Sustainability through Testing - MSME Perspective

BY

DR. K. RAJKUMAR Indian Rubber Manufacturers Research Association

Affiliated to DIPP, Ministry of Commerce & Industry, Govt of India

B-88, Road No. 24, Wagale Industrial Estate, Thane West, Maharashtra 400604

Email : rk@irmra.org , director@irmra.org ; website : www.irmra.org

Importance of testing

MSME industries do not give importance to testing due to which they :

- face huge rejection

- face huge penalty

- unexpected loss

- not budgeted cost

Less competitive

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COST OF POOR QUALITY • The rejection and rework - adds to cost of poor

quality i.e

• Rejection and reworks leads to big loss in terms of time and economy.

• The lack of inspection / testing and absence of control measures at appropriate stage, leads to not only financial loss but also delay in execution of order.

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Importance of testing to segregate quality

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Environmental hazard ??

• Disposal of rejected materials - an environmental issue and hence, the industry has to face several consequences.

• All these issues make industry less competitive / loss of business / loss of customer and finally to closure of Industry.

Solution :

• Testing of raw materials and in process materials at appropriate stage during manufacturing and will give benefit of becoming sustainable.

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Reduce the Cost of Poor Quality

• Importance of testing to minimise overall cost of poor quality.

• IRMRA conducts several skill development & training activities for MSME sectors emphasising the role of testing and its importance to become sustainable.

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Parameters to check

Basic chemicals”

– Appearance

– Volatiles content

– Ash content

– Solubility test

– Identity (IR spec)

– Assay ( GC/HPLC) or Chemical methods.

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Materials Function

Elastomer/raw rubber Basic components in rubber compounding

Fillers Used for reinforced or modified the mechanical properties

and also to reduced the cost

Plasticier To ease the processing, to modify the specific properties

and also as extender’

Anti oxidant To protect the rubber from ageing

Accelerator To increase vulcanization process and reduced the time of

vulcanization

Activator To increased the accelerator efficiency

Vulcanization agent Needed during vulcanization process to produced a

crosslinking

Other ingredients Used for specified purpose such as for coloring, as retarder

etc

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Chemical testing of Finished products

• Polymer Identification: Some of the basic polymer can be

identified easily by this technique.

• Burning characteristics

• Beilstein Test (copper wire test)

• Action of 80% Sulphuric acid

• Action of Conc. Nitric acid

• Pyrolysis test

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Identification of Rubber by chemical test

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Acetone Extraction

• Test Apparatus : Soxhlet assembly.

• Test Method : ASTM D 297 –93

• Need for Testing :

• Determination of the following ingredients:

• Polymer identification.

• Free sulphur.

• Antioxidants.

• Accelerators.

• Waxes, mineral oils.

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Ash content

• Test Method : ASTM D 297-93.

• Need for Testing

• Quality control,

• Inorganic filler determination.

• Zinc oxide determination

• Elemental analysis.

• Test Procedure : The samples are heated in a muffle furnace at 550 ± 250C (direct method). 900 ±250 C (indirect method). All organic matter will be oxidized and inorganic ash will remain

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Sulphur Analysis

• Test Method : ASTM D 297-93.

• Types of Determination :

• i). Free sulphur.

• ii).Total sulphur.

• iii).Combined Sulphur.

• Free sulphur is determined by using extracted portion of acetone extract.

• Total sulphur analysis is carried out on an untreated sample.

•

• Combined sulphur =Total sulphur – Free sulphur

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Liquid Swelling

• Test Method : ASTM D 471 –98.

• Methods of Testing : Gravimetric change.

• Volumetric change.

• Dimensional change.

• Parameter measured:

• 1. Change in mass

• 2. Change in volume

• 3. Change in hardness

• 4. Change in tensile

• 5. Color change of liquid

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Need for liquid swelling

• Rubber products in service are subjected to various types of

liquid environments.

• Due to absorption or extraction of rubber liquids, the rubber

component will either shrink or swell.

• By swelling, mechanical and functional properties of the

component deteriorate. Also dimensions of the component may

change.

