Skip to main content
Sister Publication Links
  • European Rubber Journal
  • Plastics News
web
Subscribe
  • Login
  • Register
  • Subscribe
  • News
    • ITEC
    • Automotive
    • Tire
    • Non-Tire
    • Suppliers
    • Silicone
    • Latex
    • Coronavirus
    • Executive Action
    • Government/Legal
    • Opinion
    • Technical Notebooks
    • International Elastomer Show
    • Women in Tire & Rubber
    • HEXPOL Sponsored Content
    • Goodyear recognized by Lockheed Martin as 'elite supplier'
      EV tire advancements to help secure future
      Lambillotte: Only question on AVs is timing
      CAR official says EV future brighter than autonomous
    • Motion Industries rebrands as 'Motion'
      USW opposes Taiwan tire makers' dumping counterproposal
      Goodyear-branded transmission belts set to return
      Hot topics at virtual CES: AVs, air taxis and drones
    • USW opposes Taiwan tire makers' dumping counterproposal
      Greenergy, Haldor Topsoe tech turns tires to fuel
      India decides against extending carbon black duties
      GRI expanding ag tire capacity at 3-year-old Sri Lanka plant
    • Motion Industries rebrands as 'Motion'
      Proto Labs to buy e-commerce company 3D Hubs for $280 million
      NewAge Industries celebrates 15 years of employee ownership
      India decides against extending carbon black duties
    • Tero Peltomaki named Cimcorp CEO
      Nynas expects to be stronger after reorganization
      Synthomer CEO MacLean to step down by early 2022
      Safic-Alcan and Arkema working together on distribution deal
    • Proto Labs to buy e-commerce company 3D Hubs for $280 million
      Ace Products & Consulting partners with Wallace Instruments
      Safic-Alcan extends distribution agreement with Momentive
      Momentive aims to grow silicone presence in Asia-Pacific region
    • WCCO task force navigates pandemic, expands communications
      ASTM cancels April meetings as COVID-19 continues impact
      Paycheck Protection Program funding reopens Jan. 15
      Detroit Auto Show canceled; alternative event being planned for September
    • Tero Peltomaki named Cimcorp CEO
      Synthomer CEO MacLean to step down by early 2022
      ARP Materials adds technical sales manager
      Jack Murphy joins Akron Dispersions
    • USW opposes Taiwan tire makers' dumping counterproposal
      India decides against extending carbon black duties
      Hot topics at virtual CES: AVs, air taxis and drones
      Paycheck Protection Program funding reopens Jan. 15
    • Column: Pandemic looms over everything in life, business in 2020
      Column: Lessons from the 2020 Best Places to Work
      Editorial: Silicone hit hard by pandemic, expected to bounce back
      Column: Still far way from normal
    • Effects of multiple repurposed materials for reinforcements of standard rubber compounds
      Impact of peroxide blends on the cure rate and aged properties in HNBR
      Techniques to detect long chain branching in polymers
      A comparative study looking at effects of curing kinetics and batch variation on SBR injection molding and numerical analytics
    • Rubber Division seeks abstracts for 200th Technical Meeting
      WORD panelists say evolution, authenticity keys to success
      IEC keynote: Communication key to logistics
      IEC speaker: Specialized elastomers may reduce spread of life-threatening pathogens
    • WORD panelists say evolution, authenticity keys to success
      New video celebrates women in rubber industry
      ITEC panelists say women can thrive in tire industry
      Rubber Division planning second Women of Rubber event
    • Sponsored By HEXPOL Compounding
      Faster Access to Your Polymer Compounding Experts Around the World
      Sponsored By HEXPOL Compounding
      Take a walk thru a HEXPOL Lab
      Sponsored By HEXPOL Compounding
      HEXPOL offers a unique selection of High Performance Elastomers to match your application requirements
      Sponsored By HEXPOL Compounding
      It’s what you can’t see that makes the Difference at HEXPOL
  • Blogs
    • Products
    • Wacky World of Rubber
    • New Products: Nova thinks outside the box with sealing tech
      New Products: MonTech introduces 1,500 kN lab press
      New products: 3M introduces new durable, pliable medical adhesive
      New Products: Lanxess launches energy-efficient PU elastomer
    • Wacky World of Rubber: How Trelleborg, teens sealed a spot in the world record book
      Wacky World of Rubber: Of chicken and feet, but not chicken feet
      Wacky World of Rubber: Time to go mattress shopping
      Wacky World of Rubber: Because nothing says football like 'frunk' shrimp
  • Newsletters
    • Rubber in Automotive
    • Silicone News
    • Latex News
    • Sign Up for Newsletters
    • Motion Industries rebrands as 'Motion'
      USW opposes Taiwan tire makers' dumping counterproposal
      Goodyear-branded transmission belts set to return
      Hot topics at virtual CES: AVs, air taxis and drones
    • Proto Labs to buy e-commerce company 3D Hubs for $280 million
      Ace Products & Consulting partners with Wallace Instruments
      Safic-Alcan extends distribution agreement with Momentive
      Momentive aims to grow silicone presence in Asia-Pacific region
    • Bridgestone bets on guayule as alternative natural rubber source
      Synthomer CEO MacLean to step down by early 2022
      Jack Murphy joins Akron Dispersions
      Synthomer optimistic, raises earnings forecast
  • Multimedia
    • Videos
    • Photo Galleries
  • Directory
  • Resources
    • Classifieds & Mold Mart
    • Sponsored Content
    • White Papers
    • Sponsored By HB Chemical
      The Company Behind the Inventory
      Sponsored By French Oil Mill Machinery
      Process Improvement, Cost Reduction with Custom Press Systems
    • Sponsored By Uncountable Inc.
      Cooper Standard deploys lab informatics platform to synchronize R&D
      Sponsored By Elkem
      LSR Select™: A solution to improve your financial impact in molding applications
      Sponsored By HEXPOL Compounding
      Peroxide Cureable Silicone Injection Molding
      Sponsored By HEXPOL Compounding
      Understanding and Selecting Performance Additives for Rubber Compounding
  • Data
  • Events
    • RPN Events
    • RPN Livestreams/Webinars
    • Industry Events
    • Past Events
    • ITEC Library
    • International Silicone Conference Library
    • 2021 Healthcare Elastomers Virtual Edition
      2021 Rubber in Automotive Virtual Edition
      2020 International Silicone Conference Virtual Edition
      2020 ITEC Virtual Edition
  • Advertise
  • DIGITAL EDITION
MENU
Breadcrumb
  1. Home
  2. News
May 02, 2005 02:00 AM

