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In-Plant-MaterialsOptimization

Presented BySpecialty Elastomer Recovery, Inc. (SERI)

SERI

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PRESENTATION Guiding Principals Process Polymers Processed Quality Assurance Additional Capabilities & Process

Development Suggested Procedure for In “In Process

Materials” (IPM) Optimization Practice Summary

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Who is SERI? Leader in Fine Elastomeric Powder

Technology Process Recovered FKM and High-end

elastomeric Materials to a 325 Mesh Powder

ISO Certified Excellent R&D, Pilot Plant, Laboratory and

Customer Support Unique and Proven Technology Continual Process and Product

Improvements

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SERI Manufacturing Facility

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SERI

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SERI FKM Procesing Line

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SERI Warehouse

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Guiding Principles Assist Material Approval Process Assist In Collection, Optimization and

Implementation Demonstrate Economic and Value Successful Long Term Relationship

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Objective Objective is

to Recover, Reduce, Reuse, and fully Recycle IPM Materials in a cost

effective, viable, and environmentally sound manner.

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CAPABILITIES Process many cured polymers into precise gradations

and surface morphologies. Strict adherence to QC measures which insure zero

contamination. Includes both virgin and recyclable elastomers. Finished particle size tailored to customers specific

needs. Finished powder down to a minus 325 mesh particle. Process is energy efficient, environmentally sound. Produces highly uniform products with high yields.

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The Process1

Receive

Sample(s)

2Process

to aGradation(s)

3 Lab

Evaluations

4Make Process Adjustments

If Necessary

5Feasibility

Finalize Parameters At Mfg. Facilities

6Begin Collection

&Processing

7Continue ongoingProduct/serviceimprovements

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Process Quality Assurance– Multi Elastomer Processing Two manufacturing lines.

Line 1 – Strictly FKM Materials (Black and Colors) Line 2 – Other High-end Elastomer Materials

Specialized high-pressure rotating steam cleaning system for all pipes in system.

Water flush through grinding and dewatering system. Optimal equipment engineering design to

accommodate thorough and efficient cleanout between every material produced.

Line 1 and Line 2 are contained in separate areas divided by a concrete wall with individual packaging systems.

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“In Process Material” (IPM) Optimization

Closed Loop IPM

Methodology

Materials Products

Manufacturing Operations

IPM Loop

Manufacturing

Plant Site

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Merits of an “IPM” Practice

Waste streams become resources No Chemistry Changes No Process Modification No Material Alterations Utilization of Existing Resources & Procedures Internal Cost Savings Competitive Cost Advantage Improved Production Performance Eliminate landfill burdens (cost & liability)

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Goal → Recapture “In Process Materials”

Present Practice

Landfill

> In ↓ Out $ IPM Practice

IPM Optimization

< In ↑ Out $

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THE PROCESS

The basic grinding process is called – UltraFineTM

The uniqueness is grinding in fluids, preferably water, with or without additives to achieve precision gradations, uniform chemistry, and surface morphologies

The process when used as a compounding system then becomes an IPMTM process

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The UltraFine “IPM” Process

Feed Hopper

MillingRare EarthMagnets

Conveying

Conveying

Rare EarthMagnets

Slurry Hopper

Filtration

Conveyor

Conveying

Packaging

Rare EarthMagnets

Screening

SHIPPINGCustomersCustomFine GroundElastomericPowders

Feed Hopper

RECEIVINGCustomers“IPM”

Drying

Pollution Control

Water Make-up

PumpPump

Wet Grinding

Note: Heavies & Light Contaminate Ends Removed

Conveying

Conveying

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Nature of UltraFineTM PowdersHigh Surface AreasUniform ChemistryUniform GradationsClean FlowableReplaces Costly Polymer EquivalentsHigh YieldsEnergy & Environmentally Sound

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Rubber Material: FKM Compound with 25% SERI 170 mesh Regrind Material

PROPERTIES:   Unit Results Results

Test Pieces 214 Orings     No Regrind 25% FKM Regrind

Original Hardness, Shore A (ASTM Slab) point 75 75

Properties Hardness, I.R.H.D. point 70 71

  Tensile Strength MPa 14.0 13.9

  Ultimate Elongation % 251 236

  Modulus @ 100% Elongation,Mpa % 6.3 7.2

Heat Aging Change in Hardness, Shore A point 0 +1

  Change in Tensile Strength % +39.9 +40

250°C x 70 hrs. Change in Ultimate Elongation % -19.1 -21.8

Immersion in Liquid Change in Hardness point -2 -1

Fuel C Tensile Strength % -7.7 -9.6

  Ultimate Elongation % +1.9 -1.8

23°C x 70 hrs. Change in Volume % +2.8 +2.2

Immersion in Liquid        

Methanol Change in Volume % +3.7 +3.0

23°C x 24 hrs.        

