TECHNICAL SUBMITTAL

EPDM ,Neoprene, Silicone Rubber

Profiles
&
Rubber Moulded Products
 CONTENTS [Link].

Section-1 General Information

1.1 Company Profile………………………………. 6
1.2 Quality Policy………………………………….. 7
1.3 Vision & Mission Statement…………………… 8
1.4 Quality Management System…………………… 9
1.5 Plant Equipments………………………………. 10

Section-2 Manufacturing Capabilities

2.1 Extrusion………………………………………. 11

2.1.1 Single Durometer ……………………………….. 11

2.1.2 Process Flow Chart……………………………. 14

2.1.3 Data sheets…………………………………….. 16

2.1.2 Double Durometer ……………………………. 35

2.1.3 Thermoplastic Elastomer (TPE)……………….. 36
2.2 Moulding ………………………………………. 37
2.2.1 Process Flow Chart……………………………. 39

2.2.2 Data sheet………………………………………. 40

2.3 Splicing………………………………………… 42

2.4 Adhesive on profiles…………………………… 43

2.5 Die cut for profile cut………………………….. 43
2.6 Rubber Compounding
2.6.1 Compounding………………………………….. 44
2.6.2 Kneading……………………………………….. 44
2.6.3 Process Flow Chart……………………………. 46
 CONTENTS [Link].

Section-3 Product Development

3.1 Seal and Gasket design………………………… 47
3.2 Compression Testing………………………….. 50
3.3 RMA Tolerances………………………………. 53
3.4 Colour Matching………………………………. 55

Section-4 Tooling ……………………………………….. 56

Section-5 Testing Facilities

5.1 Laboratory Equipment…………………………. 57
5.2 Infrared Thermography………………………… 62

Section-6 Certifications & Approvals 64

Section-7 LEED………………………………………….. 99

Method Statement……………………………. 102

Section-8 Warranty Certificate specimen…………………. 103

Section-9 Project References…………………………….. 104

 COMPANY PROFILE
Gulf Rubber Industries L.L.C, has been established as one of the pioneers of the Rubber
Manufacturing Industries in the Middle East. Our company is formed by the experienced professionals who have
been in this business for more than 20 years.
We are the first of its kind in the entire Middle East that have phenomenal range and capabilities of processing
synthetic and silicone rubbers to manufacture profiles that comprise of multi durometer hardness, multi material
color extrusion, profile pre-cut, TPE (Thermoplastic Elastomer), vulcanized frames, corners and various other
combinations depending upon the customer requirements.
In additional to the above products we also provide additional service to customers such as
testing,analysis,design and technical support to name a few.

Objective:
To be a leader in the rubber manufacturing and processing industry by consistently providing services
that meet and exceed performance beyond customer expectations.

Values:
 We believe in treating our customers with respect and faith.
 We grow through creativity, invention and innovation.
 We integrate honesty, integrity and business ethics into all aspects of our business functioning.
 We strive to build a positive team and family spirit.
 We believe in being a dependable source for our customers through transparency and trust.

Goals :
 Maintain and keep records of a Quality management system in accordance with international
standards, regulations and directives.
 Ensure all staff are fully trained and understand their role in providing excellent customer service as
per customer requirement.
 Make sure the services and material from supplier is consistent and meets our specifications.
 Strive for continual improvement in performance, underpinned by the necessary financial resources,
highlighting the objectives and progress through internal and external communications.
 Create a safe & healthy and sustainable environment for all the employees.
 Continual Improvements.
 QUALITY POLICY

GULF RUBBER INDUSTRIES LLC is committed to

become a market leader in rubber extrusion by achieving
profitable growth as a problem solver, and competitive
solution provider.