Flashless technology worth the price, speaker says

Brad Dawson
  • Tweet
  • Share
  • Share
  • Email
  • More
    Print

    Flashless molding is one of several ways to reduce material waste in a rubber molding operation, and with some relatively new technologies available, it can positively affect labor costs, cure times and component quality.

    John Roembke, CEO of Roembke Manufacturing and Design Inc. in Ossian, Ind., talked about flashless molding and particularly about the benefits of valve gate flashless molding during a presentation at the International Rubber Molding Conference, held April 5-6 in Dearborn, Mich.

    The development of flashless molding as a waste deterrent dates back more than 50 years, followed in the past 20-25 years by updates such as cold runner, liquid injection and valve gate molding technology, Roembke said. The most recent technology is a ``zero waste'' valve gate flashless system for high-consistency materials, he said.

    Companies are looking for ways to reduce costs at all levels in turbulent business climates which require innovative processes, offer limited business opportunities for unprepared firms and not enough business of multiple vendors, and challenge partner relationships, Roembke said.

    There are many conventional molding costs that rubber companies have grown to accept, instead of keeping an eye on them like they should, he said. These include material-related costs like handling extra material and waste disposal; labor and supply costs for press operators, and people and supplies for washing, deflashing and inspection operations; and efficiency-related costs for running molds with blocked cavities, employee downtime and various causes of longer cure times.

    If those individual costs were more closely monitored, better choices would be made regarding the type of tooling and presses needed to make profitable product, Roembke said.

    The advantages of valve gating include no material waste, ease in automating the process, less labor due to automation, a realistic challenge to chemists to reduce cure times and possibly to triple the amount of heats per shift, he said.

