An expert in polymer technology

Transcription

1 An expert in polymer technology Industrial hoses, assemblies, and couplings Polymer products for technical applications Wear- and corrosion-protection Customer products from technical polymer materials

2 in brief Group is a significant European polymer technology expert The roots of s know-how go back to 1898 when company s current operations formed a part of the Gummifabrik, later merging with the Nokia Group. The company has traded under the present name since 1989, the year when the majority of Nokia Group s technical rubber business was transferred to. Group includes three plants in Finland, one plant in China and in Hungary, a sales company in Germany and sales representation in Russia. products include industrial hoses, moulded products of rubber and plastic, rubber linings and polyurethane coatings, polyurethane and liquid silicone products, rubber compounds, sheets, and mats. Our areas of know-how comprise product and service solutions for wear and corrosion protection, industrial hoses and hose assemblies for handling liquids and other materials, and customer-specifically tailored and manufactured polymer products. Our own mould design, compound development, and product and technique design guarantee product solutions that meet customer requirements today - as well as excellent opportunities for further development in the future. s success is based on great products, efficient production, and high-quality customer service. With each customer project, we aim to arrive at a cost-effective, durable, and functioning solution, whether it involves a customized or stock product. We reach our goals through motivated and knowledgeable staff, innovative materials solutions, and our solid experience of challenges in various industrial segments. 2

3 Production Materials development uses several, quite different materials in its products and develops entirely new mixtures whenever necessary. Almost without exception, customer products can be manufactured from materials whose properties match precisely the application intended for the product in question. Customer- and product-specific rubber mixtures are developed by both our mixing plant Sekoitukset Oy, in Kerava, and Oy, in Sastamala. Sekoitukset Oy manufactures high-quality rubber compounds. We provide proprietary mixture recipes that we have developed ourselves, putting many years of experience in the sector and knowledge of new materials to work, along with mixture recipes developed by our customers. We also have extensive and varied experience with other polymers, such as polyurethane, thermoplastics, thermoplastic elastomer (TPE) materials, liquid silicone, and Nyrim plastic. We ensure continuous development through close collaboration with our material suppliers. 3

4 Production Product development Going back many years, our extensive experience of diverse polymer materials, manufacturing methods, and applications enables high-quality product development, which we carry out in co operation with our customers. In-house product and mould design and materials development ensure that our product solutions meet all customer requirements. In our design work, we utilise various simulations, such as FEM and DEM calculation, and employ modern design tools (CAD/CAM tools and Creo). In addition to having in-house resources and a full-service measurement and testing laboratory, we engage in close collaboration with various research and product development entities to ensure that we can take advantage of the latest and most innovative discoveries. This co-operation guarantees diversified, fast, cost-efficient, and innovative product development that benefits our customers. 4

5 Production Rubber compounds Sekoitukset Oy manufactures technical rubber compounds as raw material for Group s factories and numerous other companies that make rubber products, of various types. The mixing plant has a capacity of approx. 6,000 tons and uses all of the most common rubber qualities and raw materials. The plant has three mixing lines (one intermixer and two tangential mixing machines, along with a gear pump for straining), a mixing mill, and a calender. Compounds can be supplied as strips, precut sheets, continuous sheets, or precise calendered sheets. Compounds can be manufactured in line with the customer s own recipe. Recipes can be developed in collaboration with the customer for a specific application, or the customer can be offered Sekoitukset Oy s existing, tried and proven mixing recipes. 5

6 Production Tuotanto Hose production The hose manufacturing and delivery process begins with evaluation of the use, application, and other requirements. We use this information to find suitable standard hoses, or, alternatively, we can determine the material and structure requirements necessary in the design of a customer specific solution chemical, temperature, wear, or pressure-resistance, for instance. Finally, these requirements are processed into data for the hose manufacturing process. The manufacturing station in hose production at the Vammala factory creates fabric- and wire reinforced hoses, curved hoses, and connecting hoses from various polymers as the use in question demands. The factory has several production lines, for different purposes, and uses numerous material alternatives to manufacture any hose structures that the customer may require. Hose manufacturing is based on the use of metal mandrels, which produce excellent dimensional accuracy and are suitable for manufacturing diverse hose constructions no matter the application. Highly automated hose production lines enable design and manufacture of many hose sizes. If needed, hoses that require special solutions can be manufactured manually. Precise quality requirements and efficient quality control and development measures in all stages of the process guarantee high production quality, in terms of both the manufacturing process and the products. 6

7 The large number of metal mandrels and moulds used in the manufacture of our connecting hoses and hose elbows guarantees that can always provide the customer with a suitable hose. The employees who produce connecting hoses have a high level of competence and many years of experience with these products and their manufacture, ensuring that even the trickiest shapes and structures are created in an efficient and sustainable manner. Additional services provided after the hose manufacturing processes are complete, such as bespoke connector assemblies and more demanding testing and documentation procedures, are becoming increasingly commonplace as customer demands grow. has extensive experience of such requirements and services, and we wish to remain at the forefront of development in all customer specific operations. 7