Compression Set Compression = 25% % 17 16

175°C x 22 hrs.      

SERI

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HNBR Compound with 25% SERI 170 Mesh Regrind Material

PROPERTIES:   Unit Results Results

Test Pieces ASTM Dumbells   No Regrind 25% HNBR Regrind

Original Hardness, Duro A point 73 73

Properties Tensile Strength MPa 29.30 29.4

  Ultimate Elongation % 225 238

  Tear Die B kN/m 21.43 25.06

Heat Aging Change in Hardness point +1 +1

  Change in Tensile Strength % +7.4 +2.7

120°C x 70 hrs. Change in Ultimate Elongation % +1.3 -2.1

Immersion in Liquid Change in Hardness point -10 -11

Fuel C Tensile Strength % -70.3 -61.0

  Ultimate Elongation % -47.6 -42.4

30°C x 48 hrs. Change in Volume % +37.7 +37.3

Immersion in Liquid Change in Hardness point -10 -12

Fuel C +M10 Tensile Strength % -71.3 -75.0

  Ultimate Elongation % -52.4 -53.5

30°C x 48 hrs. Change in Volume % +56.7 +56.9

Immersion in Liquid Change in Hardness point -10 -11

Fuel C +E20 Tensile Strength % -71.6 -72.3

  Ultimate Elongation % -51.1 -54.5

30°C x 48 hrs. Change in Volume % +53.9 +53.7

Immersion in Liquid Change in Hardness point -8 -9

Fuel C +MTBE15 Tensile Strength % -67.9 -66.7

  Ultimate Elongation % -48.4 -47.2

30°C x 48 hrs. Change in Volume % +36.0 +36.4

Compression Set Compression = 25%% 10.6 11.0

120°C x 70 hrs. Plied Slabs

SERI

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Dynamics of the UltraFineTM

Wet Grind System

Precision Intimate Grinding in a Fluid

System

Customer

Specialty Polymer(s)

Precision Tailored Ground

UltraFineTM Powder

Light End Contaminates Removed

Heavy End Contaminates Removed

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Custom Tolling - UltraFine™ “IPM” Flow Loop

Customer –Facility1. Collecting Source Separated Materials2. Labeling3. Shipment

SERI RECEIVING4. Receiving5. Storage6. Production Scheduling

UltraFine PROCESSING7. Primary Reduction8. UltraFine Grinding9. Precision Screening

SERI PACKAGING10. Drying11. Packaging/pre-weigh12. Warehousing

SERI SHIPPING 13. Product Certification14. Final QA/QC15. Material Balance16. Shipment (Round-Robin)

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Present to Future Practice

Customer IPMConverted to CG-

FKM-170 UltraFine Powder Back to High Quality

New Parts

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The Benefit

Maintain Product Properties

Eco

nom

ic V

alue

, $

IPM Value, Time

Landfilling, $ Losses, Stop

Generally Improved Manufacturing Experiences and Significant Economic Benefit

Transition

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Future Improvements

FKM

Teflon

AflasFQM

New Specialty

Development in Time

Savi

ngs/

Profi

t

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SUMMARY OF SERI’S SERVICES TO CUSTOMERS Established Certified For Quality and Methodology Professional Staff and Services Confidentiality Precision Grinding to Produce

Specified High Quality UltraFineTM Powders

Partnering for Future Innovation and New Developments

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Result Reduced Material Costs Capture Lost Opportunity Value Improve Production Leading Edge Opportunity Improve Product Margins Maintain Competitive Edge

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Thank You

An “IPM” Partnership

SERI

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Shipping Area

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Receiving Area

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Back of Manufacturing Facility

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Manufacturing Facility

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SERI Manufacturing Facility

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Direct line to the power company