Solving Problems in Rubber Compounding and Processing - 1 Day Course

Course Number: AP3239 - Last day to register is October 29, 2015
Date: 11/13/2015 - 11/13/2015
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".
SAVE $150 off the registration fee of any course for companies who send 3 or more people to this training event.
Hotel Accommodations: If you are in need of hotel accommodations for this short course, the APTC has reserved a "special group rate" for the Marriott SpringHill Suites.
Book your group rate for The University of Akron (APTC)
(You must register by October 19, 2015 in order to lock in the special rate)
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.