated hydraulic press into which the mould is fitted. The rubber compound is prepared by extruding and cutting or cutting from sheet into a predetermined weight and shape. These pre-forms are referred to as blanks. The blank is placed directly into the cavity. The mould is then closed and heat and pressure applied to vulcanise (cure) the rubber.

Transfer Injection Moulding:

This method uses similar equipment to compression moulding except the blank is placed in a transfer chamber usually located above or below the mould cavity. A piston is used to transfer the rubber via a feed gate into the cavity when the mould is closed in the hydraulic press. The part is then cured as the compression moulding process

Injection Moulding:

This requires specialist injection equipment with the uncured rubber compound usually prepared as a strip which is fed directly into an injection unit that plasticises and prepares a predetermined “shot weight”. The rubber is then injected directly into the cavity where it is cured

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part and can assist with tool design.

Rubber to Metal Bonding

Saini Rubber has the technical expertise along with comprehensive facilities for the manufacture of Rubber to Metal mouldings, Rubber to Plastic mouldings as well as Rubber and Fabric mouldings, etc.

Bonding rubber to metals and other substrates can be very useful when designing a variety of components where both the properties of the metal and the rubber are required in a single component

Saini Rubber has developed processes to bond rubber to a range of metals and various other substrates during the moulding process. We are able to carry out the following processes

  • Shot Blasting
  • Degreasing
  • Preheating and Drying Ovens
  • Spray and Hand Painting
  • Grinding and Finishing
  • Post Vulcanisation Bonding
  • Engraving/ Etching of bonded metal surfaces

The inserts are prepared mechanically and/ or chemically depending on what the substrate is made from. They are then put into the mould as an insert and the rubber is vulcanised to the insert during the moulding of the component.

This type of product is used for a very wide range of applications including:

  • Seals
  • Anti-Vibration Products
  • Suspension Products
  • Expansion Joints

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part

Rubber Moulding Processes

Saini Rubber is able to mould Solid and Sponge Rubber Components from less than 1 gram up to 40 Kilograms.

We achieve this by utilising any one of our comprehensive range of Compression, Compression Transfer and Injection presses.

Included in our equipment are:-

Solid Moulding Presses

  • Pressure ranges from 30 to 500 tons.
  • Platen sizes from 300mm X 300mm to 1070mm X 1070mm
  • Daylight from 450mm to 1000mm

Sponge Moulding Presses

  • Pressure ranges from 25 tons to 150 tons
  • Platen sizes from 300mm X 300mm to 2250mm X 1250mm

Various moulding methods include:

  • Compression Moulding –Solid Rubber
    • Up to 500 tons and 1070mm X 1070mm for large mouldings, lower volume and one-off’s
  • Transfer Moulding - Solid Rubber
    • Up to 280 tons for rubber to metal bonding and lower/ medium volumes
  • Injection Moulding - Solid Rubber and TPE
    • Thermoset rubber up to 500 tons for larger volume production
  • Compression Moulding - Sponge
    • Up to 150 tons and platen size 2250mm X 1250mm for large sponge seals and gaskets

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part

Capabilities

Saini Rubber has the capability of manufacturing and supplying rubber components in most solid or sponge elastomers.

Utilising our wide range of production equipment we can manufacture rubber parts from less than 1 gram to as much as 40Kilos.

At Saini Rubber we are pleased to add value to our products by offering a range of post moulding processes.

Below is a list of some of our manufacturing capabilities but we are always up for a challenge!

Press sizes from 5 ton to 500 ton

  • Injection Moulding
  • Compression Moulding
  • Joint/ Corner Moulding for Extrusions
  • Sponge Moulding
  • Rubber to Metal Bonding
  • Rubber to Plastic Bonding
  • Fabric Reinforced Moulding
  • Extrusion. Continuous Cure – Autoclave
  • Extrude and cut to length
  • Extrude and Vulcanise into Rings or Frames
  • Cutting from Sheet material. Punching – Water Jet Cutting

Production is supported by many special processes for completion of final component such as cryogenic deflashing, post cure ovens, material code spotting, grinding, econo cutting, adhesive backing,individual packaging, screen printing, engraving, labelling and barcoding

  • Cryogenic Deflashing
  • Hand Trimming
  • Cutting to Length and Joining – Vulcanised Joints and Cold Bonding
  • Applying Self Adhesive Backings
  • Buffing
  • Painting – Applying Slip Coats
  • Engraving/ Etching of Bonded Metal Surfaces

Saini Rubber has both In-House formulation and mixing of materials and external compound suppliers.

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part and can assist with tool design

WE PROVIDE FULL DIMENSION AND MATERIAL CONFORMITY TO ISO 9001 CERTIFICATION

We are here to help!