• The component will not be serviceable

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Standard test oils

• ASTM oils, 1, (ap-124oC)

• ASTM oils 2, replaced by IRM 902 (ap-93oC)

• ASTM oils 3 replaced by IRM 903. (ap-70oC)

• ASTM oils 5(ap-115oC)

LOW ANILLINE POINT THE MORE SEVERE THE

SWELLING ACTION BY THE OIL

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Standard test liquid

• Fuel A Iso octane 100

• Fuel B Iso octane 70 Toluene 30

• Fuel C Iso octane 50 Toluene 50

• Fuel D Iso octane 60 Toluene 40

• Fuel E Toluene 100

• Fuel F Diesel fuel

• Fuel G Fuel D 85 ethanol 15

• Fuel H Fuel C 85 ethanol 15

• Fuel I Fuel C 85 methanol 15

• Fuel K Fuel D 15 methanol 15

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Effect of liquid swelling

• Solvent resistant rubbers

• NBR gasoline and oil-resistant applications

• Neoprene aliphatic Hydrocarbons .alcohol, glycol, slightly inferior

than NBR as oil resistant

• Hypalon -extremely resistant to most chemicals, oils and greases

and hypo chloride. resistance to micro organism and salt water

(marine application)

• Viton- aliphatic, chlorinated solvents, animal and vegetable oils at

higher temp.

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Case study (1) Company Name XYZ Rubber company

Prduction Log sheet

Date shift Lot No. Batch No. Qty prodn cost ?

10-09-2018 I 100 1 120 10200

I 2 120 10200

I 3 120 10200

I 4 120 10200

I 5 115 9775

II 6 120 10200

II 7 110 9350

II 8 95 8075

II 9 120 10200

II 10 120 10200

II 101 1 120 10200

II 2 117 9945

III 3 120 10200

III 4 120 10200

III 5 125 10625

III 6 120 10200

III 7 120 10200

III 8 120 10200

III 9 120 10200

III 10 120 10200

2362 200770

No. of days 25 59050 5019250

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Case study 2

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Company Name XYZ Rubber company

Prduction Log sheet

Date shift Lot No. Batch No. Qty prodn cost ? Segregated

10-09-2018 I 100 1 120 10200

I 2 120 10200

I 3 120 10200

I 4 120 10200

I 5 115 9775 115 Rejection

II 6 120 10200

II 7 110 9350

II 8 95 8075 95 Rejection

II 9 120 10200

II 10 120 10200

II 101 1 120 10200

II 2 117 9945

III 3 120 10200

III 4 120 10200

III 5 125 10625 125 Rejection

III 6 120 10200

III 7 120 10200

III 8 120 10200

III 9 120 10200

III 10 120 10200

2362 200770 335 14.2 28475

No. of days 25 59050 5019250 28475

Testing advantage – case 2

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Rs. In Lakhs Rs. In Lakhs per month Annual

Total sales 50 602

Total rejection 0.28 3.42

Approved 50 599 Profit 25% 12 150

Can we eliminate the rejection ? Through Testing and Inspection ???

Case study (1) Company Name XYZ Rubber company

Prduction Log sheet

Date shift Lot No. Batch No. Qty prodn cost ?

10-09-2018 I 100 1 120 10200

I 2 120 10200

I 3 120 10200

I 4 120 10200

I 5 115 9775

II 6 120 10200

II 7 110 9350

II 8 95 8075

II 9 120 10200

II 10 120 10200

II 101 1 120 10200

II 2 117 9945

III 3 120 10200

III 4 120 10200

III 5 125 10625

III 6 120 10200

III 7 120 10200

III 8 120 10200

III 9 120 10200

III 10 120 10200

2362 200770

No. of days 25 59050 5019250

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Supervisor thinks if one can produce 125 in one batch why not in entire

operation ?

Case study 2

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Research & Testing needs

Company Name XYZ Rubber company

Prduction Log sheet

Date shift Lot No. Batch No. Qty prodn cost ? Segregated

10-09-2018 I 100 1 120 10200

I 2 120 10200

I 3 120 10200

I 4 120 10200

I 5 115 9775 115 Rejection

II 6 120 10200

II 7 110 9350

II 8 95 8075 95 Rejection

II 9 120 10200

II 10 120 10200

II 101 1 120 10200

II 2 117 9945

III 3 120 10200

III 4 120 10200

III 5 125 10625 125 Rejection

III 6 120 10200

III 7 120 10200

III 8 120 10200

III 9 120 10200

III 10 120 10200

2362 200770 335 14.2 28475

No. of days 25 59050 5019250 28475

Fact is something is different >>>>>>>

Thank you

IRMRA - An accredited Lab for your Research & Testing needs

9/27/2018