Reclaim Rubber

Details:

• Production Process: Whole Tyre Reclaim Rubber is typically produced by shredding end-of-life tyres into small pieces or crumb rubber. These tyre scraps are then subjected to a reclaiming process involving heating, shredding, and devulcanization, which breaks down the rubber polymer chains and allows for the reclamation of usable rubber material.
• Composition: Whole Tyre Reclaim Rubber typically contains a mix of rubber compounds, including Natural Rubber (NR), Synthetic Rubber such as Styrene-Butadiene Rubber (SBR) or Butadiene Rubber (BR), Carbon Black, and various additives used in tyre manufacturing.
• Particle Size: The particle size of Whole Tyre Reclaim rubber can vary depending on the reclaiming process, but it is generally available in fine to coarse granules or powder form.

Properties:

• Elasticity: Whole Tyre Reclaim Rubber retains a considerable degree of elasticity, allowing it to deform under stress and return to its original shape when the stress is removed.
• Tensile Strength: While not as high as virgin rubber, Whole Tyre Reclaim Rubber still maintains adequate tensile strength for many applications, making it suitable for use in various rubber products.
• Abrasion Resistance: It offers good resistance to abrasion, making it suitable for applications subjected to wear and tear, such as tyre treads and conveyor belts.
• Flexibility: Whole Tyre Reclaim Rubber exhibits flexibility, allowing it to be molded or shaped into different forms to suit various applications.
• Cost-Effectiveness: One of the main advantages of using Whole Tyre Reclaim Rubber is its lower cost compared to virgin rubber, making it an economical choice for many applications.

Applications:

• Tyre Manufacturing: Whole Tyre Reclaim Rubber is commonly used in the production of new tyres, where it is mixed with virgin rubber to create tyre compounds for treads, sidewalls, and other tyre components.
• Automotive Components: It finds applications in various automotive components such as rubber mats, gaskets, seals, and vibration dampers.
• Construction Materials: Whole Tyre Reclaim Rubber is used in the manufacture of construction materials such as rubberized asphalt for road surfaces, roofing materials, and sound insulation.
• Industrial Products: It is utilized in industrial products including conveyor belts, hoses, molded rubber parts, and anti-vibration mounts.
• Sporting Goods: Whole Tyre Reclaim Rubber is used in the production of sporting goods such as playground surfaces, athletic tracks, and gym flooring mats.
• Consumer Products: It can be found in consumer products like floor mats, mud flaps, and rubberized fabrics.

Overall, Whole Tyre Reclaim Rubber offers a sustainable solution for recycling end-of-life tyres while providing a cost-effective alternative to virgin rubber in a wide range of applications across various industries.

Manufacturing Process:

1. Collection and Sorting:
   • Collection: Used natural rubber products, such as tires, rubber bands, and industrial rubber goods, are collected.
   • Sorting: The collected material is sorted to remove contaminants and non-rubber components, such as metal wires and fabric.
2. Shredding and Grinding:
   • Shredding: The sorted rubber is shredded into smaller pieces to facilitate further processing.
   • Grinding: The shredded rubber is ground into finer particles using mills or granulators. This increases the surface area and prepares the material for devulcanization.
3. Devulcanization:
   • Heat and Chemical Treatment: The ground rubber is subjected to heat and chemical treatments to break the sulfur cross-links formed during the original vulcanization process. This step, known as devulcanization, is essential to restore the rubber’s ability to be reprocessed.
   • Processing: The devulcanized rubber is then mixed with additives such as plasticizers, stabilizers, and fillers to improve its properties and make it suitable for new rubber formulations.
4. Compounding and Processing:
   • Compounding: The reclaimed rubber is blended with other raw materials and additives to create a new rubber compound.
   • Processing: The compound is then processed into its final form through extrusion, molding, or other methods, similar to the production of new rubber products.

