Solving Problems in Rubber Compounding and Processing - 1 Day Course

Course Number: AP3239
Time: 8:00 AM - 4:00 PM
Location: Houston, Texas
Cost: $1,000 USD
SAVE $50 by taking with "Compounding for Performance" OR "Understanding Raw Materials, the Building Blocks of Rubber Compounding".
SAVE $100 by taking with "Compounding for Performance" AND "Understanding Raw Materials, the Building Blocks of Rubber Compounding".
CEU's: 0.75
Instructor: John Dick

Course Overview

This course is crucial for anyone in the rubber compounding field. It provides an in-depth look at processing problems in mixing, extrusion, calendering and molding. Statistics and methodologies for solving factory problems and case studies are covered as well. Participant’s current processing problems can be discussed with the instructor.  The course includes a copy of John Dick's book, How to Improve Rubber Compounds (Hanser Publications).

Take this course with "Compounding for Performance" and/or "Understanding the Global Raw Material Supply Chain to the Rubber Industry" for registration savings.

Course textbook:

How to Improve Rubber Compounds




How to Improve Rubber Compounds - 2nd Edition by John Dick


Course Outline

Introduction to Factory Problems

  • Plant receiving area
    • Cold flow
    • Stability of pre-powdered blends


  • Quality of mix
  • Uncured elasticity (nerviness)
  • Viscosity
  • Dispersion
  • Bloom
  • Green strength
  • Tackiness
  • Stickiness
  • Lump-mill bagging
  • Mill back rolling


  • Die swell
  • Extrusion rate
  • Appearance (surface smoothness of extrudate)
  • Shear thinning

Calender Release

  • Blisters
  • Calender release


  • Mold release
  • Mold filling
  • Non-fills
  • Porosity
  • Shrinkage of the cured part
  • Backrinding

Statistics and Methodologies for Solving Factory Problems

  • Basic statistical methods to identify special causes of variation
    • Important principles of Statistical Process Control
    • Random variation vs. special causes
    • Establishing control limits and specification limits
    • Methods to detect special causes of variation

Corrective Actions in the Short Term

  • Develop a SOP for taking corrective actions for short-term problems
  • Develop a strategy for establishing long-term solutions to chronic problems
  • Brainstorming for solutions to problems
  • Cause and effect diagrams

Six Sigma Techniques for Solving Chronic Rubber Factory Problems

  • Methodology
  • Statistical methods
  • Examples of success in the rubber industry

Nature and Techniques for Solving Problems in Rubber and Compounding and Processing

  • Changing one variable at a time techniques for improvement of a rubber compound
    • Advantages and disadvantages
  • Applying a Design of Experiment
    • Advantages and disadvantages
  • Interactions
    • Multiple response interactions of compound properties
    • Chemical interactions of compounding ingredients

Case Studies of Rubber Compounding and Processing Problems

Different case studies that include processing and compounding problems will be discussed and reviewed in interactive groups. Then overall discussions will take place to discuss possible solutions and methodologies.

The course textbook, How to Improve Rubber Compounds, will be used throughout the course and during exercises.

Course Registration

General Course Registration:
Download a Printable Registration Form [PDF].

Registration Information:
Registration for a class is due three weeks prior to the scheduled class date.

All registrations must be guaranteed by check, a purchase order number or a credit card, otherwise the registration will not be processed. Checks should be made payable to "The Akron Polymer Training Center" and must include a copy of your completed registration form. COURSE FEES ARE DUE PRIOR TO ATTENDING.

All registrations whether by phone, fax or mail will be confirmed and considered binding and subject to all cancellation policies. If you do not receive a confirmation prior to the class, please call The Akron Polymer Training Center to verify your registration.

Course fee includes classroom instruction, instructional materials, parking permits, continental breakfast, lunch, beverages, and refreshment breaks. Travel and hotel accommodations are not included.


Visit our registration webpage to view our cancellation/withdrawal policies.

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Akron, OH 44325
Phone: 330-972-7111
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