Our strategies to become leader are:

Identifying and exceeding the customer’s expectations by

providing the best quality, technology and service, at
optimum cost in timely manner to achieve customer
satisfaction
To develop partnership with supplier / service provider to
use their core competency to provide best value
propositions to customers.
Ensure all staff are developed to have skills and competence
required to provide excellent customer service as per
customer requirement
Provide financial, machinery, material, technology
resources and utilize them optimally to achieve operational
excellence
To establish objectives and reviewing them at necessary
intervals, to identify improvement opportunities and take
suitable actions for continual improvement.
Comply with applicable regulatory and Legislative
requirements.
 Our Vision:

To be a market leader in rubber extrusion

(exceed our customers' expectations in terms of product development, quality, delivery, technology and service).

Our Mission:

Sealing with comfort

(To achieve profitable growth as a problem solver, competitive solution provider of quality products and services to
our customers as an industry leader).

The top priority of GRI is to completely fulfill customer requirements. This entails perfect workflow and delivery
reliability. We are striving to attain zero defects, eliminate waste, conserve natural resources and preserve our
environment.

It is the understanding of GRI that quality does not only refer to their own products, but also to the entire company
and its business processes.

This comprehensive approach includes the following components:

 Service quality (customer orientation).

 Internal processes and procedures, including institutional performance review.

 Employee quality (education and training).

 Process and planning quality (process management and production control).

 Materials Management.

 Internal logistics.

 Technical equipment (‘state of the art’).

 Preventive and Predictive maintenance.

 KAIZEN workshops.

 5S implementation and control

 QUALITY MANAGEMENT
GRI’s prime focus of Quality Management is to ensure the consistency of our product and our services.

We have four main components in Quality Management:

 Quality planning.
 Quality control.
 Quality assurance.
 Quality improvement.

In order to reinforce the above 4 components, We use quality control of processes as well as products
to achieve more consistent quality.
Total quality and continuous improvements nurture successful partnership.

Quality Management System Planning

It is a systematic process that translates quality policy into measurable objectives and requirements,
and lays down a sequence of steps for realizing them within a specified timeframe.
Total quality management system(QMS) is planned for every department keeping in mind the process
and competency for the required job. A daily routine of the QMS implementation ensures high quality
at all times.

Quality Control

Quality Improvement is a formal approach to the analysis of performance and systematic efforts to
improve it. The systematic approach includes approach to reduction or elimination of waste, rework,
and losses in production process

Quality Assurance
Total quality management is the foundation of our entire organization. To ensure quality materials are
used for every customer application, we mix and test our own materials on site. We can design and
build process equipment in-house to ensure that your product is manufactured exactly the way you
need it. Every manufacturing operation has specific quality standards based on customer requirements
as well as our own internal standards. From sales to shipping, our focus is on the quality of our service
and the quality of our products.
 PLANT EQUIPMENT & CAPACITY (per month)

 EPDM Rubber Extrusion 150 metric tons

 CO Extrusion 60 metric tons
 Silicone Rubber Extrusion 25 metric tons
 TPE Extrusion Profile 25 metric tons
 Molding 10 metric tons

EXTRUSION
 Rubber Extrusion Line 3 Lines
 Silicone Extrusion Line 1 Line
 Peroxide Cured Extrusion Line 1Line

MOULDING
 Compression Moulding 2 No.
 Transfer Moulding 4 No.

COMPOUNDING
 Kneader and Mixing Mill 135 metric tons
 Silicone Mixing Mill 25 metric tons

TOOL ROOM
 Capacity to develop 30 Dies and 4 Moulds

LABORATORY
•Mooney Viscometer.
•Hardness Tester.
•Moving Die Rheometer.
•Compression Set Instrument.
•Tensile Tester.
•Hydrometer.
•VMS Instrument.
•IRHD.
•Specific Gravity Instrument.
•Flash point apparatus.
•Hot Air Oven.
 EXTRUSION
We can help with your next project including the design and development of custom profiles for virtually any
application. We feature a number of specialty products and services, including:

1. SINGLE DUROMETER:

We provide open and closed-cell sponge and dense polymer extrusions in continuous lengths, intricate profile
shapes and various colors. Each of our profiles is highly engineered; beginning with end-use assessment through
compound development, meeting tolerance requirements to produce a profile that is unique. We can compound
seals and gaskets made from virtually any type of rubber.

