7 Ways That a Rubber Extruder is Used in Everyday Life

Rubber Extruder

Rubber extruders are extremely useful pieces of machinery that can be used in a variety of applications. From creating custom gaskets to creating rubber seals, there are many everyday products that are manufactured by rubber extruders. Here, we’ll explore 7 products that are used daily.

1.    Tires

In automobile manufacturing, rubber extruders are used to create tires components. One application that they are used in is to form a continuous rubber strand of a specific width and thickness for the tread of the tire.  Often times multiple extruders are used to combine different rubbers into very specific tread profiles to offer the ultimate tire ride as well as durability.

The quality of the extrusion process is essential for the safe and reliable operation of a vehicle. At Steelastic, we utilize rubber extruders for calenderless tire manufacturing. This innovative process saves time, materials and labor when manufacturing tires.

2.    Windows

In the construction industry, rubber extruders are often used to make seals for windows, doors, and other items that need to be airtight. The rubber seals made by the extruder can be used to help reduce drafts and improve insulation, as well as create an aesthetically pleasing look. Additionally, rubber seals can be used to reduce noise levels and create better soundproofing. The rubber seals made through the extrusion process can also be used to protect against dust, wind and moisture.

3.  Manufacturing

Rubber extruders are used to create custom parts for machinery that needs to function in specific ways. This is often done to improve the safety and efficiency of the machinery. These components can include seals or gaskets.

The extrusion process shapes the rubber into the desired shape and size, to ensure that the parts are accurately sized and shaped to fit for optimal performance. The rubber extruder also helps to reduce material waste and manufacturing time, making it an efficient and cost-effective way to create custom parts for machinery.

4.    Medical Devices

In hospitals, you can find tubes and custom seals for medical devices

5.    Footwear

Did you know that custom soles for shoes are made from rubber extruders? Through this process, manufacturers can create highly customized soles that provide the perfect combination of cushioning, support, flexibility, and durability. This helps to ensure that the shoe will provide the necessary comfort and support to the wearer while they are walking or running.

Additionally, rubber extruders can be used to create soles with special features, such as grooves or treads, that can further enhance the performance of the shoe. This makes rubber extruders an invaluable tool for shoe manufacturers, as they allow them to create the perfect sole for any type of shoe.

6. Sport Equipment

Rubber extruders are used in sports equipment to form rubber grips, such as handles on golf clubs, tennis rackets, and bicycle handlebars. The rubber can also be used to make protective padding for sports helmets, padding for shoes, providing both comfort and safety.

7.    Toys

Rubber extruders are used to create rubber components for children’s toys, such as rubber handles for toy vehicles, rubber wheels for toy cars and rubber tubing for water guns. The rubber components are then incorporated into the final product, such as a plastic car with rubber tires. In addition, rubber extruders are also used to create rubber stoppers and seals for toy containers, such as those used to store plastic blocks or stuffed animals.

Discover Steelastic: The Technology Moving You Forward

Overall, rubber extruders provide versatile and value products for our everyday life. From automotive parts to medical equipment, people around the world benefit from rubber extruders. Learn more about the rubber extrusion process at Steelastic. Visit our website and learn how we lead the way forward with tire technology.

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Advantages of Steelastic’s Calenderless System

Calenderless System

Discover the advantages of Steelastic’s calenderless tire manufacturing system, and how it affects your ability to be flexible, lean, dependable—and deliver on your ROI.  

Table of Contents  

Calenderless Tire Manufacturing

What is Calenderless Tire Manufacturing?

For years, tire manufacturing has relied on the calendering process to produce the reinforced  rubber materials that are used to create the components within a tire. Calenderless Tire manufacturing relies on extrusion to create these same tire components.  

In this post, we will explore the calendering process more in-depth, and you will discover how going calenderless can be a great advantage to your company.  

Components Produced

At Steelastic, we support you with the calenderless equipment you need for quality tire components.  

Our extruders produce the following components so that you can produce exceptional tires:  

  • Tread  
  • Sidewall  
  • Cap Strip  
  • Radial Belt  
  • Body Ply  
  • Inner Liner & Single Compound Components  
  • Bead Apex  

Equipment Required

When you choose a calenderless tire production system, you’re choosing a simpler manufacturing process that requires less capital equipment.  

The chart below compares the equipment needed for calendering versus a calenderless system.  

Capital Equipment Required Chart

Advantages of Going Calenderless

The future of tire manufacturing is here. Discover the benefits of calenderless tire production. 

Lower Total Cost of Ownership

When you’re considering an investment in tire technology, it’s critical to assess the entire cost of ownership – not just operation. When you choose Steelastic’s proprietary calenderless system, you can save money. Here’s how:  

Lower Cost of Equipment

Equipment can be a huge capital investment, but it doesn’t have to be. If you are planning to produce fewer than 6 million  tires per year, the cost of Steelastic’s calenderless system might be for you. With a lower investment, tire manufacturers can pay off their equipment more quickly and receive a quicker return on their investment.  

No Special Foundation is Required

Traditional calendering equipment is large and heavy, requiring a special foundation and additional cost. When you choose Steelastic, you don’t need to lay a new foundation.  

Lower Utility Usage

Tire production requires a variety of utilities, but when you choose a calenderless tire production process, your annual cost is far lower. In fact, if you’re producing 6 million tires per year, your annual savings could be nearly $500,000. That’s a 12% savings in operating costs that goes straight to your bottom line.  

Yearly Energy Costs Breakdown Comparison Chart

More Flexible

A hallmark of the calenderless tire manufacturing systems is its modular design that allows for quick changeovers, lending itself well to flexibility.  

