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RubberWorld Volume 258, No. 4

The technical service magazine for the rubber industry.

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Vulcanisation technology – innovation of the extra class

For more than 40 years, we have been a partner to the industry and manufacture technologically sophisticated vulcanization systems in our production plant near Düsseldorf.

Through close research and development and innovative processes, Gerlach Maschinenbau has gained the technological leadership in the continuous hot-air vulcanization of rubber profiles.

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HeatStraD

The HeatStraD is used to validate and investigate the physical cross-linking behavior of elastomers.

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Stand-Alone PCT

The requirements for the reduction of environmental load are increasing and so it is for our machines. If your machines have not yet been equipped with a PCT system, we have some good news for you.

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Removal caterpillar BA 400

Our mobile, compact and yet powerful belt extractor BA 400 is i.a. suitable for the continuous withdrawal of rubber profiles (with and without steel reinforcement), hoses or plastic profiles. It is developed for a flexible and variable production process, ensuring safety regulations in accordance with EU directives.

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GAK – Effects of operating parameters on hot air vulcanisation

Holistic energy concept for hot air vulcanisation using innovative air flow and heat transfer

 

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ÖKOPROFIT district of Viersen

Certificate of successful participation in the ÖKOPROFIT 2016 project

Josef L. Rameckers Maschinenfabrik GmbH & Co. KG and Gerlach Maschinenbau GmbH

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Pre-shock type P 158

Pre-shock type P 158

Through the use of special short-wave infrared radiators, excellent profile surfaces as well as early dimensional stability with solid and moss rubber products are achieved.

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Pre-shock type V 116

Pre-shock type V 116 – Infrarot PreShock

With the type V116 we offer you the classic of the infrared pre-shocks. Through the use of special short-wave infrared radiators, excellent profile surfaces as well as early dimensional stability with solid and moss rubber products are achieved.

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Shock channel SHF 147 with UHF, PCT Shock channel SHF 145 with UHF

Hot air vulcanization duct with microwave support (UHF), designed for ultrafast profile cross-linking at high production speeds and high demands on the profile surface, the cell structure with moss rubber profiles and a rapid hardening of the profile geometry.

SHF 147, UHF, PCT
high-performance shock channel with microwave support and integrated Pollution Control Technology (PCT) for exhaust air cleaning in the efficient circulating air system.

SHF 145, UHF
high-performance shock channel with microwave support in the fresh-air system.

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Hot air shock channel HLK 111

Hot-air shock channel for ultra-rapid profile cross-linking. Compact and flexible shock module of the extra class.

The accelerated hot air flowing turbulently in the duct generates the fastest possible heat transfer. For further performance improvement, all our pre-shock variants can be optionally added.

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Cooling channel type 179

Specially designed surge nozzles characterize our cooling channel type K179. Even in extremely polluted and calcareous water, the cooling function is maintained by the permanent water flow.

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Caterpillar Type BA 501

Suitable for the continuous withdrawal of rubber profiles (with and without steel reinforcement), hoses or smaller plastic profiles

With the BA-501 belt extractor, we present an intelligent, easy-to-use, powerful machine concept
. Suitable for the continuous withdrawal of rubber profiles (with and without steel reinforcement), hoses or smaller plastic profiles.

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Flow burner type V119

With our flow burner type V119 we offer you a new gas-heated infrared PreShock.

Through the use of gas, this system offers maximum performance with low energy consumption. Air convection combined with infrared radiation is the ideal prerequisite for rapid pre-crosslinking of your rubber profiles.

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Triple hot air vulcanization channel HLK 106 and HLK 114

Modular hot-air vulcanization channel designed for the vulcanisation of flexible profiles and hoses.

HLK 106
Triple hot air vulcanization channel on three levels without water cooling.

HLK 114
Triple hot air vulcanization channel on three levels with additional water cooling on 2 levels.

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Hot air vulcanization channel HLK 110 with PCT, HLK 109

Modular hot-air vulcanization channel designed for the vulcanization of flexible profiles and hoses.

HLK 110 with PCT
Hot air vulcanization channel with integrated Pollution Control Technology (PCT) for exhaust air purification in the efficient recirculation system.

HLK 109
Hot air vulcanization channel with fresh air system.

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Vulcanization technology – Multifunctionality in a compact design

The focus is on the innovative possibility of a 360 ° pre-crosslinking as well as a power decoupling adapted to the profile geometry. Depending on the profile cross-section, material characteristics and production speed, the radiator temperature and thus the IR radiation intensity can be varied in some areas.

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Quality Management DIN ISO 9001

Use Certified Partners to ensure the highest level of safety, accuracy and quality.

Gerlach Maschinenbau GmbH relies on Quality Management DIN ISO 9001 when it comes to the design and construction of machines for rubber and plastics production with the fields of design, planning, machining, sheet metal processing, electrical engineering, final assembly and service as well as trade in machines and accessories.

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Hot air shock channel type 111

With the diverse options of our hot-air shock channel type 111, we offer a compact and flexible unit. By using special materials, shock temperatures of up to 550 °C can be generated. The accelerated hot air flowing turbulently in the duct generates the fastest possible heat transfer. For further performance improvement, all our pre-shock variants can be optionally added.

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Cooling channel type 179

Specially designed surge nozzles characterize our cooling channel type K179. Even in extremely polluted and calcareous water, the cooling function is maintained by the permanent water flow. Additional stowages allow the profile to be submerged and guarantee good heat dissipation. The built-in blow-off stations with rigid and flexible nozzle systems ensure perfect drying even for complicated profiles. The use of heat exchangers for connecting existing cooling systems is self-evident.

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Removal caterpillar BA 400

Suitable for the continuous withdrawal of rubber profiles (with and without steel reinforcement), hoses or smaller plastic profiles.

Belt extractor BA 400, developed for a flexible production process, ensuring safety regulations in accordance with EU directives. A comprehensive safety concept protects man and machine against injuries and damage.

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SHF 147

With the integrated exhaust air purification (PCT) and the tried and tested recirculation system, the SHF 147 shock channel is an efficient high-performance system. Designed for high production speeds, this plant technology is predominantly used in automotive profile extrusion. The modular construction in 3 m zones consisting of shock, microwave and hot air zones is supplemented by additional options, such as selective profile transport via driven rollers or conveyor belt, as well as other additional functions. As a result, you get a smooth and matte profile surface, fine cell structure with moss rubber, as well as fast solidification of the profile geometry.

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Pre-shock type P 158

Through the use of special short-wave infrared radiators, excellent profile surfaces as well as early dimensional stability with solid and moss rubber products are achieved. Characteristic for this machine is the radiator arrangement in four different planes and thereby a selective possibility of the 360 ° pre-crosslinking of the product. The machine equipment and very good power modulation, in the range 0 – 100%, enable high flexibility in production operation. For the support of the profile, removable guide rollers can be used with the possibility of an axial distance adjustment depending on the profile sag. The IR radiators are protected in all levels by special glass panes and the integrated cooling also ensures an increase in the service life.

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