 CR-NEOPRENE

Good permeability, good resistance to the ozone, to the sea water, to animal and plant fats, to sunlight, to
the weather and to the different types of Freon.
Temperature. -40°C + 90°C
On demand self-extinguishing.

 EPDM
EPDM is a standard quality compound. Good heat resistance, high temperature ozone, high resistance to
permanent deformation. Excellent ozone/weathering resistance; excellent hot water and steam resistance; good
resistance to inorganic and polar organic chemicals. Low resistance to hydrocarbons. Good resistance to steam,
to sea water and to glycols, to alcohols, to chemical aggressive and oxidation.
For temperature resistance we have two different groups:
SULPHUR EPDM: -45°C + 100°C
PEROXIDE EPDM: -45°C+ 130°C
 EPDM line starts from mixing to Extrusion heating, temperature, pressure then to the final product and then is
the final inspection where the product is monitored and tested.
This is quality that is produced where GRI is one of the pioneers of manufacturing.

 NBR
Good oils resistance, good physical and mechanical properties. Very good permeability for air and gas. Good
resistance to mineral/animal and plant fats, to hydrocarbons/Petrol and to gas.
For temperature we have:
Low Nitrile or standard type: -25°C + 110°C
Medium Nitrile: -30°C + 130°C

 SBR
Very good physical-mechanical properties, good resistance to abrasion,
to the permanent deformation. Good resistant to some freon types, to glycols and brake fluid.
Temperature: -40°C + 100°C

 SILICONE
Very good resistance to heat and good flexibility at low temperatures (-40°C till +200°C).
Very good electro-insulating characteristics - Lack of toxicity in contact with food substances (FDA grades).
Good resistance in water and salt solutions till 100°C, to the weather, ozone, animal/plant oils, alcohols and
glycol.

 SILICONE H.T.
Characteristics and chemical resistances like standard silicone but with the best resistance to high temperatures -
till 300°C
 SILICONE L.T.
Characteristics and chemical resistances like standard silicone but with best resistance to the low temperature (till -
90°C).

 FLUOROSILICONE (FVMQ)
Very good chemical resistance - Very good physical-mechanical properties also at high and low temperatures (-
55°C + 200°C).
High resistance to permanent deformation - Oils resistance from -60°C till + 200°C - good chemical resistance
to different fluids, oils, hydrocarbons and solvents.

 VITON
Very good resistance to aging, to heat, high chemical resistance to different substances. Very good permanent
deformation.
Very good resistance to oils, mineral/plant and animal fats, to hydrocarbons, chlorinated aliphatic and aromatic ,
hydrocarbons/petrol.
Temperature: - 40°C + 220°C continuous - till 250°C

2. SPONGE

 CR-NEOPRENE
Good permeability, good resistance to the ozone, to the sea water, to animal and plant fats, to sunlight, to
the weather and to the different types of Freon.
Temperature. -40°C + 90°C
STANDARD DENSITY 600 KG/M3
On demand self-extinguishing

 EPDM
EPDM is a standard quality compound.
Good heat resistance, high temperature ozone, high resistance to permanent deformation.
Good resistance to steam, to sea water and to glycols, to alcohols, to chemical oxidation
For temperature resistance we have two different groups:
SULPHUR EPDM: -45°C + 100°C
PEROXIDE EPDM: -45°C+ 130°C
 SILICONE
Very good resistance to heat and good flexibility at low temperatures (-40°C till +200°C).
Very good electro-insulating characteristics.
Good resistance in water and salt solutions till 100°C , to the weather, ozone, and glycols.

STANDARD DENSITY:300 KG/M3 - 450 KG/M3 - 600 KG/M3

PROCESS FLOW CHART – EPDM EXTRUSION

Mixing

Chiller
System
Extrusion

Microwave Curing

Hot air oven Curing

Cooling

SPM (if required)

Puller Rechecking/
Segregation/
Winding Scrap

IF NOT OK
Inspection
IF OK

Packaging Dispatch