8 Production Tuotanto Rubber lining s extensive elastomer processing range includes lining of structures that uses rubber materials, or rubber lining. The most important applications include process equipment and tanks that could otherwise experience wear and tear and corrosion. s rubber lining solutions are used in the mining, energy, and chemical industries, among other fields. The design and manufacture of the rubberlined structure and also the lining work itself are standardised operations. s certified operation system guides both the structures design and manufacture and the documentation of quality assurance. Knowledge of processes and close collaboration with customers enable us to choose the correct materials and processing methods. The largest autoclave used on the production line for rubber lining is 3.8 m in diameter and 12 m long. It enables optimal vulcanisation of even larger pieces. Pieces of any size can be lined with rubber on the customer s premises. The materials used are either s proprietary mixtures that have stood the test of time or products provided by international material suppliers. This enables us to offer the best materials possible for use in our customers applications, always. 8

9 Production Products moulded from rubber Moulded products are manufactured in all size categories, as large series or in small batches. We manufacture moulded products from rubber, silicone rubber, and liquid silicone. We have an extensive range of production machinery. The processes use an automated injection moulding line, several extruders, and a wide selection of multiple-unit presses (of several sizes). The clamping force of our largest presses reaches thousands of tons, and our machine stock allows us to dimension moulds in the category of up to several metres. In-house tool manufacturing enables rapid turnaround from the design table to finished products. Moulded products are developed with 3D technology, and materials are simulated through FEM calculations. Moulds are manufactured with CNC lathes by the professionals in our in-house mould manufacture department or by approved business partners. We perform manufacturing of moulded products at both Finnish and Chinese units. 9

10 Production Tuotanto Products moulded from plastic manufactures customer-specific special products and standardised hoses and moulded products from plastic by applying die-casting and extrusion methods. The department s range of raw materials comprises all main types of thermal elastomer, basic plastics, technical plastics such as POM and PA, and PA + fibreglass compounds. There is wide variation in product size, from very small to extremely large. We can manufacture plastic products of up to 2,000 cm3 with our equipment. We can deliver both large and small series in accordance with customer needs. The quality of our production is guaranteed through extensive testing of materials, and we use a co-ordinate measuring machine for measurement of end products. 10

11 Production Moulded elastomers We develop and manufacture technical elastomer products from polyurethane, ceramic polyurethane compounds, and a material called Nyrim, for use in various industries. s strengths include a special precision casting technique for elastomers, mastery of manufacturing parameters, and a diversified range of mould solutions. Our modern casting machines enable us to manufacture castings large and small. This, in combination with highly skilled employees, guarantees the best possible products and services for all of our customers. 11

12 Products Tuotteet Industrial hoses and assemblies s areas of strength include both standardised and customised industrial hoses and hose assemblies for use in industry. Our service covers all parts of the process necessary, from evaluating the purpose and application of the product to specifying the correct materials and hose structures, all the way to manufacturing and delivery. Our hoses are used in the food, chemical, construction, mining, and mechanical engineering industries, among many other fields. Rubber is a flexible material that offers numerous advantages for transfer lines in terms of design, ease of use, and maintenance, be the product a light work hose or a heavyduty sludge transfer line. For instance, connections in a rubber hose can be changed easily as process requirements dictate. Being flexible, the rubber absorbs the kinetic energy of the substance transferred, dampens the impact on the hose, and cushions vibration caused by pumps. In addition, the rubber material is restored after its transformation without any damage. 12

13 Products Connecting hoses Flanged connecting hoses and compensators are used to prevent and dampen trembling, vibration, and sound conveyed to a pipeline; even out tension and thermal expansion; and facilitate installation work and design. Additionally, connecting hoses can be used as wear-resistant pipes and pipe elbows or in dosing and adjustment valves. The most typical applications of connecting hoses are found in the chemical, construction, and mining industries, but their universal applicability constantly increases their range of use. 13

14 Products Rubber lining Structures lined with rubber or other elastomers are used in several branches of industry to prevent corrosion and wear damage to various surfaces. Rubber lining makes structures maintenance-free and provides long-term protection against alkalis and strong acids. Rubber can be used to line steel, cast iron, acid-proof steel, and sometimes even concrete surfaces. provides products and services to the mining and process industries; the energy industry; and the chemical, forest, and maritime industries, among others what all these sectors have in common is processing of erosive elements, solids or sludge, or corrosive materials. 14

15 Products Mill linings We design and manufacture mill linings for the needs of the mining and process industry. All lining design proceeds from consideration of the customer s process and its requirements. We use 3D simulation in the design work, to aid in selection of the correct lining profile. Lining parts are manufactured from TRL rubbers that have been specifically developed for demanding applications in the mining and process industry. Our product range includes both rubber and steel-coated rubber linings with fasteners. We also provide our customers with lining installation service or monitoring of the installation work. Our extensive expertise, close collaboration with the customer, and many years of experience give us the ability to act as a trustworthy lining supplier. 15

