FORMAT NO: F/SOP/04
WESTERN RUBBERS INDIA PVT. LTD. REV NO.: 00
REV DT: 00
DT: 01.01.2023
STANDARD OPERATING PROCEDURE
TITLE Control of Products
1. Purpose
To define the standard procedure for preparing rubber compound by accurately mixing raw
materials as per the formulation and process parameters.
2. Scope
This SOP applies to all rubber compounding activities carried out in the Mixing Department
for production of molded, extruded, or calendared rubber products.
3. Responsibilities
- Mixing Operator – Execute the compounding as per process.
- Shift In-Charge – Ensure correct batch formulation is followed.
- Quality Control – Inspect and approve compounded batch.
- Maintenance – Ensure equipment is in proper working condition.
4. Equipment & Tools
- Internal Mixer (Banbury) / Kneader
- Open Mixing Mill
- Weighing Scale (Calibrated)
- Storage Bins for raw materials
- Batch-off Unit
- Protective Gear (Gloves, Apron, Safety Glasses)
5. Materials Required
- Base Rubber (e.g., NR, SBR, EPDM)
- Fillers (e.g., Carbon Black, Silica)
- Processing Oils (e.g., DAE, TDAE)
- Activators (ZnO, Stearic Acid)
- Antioxidants
- Vulcanizing Agents (e.g., Sulfur, Accelerators)
6. Procedure
**6.1 Pre-checks**
- Ensure the mixing mill or kneader is clean and free of previous compound residues.
- Check all weighing scales are calibrated.
- Wear all necessary PPE.
**6.2 Raw Material Weighing**
- Collect formulation sheet for the product code.
- Weigh each ingredient with ±1% tolerance.
- Use clean, labeled containers for each ingredient.
**6.3 Mixing Process**
A. For Kneader/Internal Mixer:
1. Charging Sequence:
- Load base rubber.
- Add activators and fillers (ZnO, Stearic Acid, Carbon Black).
- Add oils and plasticizers.
- Add remaining chemicals (e.g., accelerators, sulfur) as per cooling stage.
2. Mixing Time:
- Maintain total mixing cycle: ~7–12 mins depending on batch size.
- Rotor Speed: As per specification (e.g., 40–60 rpm).
- Dump temperature: Should not exceed 110°C (unless specified).
3. Unloading:
- Remove compound and sheet it on mixing mill.
B. For Mixing Mill (Secondary Mixing / Final Mix):
1. Warm up the mill rolls.
2. Add master batch for final mixing.
3. Add curing agents (sulfur, accelerators).
4. Mill compound for uniform dispersion (approx. 4–6 passes).
5. Sheet out into required size/weight strips.
**6.4 Batch-off & Storage**
- Cool compound using batch-off unit with dusting powder.
- Tag each batch with Batch Number, Compound Code, Date & Shift.
- Store in designated racks for minimum 8 hours before further processing.
7. Quality Control Checks
- Mooney Viscosity
- Specific Gravity
- Rheometer Test (for curing profile)
- Visual checks for dispersion
8. Safety Precautions
- Always wear PPE.
- Keep flammable chemicals away from heat sources.
- Use extraction systems to remove fumes.
- Follow lockout-tagout (LOTO) procedure during maintenance.
9. Documentation
- Batch Manufacturing Record (BMR)
- Material Issue Slip
- QC Report
- Deviation Report (if applicable)
10. References
- Material Safety Data Sheets (MSDS)
- Product Specification Sheet
- ISO 9001 / IATF 16949 Quality Manual