Tire manufacturers can process a variety of materials, including steel, aramids, nylon, fiberglass, rayon, polyester and more, making it well suited for multi-SKU applications.  

Quicker Delivery

The typical lead time for a calenderless tire manufacturing system is 50-54 weeks depending on the size and complexity of the equipment. Due to the small footprint and more simple nature of the machine, tire manufacturers can expect an installation time of 2-3 weeks. This is nearly half of the installation time needed for a traditional calenderless system.   

Lean Operation

Efficient Human Resources

A traditional calendering system requires multiple workers, but a calenderless cutter system requires only one. This allows plant managers to utilize workers more efficiently in other parts of the tire production process.  

The simple design of the calenderless system expedites the training process, allowing workers to be fully trained in months, as opposed to years of training required for the traditional calender component preparation production methods.  

Less Waste

When you go calenderless, you create less waste. It’s a single extrusion process, from raw materials such as cord and compound to a finished component. Without a need to stage calender material, the calenderless system produces less than 1% overall scrap.  

Higher Quality

The calenderless system gives precision belt width, gauge and angle control, resulting in higher production control and consistency. In fact, the combined cutting and splitting operation found in the calenderless system ensures that splicing is highly repeatable and consistent. This creates higher quality tires with a straight belt edge and improved cord control and position—and superior rubber-to-cord adhesion.  

A Trusted Partner

Did you know that we’re trusted by more than 700 companies around the world? With calenderless machines on five continents, Steelastic has built a reputation for trust and reliability, following three principles.  

1. Partnership

When you purchase from Steelastic, you can be sure to find a true partner in business. We’ll listen to your needs, adapt and support your business goals.  

2. Flexibility

At Steelastic, we understand the rubber industry’s diverse and changing needs. That is why we’ve built and adapted the calenderless tire manufacturing equipment to fit within your existing production line, supporting your current needs, instead of requiring the manufacturing process to align with a pre-determined output. 

3. Field Support

When problems do arise, you can depend on Steelastic to show up with support, audits, preventative maintenance and training when you need it most.  

Request a Quote

Deciding on a supplier for your tire manufacturing equipment is a big investment. We understand that. 

But if you’re ready to learn more, contact us for a no-pressure conversation. We’re here to learn about your business, your needs, and how we can support you.  

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The Pros and Cons of a Calenderless System

Calenderless Cell

Since 1970, the Steelastic Company has been moving the world forward with tire technology. We offer most of the equipment you need for tire component manufacturing, offering products for both the traditional calender and calenderless manufacturing.  

What is ‘calenderless’ tire manufacturing?  

Calenderless tire manufacturing combines principles of lean manufacturing with the latest tire technology. Traditionally, tire manufacturers rely on calendaring to process their rubber into components that can be used for tire construction.  

As time and technology progress, some things change. And that can be a good thing.  

Steelastic’s calenderless tire manufacturing system is an extrusion-based system that produces belt/breaker, body ply, cap strip, inner liner, sidewall, tread, and bead apex. But what’s so great about going calenderless anyway?  

The Pros of a Calenderless Tire Manufacturing System 

Reduced Wastage

A calenderless system allows tire manufacturers to produce shorter runs of various tire types and sizes. This reduces waste, as it allows tire manufacturers to produce different types of tires, without wasting resources for a longer run on the manufacturing line.  

Lower Cost

When waste is reduced, it lowers the overall manufacturing costs and increases net profits.  

Additionally, when companies go calenderless, they no longer need expensive and bulky calendaring equipment or off-line processing equipment.  

Increased Efficiency

A calenderless system is a more efficient use of resources, time and labor. As an automated process, it reduces labor costs, and cycle time, while increases production capacity so you can hit your goals for manufacturing and profit margins.  

Increased Quality Control

Traditional calendaring requires precise measurements on large production volumes that are difficult to obtain. Using a calenderless system inherently reduces the complexity of the system and ensures the highest quality for your tire manufacturing company.  

Complexity of System

A calenderless tire manufacturing system is a single cell operation.   Raw materials are input into the system and finished tire component preparation materials are produced.   While it has a smaller footprint and requires less overall equipment, it is not a simple machine. However, the complex nature of a calenderless system is much less than that of the calender solution.  First of all, the calenderless equipment can be supplied in two thirds of the time frame of the calendered solution.  Also, operators can be training to be experts is months as opposed to years.  However, at Steelastic, we understand that our customers still need our support and that’s why we offer 24/7 service support that is available on the phone, online or in-person, and strategically placed around the globe to offer support when you need it most.  

The Cons of a Calenderless Tire Manufacturing System 

Large Capacity Tire Production Requirements

The calenderless system cannot match the production volume capabilities of a calender system.  The calender process is capable of mass producing a singular specification material at a very high rate.   This tends to lead to a slight advantage to calendered solutions on facilities that produce more than 6-7 million tires per year.   

Initial Cost of Installation for large volume plants

Every change in manufacturing systems has a cost, or investment, depending on how you look at it. While a calenderless tire manufacturing system is costly, we think that the efficiency and flexibility gained makes it a worthwhile investment in the future of tire manufacturing.  

Schedule a Free Trial  

Are you interested in learning more about the benefits of calenderless tire manufacturing? See it firsthand at our headquarters in Cuyahoga Falls, Ohio. We will show you our calenderless manufacturing system, so that you can conduct trials to produce tire components to your own specifications. After the trial, we will pack and ship the components to your facility for tire building, testing and validation. Schedule a trial >> 

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