Characteristics

1. Material Source: Produced from reclaimed natural rubber, which comes from recycled tires, industrial rubber products, or other sources of used natural rubber.
2. Elasticity: Retains high elasticity and flexibility, though the level of performance can vary based on the source material and the reclaiming process.
3. Cost: More economical than virgin natural rubber, providing a budget-friendly alternative for many applications.
4. Variable Quality: The properties of reclaimed natural rubber can vary significantly depending on the original material and the recycling process.

Key Characteristics

1. Elasticity and Flexibility: Maintains good elasticity and flexibility, which are key attributes of natural rubber. This makes it suitable for applications where these properties are important.
2. Cost-Efficiency: Provides a lower-cost alternative to new natural rubber, offering savings while still delivering acceptable performance.
3. Variable Performance: Performance characteristics can be inconsistent, affecting its suitability for high-performance applications.
4. Environmental Benefits: Contributes to sustainability by recycling used rubber products and reducing waste.

Applications

1. Inner Tubes: Used in bicycle and motorcycle inner tubes where elasticity and flexibility are important. However, it is less commonly used in high-performance applications compared to virgin natural rubber.
2. Footwear: Applied in the production of various footwear components, especially where cost savings and good elasticity are needed.
3. Industrial Products: Utilized in various industrial products such as mats, seals, and gaskets, where the elasticity and cost benefits of reclaimed natural rubber are advantageous.
4. Rubber Goods: Employed in the manufacturing of lower-performance rubber products, including certain consumer goods and industrial components.
5. Automotive Components: Sometimes used in automotive parts that do not require the highest performance levels but still benefit from the elasticity and cost-effectiveness of reclaimed natural rubber.

Natural Reclaim Rubber offers a cost-effective alternative to virgin natural rubber while retaining many of its desirable properties such as elasticity and flexibility. It is suitable for a range of applications where good performance can be achieved with recycled material, making it an environmentally friendly option.

Manufacturing Process:

1. Collection and Sorting:
   • Collection: Used butyl rubber products, such as tires, seals, and other rubber goods, are collected.
   • Sorting: The collected rubber is sorted to remove any contaminants and non-rubber materials, such as metal or fabric.
2. Shredding and Grinding:
   • Shredding: The sorted butyl rubber is shredded into smaller pieces to facilitate further processing.
   • Grinding: The shredded rubber is ground into fine particles, often using a mill or granulator. This process increases the surface area and makes it easier to reclaim.
3. Devulcanization:
   • Heat and Chemical Treatment: The ground rubber is subjected to heat and chemical treatments to break down the sulfur cross-links that were formed during the original vulcanization process. This step, known as devulcanization, is crucial for restoring the rubber’s ability to be reprocessed.
   • Processing: The devulcanized rubber is mixed with various additives, including plasticizers and stabilizers, to improve its properties and make it suitable for new rubber formulations.
4. Compounding and Processing:
   • Compounding: The reclaimed rubber is blended with other raw materials and additives to create a new rubber compound.
   • Processing: The compound is then processed into its final form through extrusion, molding, or other methods, similar to the production of new rubber products.

Characteristics

1. Material Source: Made from recycled butyl rubber, which includes used tires, rubber seals, and other rubber products.
2. Air Retention: Maintains relatively good air impermeability, though not as high as that of virgin butyl rubber.
3. Cost: More economical than virgin butyl rubber, making it a budget-friendly option.
4. Variable Quality: The quality can vary based on the source and the recycling process, affecting its performance.

Key Characteristics

1. Cost-Efficiency: Provides a cost-effective alternative to virgin butyl rubber, offering significant savings for applications where high performance is not critical.
2. Air Impermeability: Retains good air retention properties, though slightly less effective than new butyl rubber, making it suitable for applications requiring moderate air impermeability.
3. Weather Resistance: Offers reasonable resistance to weathering, ozone, and UV exposure, although not as robust as virgin butyl rubber.
4. Processing: May require modifications in processing compared to virgin butyl due to differences in material consistency and performance.
5. Sustainability: Utilizes recycled materials, contributing to environmental sustainability by reducing waste and reliance on new raw materials.

