Working method at RIS Rubber
We take a personal approach, working closely with our customers to develop the best solutions. As experts in rubber, we work with you to bring your ideas and requirements to life in the form of a finished product.
From design, engineering and the development of associated moulds to the production of the final product, you can leave everything to us. Fully customised, for every product and every need.
The production of moulded rubber products and rubber-to-metal bonded parts takes place in the Netherlands (Lelystad) and Bulgaria (Kula). Collectively, we have 100 moulding machines at our disposal. In addition to the Pressing department, the production process also involves the Rubber Preprocessing, Metal Preprocessing and Product Postprocessing departments. The moulds – shapers of the product – are designed and extensively tested in Lelystad before commissioning.
THE FIRST STEP:Â DESIGN AND DEVELOPMENT
The creation of every rubber product begins in the Research & Development department, where we design and develop new rubber products daily. This process is based on drawings and supported by FEM calculations. FEM (Finite Element Method) is a numerical analysis technique that enables us to simulate and evaluate the behaviour of the rubber product, helping to identify potential improvements. In addition, we select the appropriate rubber type and any other required materials. Once the design is finalised on paper, it is presented to the customer. Following approval, one of our mould engineers begins work on the mould.
THE SECOND STEP:Â SAMPLING PHASE
A mould gives the rubber its unique and desired shape. We design and test the mould at our location in Lelystad. The mould is constructed based on our in-depth knowledge of the rubber compound, the production process and the type of moulding machine. Once the mould is ready, we conduct a sample production run. Once the customer is satisfied, series production begins. To verify that the new rubber product performs as expected, this essential test phase is carried out meticulously.
THE THIRD STEP:Â PREPROCESSING
Every rubber product is unique in terms of size and composition. The rubber compound is delivered to the factory as a raw material; in most cases in a form that can be used immediately for production. If preprocessing is required, we handle it in-house.
For rubber preprocessing, the material is first blended into a homogeneous mass on a roller mill and, if necessary, cut to size using a slicing machine. If needed, RIS can also punch or extrude the rubber into the required form. Any scraps can be re-used after kneading on the roller mill mixer again, so no material goes to waste. Once the rubber has been preprocessed into the correct shape, it is sent to the Pressing department for production.
RIS specialises in co-vulcanising metal parts within a rubber product. To ensure proper adhesion between rubber and metal, we also pretreat the metal.
THE FOURTH STEP:Â VULCANISATION
Our machinery includes two types of moulding machines: injection moulding machines for smaller moulded rubber products and compression moulding machines for larger, heavier rubber products.
INJECTION MOULDING MACHINE
An injection moulding machine directly injects heated rubber into a mould. This method is particularly suitable for larger production runs because production times are relatively short. Additionally, an injection moulding machine can precisely inject the required volume, resulting in minimal waste. The products we make using our injection moulding machines range from tens of grams to a maximum of 20 kg. These include solid rubber products, rubber-to-metal bonded parts, and quite often, coloured products.
COMPRESSION MOULDING MACHINE
In a compression moulding machine, rubber is compressed under high pressure. The mould will already have been fitted in the moulding machine, and the rubber is manually placed inside for each product. The machine then closes with a clamping force of up to 2,000 tonnes. The combination of heat and clamping force form the rubber in the desired shape. The largest compression moulding machine at RIS has a platen surface area of 2,500 x 2,500 mm.
THE LAST STEP:Â POSTPROCESSING
Most moulded rubber products and rubber-to-metal bonded parts require postprocessing. This mostly manual process is carried out in a dedicated department within our factory. All rubber products leaving the factory undergo thorough inspection. This production step demands both time and precision.
Thanks to our wide range of rubber moulding machines, RIS can produce the desired product for every customer. Operating from two locations allows us to be highly flexible and deliver quickly. From single pieces to large production runs, from small to very large products, RIS can meet practically any need.
LET'S MAKE THINGS
TOGETHER
OPTIONAL STEP:Â TESTING
After postprocessing, there is an optional step: testing. We can either test each product individually or perform random sampling based on customer-defined requirements. This might include an additional hardness check or perhaps a shear test. RIS Rubber has a dedicated department that conducts various tests daily. The results of these tests are provided to the customer along with the products.