16 Products Moulded elastomers Polyurethane elastomers are used for responding to challenging applications in which extremely good mechanical properties, excellent wear-resistance, tear-resistance, and protection against corrosion are required. The products either are made completely from polyurethane or are lined steel structures. These products are used in diverse ways, in many sectors of industry. For instance, Pucast polyurethane and Nyrim products are used all over the world in the process and mining industry, for mechanical wood processing equipment, and in demanding special applications. The applications of moulded elastomers include uses in the mining industry, electrotechnical industry, process industry, and machine and equipment industry. Our close co-operation with material suppliers strengthens our position as an elastomer expert. 16

17 Tuotteet Products Applications of elastomers are found in mineral processing, the process industry, and machinery and equipment manufacturing, among other fields. Highquality electrotechnical ESD and insulator components are made from special elastomers. can utilise its expertise to find the right solutions for all customers, whether in Arctic conditions or for tropical environments. 17

18 Products Technical rubber products Common applications of technical rubber products include bearings of various types, vibration dampers and sound insulators, gaskets, foils, and protection against corrosion and wear and tear. has at its disposal a broad range of polymer-based rubber compounds that offers the best solution for each application. Our extensive experience with numerous materials and their applications can assist the customer in selecting the right product. 18

19 Products Technical plastic products In the field of plastic products, specialises in thermoplastic elastomers that are required to have qualities similar to those of rubber or polyurethane and in technical plastic products from which special strength and dimensional accuracy are demanded. Our competence has earned the trust of the shipbuilding industry and suppliers of rail-attachment systems for the railway industry, among many others. High quality is guaranteed by top-quality materials and use of our co-ordinate measuring machine in daily production. 19

20 Products Silicone products Liquid silicone has excellent properties, so it is used for the manufacture of products for particularly demanding applications. Silicone retains its elasticity well and withstands ozone, UV light, and extreme heat and cold. Because it is neutral, silicone is well suited to use in the food and pharmaceutical industries. Our silicones also fulfil the RoHS (Restriction of Hazardous Substances) requirements of the electrical and electronics industry. In addition, can provide special UL 94 V0 approved, fireproof qualities. In our manufacturing techniques, diverse die-casting and multiple-unit press methods enable high quality creation of a wide range of products. Our products include respirator components; diving equipment; and films, bellows, lead-ins, accordion rubbers, and profile gaskets for dental instruments. 20

21 Products Customer-oriented solutions Partnership with a customer in product development entails long-term collaboration. We have mastered the design conditions and processing technology for diverse elastomer materials, and our strengths include skills in thorough mapping of the customer s needs and selection of the correct material, design, and manufacturing method to match those needs. s vision is to be the technology and materials leader in our chosen product and market areas. We want to provide the best delivery capability the market has to offer. Our model of operation includes provision of product and service packages that are appropriate for each client. Our objective and goal is to be a business partner that places a focus on the customer and supports the customers business operations. Reliable and accurate delivery and flexible service help to guarantee customer satisfaction. 21

22 Quality and the environment Customer satisfaction is a sign of quality for us at. A good customer relationship requires not only a good product but also professional service a positive image of the operation as a whole indicates success. In employees expertise, and we continuously develop and improve our materials. We invest heavily in occupational safety, prevention of errors and defects, and environment-friendly models of operation. collaboration with our customers, we develop solutions for their individual needs, deliver the products as agreed, and observe common rules when dealing with matters related to both the environment and industrialsafety. We work fully in accordance with a documented and certified system of operation: s Vammala, Kiikka, and Kerava factories have ISO 9001 and ISO certificates, and the Chinese factory has ISO We pay constant attention to the smoothness of our production processes and our 9001 certification. In addition, the Vammala factory has an ISO/TS certificate. 22

23 Principles of operation Deliveries Logistics Reporting Quality assurance Manufacture Customer requirement An integral part of the customer s product development, we aim for long-term co-operation, providing high-quality elastomer products. Research Training Design Subcontracting Raw materials We at aim at creating added value for our customers. The only way to succeed in this is to manufacture excellent products and services. In a nutshell, our entire operating principle can be presented as a cycle, starting from finding out the customer s needs and ending with the final delivery. The key is to identify the customer s needs and be familiar with the customer s process. Every project, whether old or new, starts by meeting with the customer to discuss their needs. After the charting phase, we begin the research work, adopt a new production method, if necessary, and carry out the design work and the potential subcontracting. The selection of raw materials is a separate phase that significantly affects the success of the end product. The manufacturing process includes careful quality control and efficient reporting, resulting in a product that matches the desired properties as closely as possible. Mould The process is finished off by the delivery and the logistics, but the cycle never really ends. Our development work continues on the basis of the experience gained and through new coatings and solutions. 23

24 Download Oy Vammala works Nokiankatu 1 FI Sastamala, FINLAND Oy Kiikka works Unto Korpelan katu 1 FI Sastamala, FINLAND Compounds Ltd. Sementtitehtaankuja 12 FI Kerava, FINLAND (Suzhou) Technology Co., Ltd 3 B Suchun Industrial Square 428 Xinglong street Suzhou CHINA in Russia Nevsky pr. 79/2, office St. Petersburg Russia T.OY-TEK Schlauchtechnologie GmbH Düsseldorfer Str. 134 D Mülheim GERMANY T-Plasztik Ltd. Tisza u. 4. H-5055 Jászladány Hungary JiPS.fi