SANTA ANA, Calif.—On the manufacturing floor, efficiency is key. Processes that create a time or cost savings are desired across the board. When one achieves both, with additional benefits to boot, it's a game-changing technology.
Santa Ana-based Maverix Solutions Inc. developed Mavcoat MD-4, a mold release coating for the rubber industry that revolutionizes the molding process. There is no coating cure time, nor does it leave a white film behind.
Mavcoat MD-4 is a water-based, semi- permanent release coating for all organic rubber elastomers.
"We've taken this ceramic technology I created and now adapted to use in the rubber industry," said Maverix President Mark Danzo, who started the company 18 years ago in his garage.
"It was derived from making mold release coatings for the composites industry. In the world of composites, epoxy is used to impregnate or strengthen carbon fiber and other materials."
Epoxy is a difficult material to release, he said, but as the aerospace industry began to demand higher molding temperatures and longer cure cycles, there was a need for a mold release coating to withstand this harsh environment.
"To do that, I believe that ceramic coatings would be necessary because they are able to withstand high temperatures for very long periods of time," Danzo said.
After the composite industry, Maverix started to develop this technology for the rubber industry. It also works for rotational plastics.
Maverix began research and development on Mavcoat MD-4 about three years ago. It was released to the market about 15 months ago.
"Competing mold releases are called or counted as semi-permanent. That means our competitors apply their release coatings and they have to have a cure cycle," Danzo said.
When using standard mold release coatings, operators have to apply the coatings and then wait 10-15 minutes for the coating to cure before they can start molding the rubber.
"I thought that was a waste of time," Danzo said. "In the world of rubber, high volume production is critical to lowering your cost and being competitive.
"Our customers were tired of waiting 15 minutes for the coating to cure. With our technology, it is ready immediately upon spraying or application to the mold surface. So, it's fairly groundbreaking technology."