1. Raw material problems

1.1 The water content of rubber raw materials is too high

The water content of rubber raw materials is too high, which is a frequent issue during the manufacturing process. Excessive water content causes the rubber to degrade and mold during storage and processing, reducing the product’s quality and service life. To address this issue, we implemented a number of actions, including:

Maintain stringent control over the acquisition of raw materials: choose suppliers of rubber raw materials who have undergone stringent testing and screening to guarantee that the raw materials’ water content falls within the acceptable limit.
To prevent raw materials from absorbing moisture during storage, maintain a consistent temperature and humidity level in the storage area.
Improve the drying process by completely drying the raw materials before processing them to make sure their water content satisfies industrial needs.

1.2 Excessive impurity content

The purity and performance of rubber goods will be directly impacted by excessive impurity content, which also raises uncertainty and the scrap rate throughout the production process. In order to address this issue, the following steps have been taken:

Strict raw material screening involves repeatedly removing contaminants from raw materials using chemical and physical screening techniques.
Enhance testing standards: To make sure raw materials meet standards, thoroughly test each batch for impurity content using state-of-the-art tools and techniques.
Enhance the purification process: Incorporate effective purification technology into the manufacturing process to eliminate additional impurities from the raw materials and enhance the product’s quality and functionality.

2. Formula problems

2.1 Improper selection of additives in the formula

additions should be chosen scientifically by conducting tests and analyzing data to determine which kinds of additions will work best to enhance the performance of the final product.
Optimize additive ratios: Precisely compute and optimize the quantity of additives used in accordance with the requirements of various goods to prevent adverse effects on product quality resulting from incorrect additive selection.
Constant observation and modification: To guarantee that additives serve the greatest purpose during the manufacturing process, keep an eye on the impacts of the additives and make modifications in response to real-world circumstances.

2.2 Imbalance in the proportion of various ingredients

Precise ratio computation: To guarantee the rationality and science of the recipe, the ratio of every component is precisely determined using sophisticated formula design software and technology.
Strict quality control: To prevent an imbalance in the ratio that might damage the product’s quality, the amount of each ingredient used in the production process is rigorously regulated.
Experimental verification: To guarantee the stability and consistency of the recipe, the ratios of each component are modified and optimized through a significant number of experimental verifications as well as real production testing.

3. Production process problems

3.1 Insufficient mixing

Optimize mixing equipment: Use efficient mixing equipment to guarantee that the raw ingredients and additives can be thoroughly blended.
Improve mixing process: According to the characteristics of different raw materials, modify the mixing duration and speed to guarantee that the mixing process gets the greatest impact.
Strict monitoring procedure: Using cutting-edge testing tools, the homogeneity, and consistency of the mixture are guaranteed throughout the mixing process, since the mixing condition is tracked in real time.

3.2 Incomplete gas discharge during molding

Enhance the mold design by making sure that the gas can be released smoothly, expanding the exhaust channel, and optimizing the mold structure.

Modify the molding parameters: Conduct tests to determine the optimal process parameters that guarantee the full discharge of the gas, and then modify the molding temperature, pressure, and time.

Employ vacuum molding technology: To further eliminate gas waste, vacuum molding technology is employed during the molding process of specific unique items.

3.3 Improper control of subsequent heat treatment temperature/time

Precisely regulate heat treatment temperature and time: To guarantee a stable and dependable heat treatment process, precisely regulate the heat treatment temperature and time using cutting-edge temperature control tools and technologies.

Create a standard process flow: Create a thorough heat treatment process flow and adhere to it carefully, taking into account the various demands of the product.

Constant monitoring and optimization: To guarantee that every batch of goods can meet the anticipated performance indicators, temperature and time are tracked in real time during the heat treatment process and adjusted based on the actual impact.

4. Prevention and solution measures

4.1 Raw material quality control

Ensuring the quality of raw materials is vital in the manufacturing and production process. Effective quality management of raw materials has the potential to save manufacturing costs, increase product quality, and decrease the rate of scrap. To make sure that every batch of raw materials satisfies the highest requirements and guarantees the quality and stability of the product from the source, we employ a number of stringent testing and screening procedures.

4.2 Strict raw material testing and screening

We have put in place a stringent raw material testing and screening method to guarantee the purity and quality of raw materials. Testing for physical characteristics, contaminants, and chemical composition must all be completed by each batch of raw materials. These exacting tests must be passed before any raw materials may be used in manufacture. By ensuring that each raw material utilized in the manufacturing process is of the greatest quality, these testing, and screening procedures reduce production risk and quality issues.

4.3 Reasonably reduce moisture and impurity content

The management of moisture and impurity levels is crucial for raw material quality control. While contaminants will immediately damage the product’s performance and purity, an excessive moisture content might cause raw materials to decay or mold during processing and storage. To guarantee the purity and stability of the raw materials, we employ cutting-edge drying and purification technology to appropriately lower the moisture and impurity content in the raw materials. By taking these steps, the products’ shelf life is increased in addition to their quality being enhanced, giving consumers higher-quality, more dependable products.

5. Optimize formula design

5.1 Select appropriate types and amounts of additives

A fair selection and use of additives can greatly enhance the performance and quality of the product. Through extensive testing and analysis, we have identified the optimal types and amounts of additives to guarantee that every product can achieve the desired effect and quality standards. At the same time, we strictly control the amount of additives used to avoid side effects and cost increases caused by excessive use. A variety of additives have different functions and effects.

5.2 Adjust the ratio of each ingredient to improve the stability of the formula

The product’s performance and quality are closely correlated with the formula’s stability. We continually modify the ratios of each element to determine the ideal combination to increase the stability of the formula while improving the formula design. These modifications can improve the product’s performance to satisfy a wide range of client requests, in addition to guaranteeing that the product maintains a consistent quality across batches and production settings. We adjust and optimize the recipe using cutting-edge technical tools and scientific techniques to make sure every product is ready to be offered to clients in the best possible condition.

6. Improve the production process

6.1 Strengthen the control of the mixing process

Controlling the mixing process is a crucial phase in the production process that guarantees the product’s quality and homogeneity. To get the ideal ratio, we may make sure that the additives and raw materials are well combined by tightening up the control over the mixing process. To guarantee consistency and uniformity in every batch of mixes, we employ sophisticated mixing equipment and rigorous process parameter control, which enhances the product’s overall performance and stability.

6.2 Optimize the molding process to ensure that the gas is fully discharged

Another crucial step in the production process that has a direct impact on the product’s final form and quality is the molding process. We give the issue of gas emission particular consideration when we optimize the molding process. We make sure that the gas can be completely released throughout the molding process to prevent the creation of pores or faults inside the product by refining the mold design and molding parameter management. This boosts the product’s physical attributes and longevity, in addition to improving its aesthetic qualities.

6.3 Precise control of subsequent heat treatment parameters

One of the crucial processes that influences a product’s performance is heat treatment. Accurate management of the conditions for the subsequent heat treatment may greatly enhance the goods’ durability and mechanical qualities. Using extensive testing and data analysis, we establish the ideal heat treatment temperature, duration, cooling rate, and other factors. Ensuring that all product batches fulfill customers’ high quality criteria and expected performance indicators is ensured by strictly implementing these control procedures.