Applications

1. Inner Tubes: Frequently used in inner tubes for bicycles, motorcycles, and automobiles. It provides an economical solution while still offering adequate air retention and durability.
2. Industrial Products: Incorporated into various industrial applications such as gaskets, seals, and rubber mats where cost-effectiveness is important, and performance requirements are moderate.
3. Building Materials: Used in construction materials and products where the performance demands are less stringent and cost savings are a priority.
4. Automotive Parts: Applied in automotive components like vibration isolators and less critical seals and gaskets, where reclaimed butyl rubber’s properties are sufficient.
5. Consumer Goods: Utilized in a range of consumer products, including certain types of footwear and rubber goods, due to its affordability and functional performance.

Butyl Reclaim Rubber offers a practical and cost-effective alternative to virgin butyl rubber, particularly in applications where high performance is less critical and cost savings are beneficial. It combines some of the desirable characteristics of butyl rubber with the added advantage of being an environmentally sustainable option.

Manufacturing Process:

1. Collection and Sorting:
   • Collection: Waste chlorobutyl rubber products, such as tires, seals, and gaskets, are
     collected.
   • Sorting: The collected material is sorted to remove contaminants and non-rubber
     components, such as metals and textiles.
2. Shredding and Grinding:
   • Shredding: The sorted rubber is shredded into smaller pieces to facilitate further
     processing.
   • Grinding: The shredded rubber is ground into finer particles using mills or
     granulators. This increases the surface area and prepares the material for devulcanization.
3. Devulcanization:
   • Heat and Chemical Treatment: The ground chlorobutyl rubber is subjected to heat and
     chemical treatment to break the sulfur cross-links formed during the original vulcanization process.
     Devulcanization is essential to restore the rubber’s ability to be reprocessed.
   • Processing: The devulcanized rubber is mixed with additives such as plasticizers,
     stabilizers, and fillers to enhance its properties and make it suitable for new formulations.
4. Compounding and Processing:
   • Compounding: The reclaimed rubber is blended with other raw materials to create a new
     rubber compound.
   • Processing: The compound is then processed into its final form through extrusion,
     molding, or other methods, similar to the production of new rubber products.

Characteristics

1. Material Source: Produced from recycled chlorobutyl rubber, often from used tires, seals, or
   other rubber products.
2. Weather Resistance: Retains some of the superior weather and ozone resistance characteristics
   of chlorobutyl rubber, though performance may be slightly reduced compared to new chlorobutyl.
3. Cost: More affordable than virgin chlorobutyl rubber due to the recycling process, offering a
   cost-effective alternative for many applications.
4. Variable Quality: The quality and performance can vary based on the source material and
   recycling methods used.

Key Characteristics

1. Enhanced Weather Resistance: Provides improved resistance to ozone and weathering compared to
   standard butyl rubber, though not as high as virgin chlorobutyl rubber.
2. Cost-Efficiency: Offers a more budget-friendly alternative to new chlorobutyl rubber, making it
   suitable for applications where cost savings are important.
3. Chemical Resistance: Maintains a level of chemical resistance, though not as high as that of
   virgin chlorobutyl.
4. Processing Considerations: Requires specific processing adjustments compared to virgin
   chlorobutyl due to variability in material properties.

Applications

1. Inner Tubes: Used in inner tubes for tires, particularly in applications where enhanced weather
   resistance is beneficial but where cost savings are a priority. It’s less common than butyl reclaim but used
   where specific performance attributes are needed.
2. Automotive Parts: Applied in automotive components such as seals and gaskets that require good
   resistance to environmental factors, offering a balance between cost and performance.
3. Industrial Applications: Utilized in industrial products where moderate chemical and weather
   resistance is required, such as in certain gaskets, seals, and vibration isolators.
4. Consumer Goods: Employed in various consumer products that benefit from its enhanced weather
   resistance, including some types of rubber goods and footwear.

Chlorobutyl Reclaim Rubber provides a cost-effective and environmentally friendly alternative to virgin chlorobutyl
rubber, retaining many of its beneficial properties while offering improved cost savings. It is particularly
suitable for applications where weather resistance and cost efficiency are important considerations.