    The disadvantages of the valve gate system include requiring more disciplined processes than normal compression molding and consistent material specifications; appropriate press control, which is no good for a 30-year-old press, and a greater mold investment, Roembke said. The key factors, though, are that it requires employees willing to learn and implement the new technology, and it takes an investment in time, money and talent to successfully implement the system, he said.

    In comparing the costs of a valve gate system with transfer hot pot and cold pot molding configurations, Roembke found the initial tooling costs for valve gating were indeed much higher. But the annual heats per shift were much higher in the valve gate system, and the annual waste cost was nothing while the transfer systems' were in the thousands of dollars.

    The positive return from the valve gate automated process includes better quality with smaller molds and fewer rejects, and better use of an employee within a production cell, allowing the operator to run multiple presses, perform quality spot checks, clean molds and package product, Roembke said. The press operator/technician would have total accountability for the process, the product, tooling and equipment.

    In using the valve gate technology, Roembke took on a project from molding company Polyneer Inc., located in New Bedford, Mass. The firm needed 60 million parts per year under the following conditions: run the project with a maximum of three presses and meet requirements of 100-percent inspection, flash-free, no imperfections and minimum material waste, he said.

    The job also was to be completed-production, inspection and shipping-by only one person, he said.

    The outcome yielded only one major problem, that the one technician was not fully utilized, Roembke said. The automation reduced the need for labor and eliminated waste to the point where that employee could be given more to do. The proposed solution to this ``problem'' was to add a fourth press and possibly a fifth down the road to the production cell, he said.

    Roembke said he believes automation and technology can help companies improve their efficiency in this manner, but it takes investment on their part to make it happen.

    Letter
    to the
    Editor

    Rubber & Plastics News wants to hear from its readers. If you want to express your opinion on a story or issue, email your letter to Editor Bruce Meyer at [email protected].

    SIGN UP FOR NEWSLETTERS
    EMAIL ADDRESS

    Please enter a valid email address.

    Please enter your email address.

    Please verify captcha.

    Please select at least one newsletter to subscribe.

    Get our newsletters

    Staying current is easy with Rubber & Plastics News delivered straight to your inbox, free of charge.

    Subscribe Today

    Subscribe to Rubber & Plastics News to get the best coverage and leading insights in the industry.

    SUBSCRIBE
    Connect with Us
    • LinkedIn
    • Facebook
    • Twitter

    MISSION

    To serve companies in the global rubber product industry by delivering news, industry insights, opinions and technical information.

    web
    Contact Us

    2291 Riverfront Pkwy, Suite 1000
    Cuyahoga Falls,
    OH 44221

    Customer Service:
    877-320-1726

    Resources
    • About Us
    • Digital Edition
    • Contact the Staff
    • Advertise
    • Order Reprints
    • Privacy Policy
    • Privacy Request
    • Terms of Service
    • Careers
    • Ad Choices Ad Choices
    • Sitemap
    Partner Sites
    • Tire Business
    • European Rubber Journal
    • Plastics News
    • Plastics News China
    • Urethanes Technology
    • Automotive News
    • Crain Brands
    Copyright © 1996-2021. Crain Communications, Inc. All Rights Reserved.
    • News
      • ITEC
      • Automotive
      • Tire
      • Non-Tire
      • Suppliers
      • Silicone
      • Latex
      • Coronavirus
      • Executive Action
      • Government/Legal
      • Opinion
      • Technical Notebooks
      • International Elastomer Show
      • Women in Tire & Rubber
      • HEXPOL Sponsored Content
    • Blogs
      • Products
      • Wacky World of Rubber
    • Newsletters
      • Rubber in Automotive
      • Silicone News
      • Latex News
      • Sign Up for Newsletters
    • Multimedia
      • Videos
      • Photo Galleries
    • Directory
    • Resources
      • Classifieds & Mold Mart
      • Sponsored Content
      • White Papers
    • Data
    • Events
      • RPN Events
      • RPN Livestreams/Webinars
      • Industry Events
      • Past Events
      • ITEC Library
      • International Silicone Conference Library
    • Advertise
    • DIGITAL EDITION