Rubber technology

Rubber sheets

Perfect coordination for optimum product quality


As a machine supplier for the global rubber industry, KraussMaffei Berstorff has comprehensive experience, ranging from extrusion technology, to calendering, all the way to doubling and winding technology.

In addition, with complex systems one factor is becoming ever more important: professional project processing. All components in the project work have to mesh like the gears in a gearbox. This can only be ensured if everything is controlled by one hand.

KraussMaffei Berstorff offers various system concepts that cover the entire process of rubber sheet manufacturing.

Roller-head systems

Optimal solution for the highest quality

Customer-specific roller head systems continuously create up to 20 mm-thick rubber webs free of bubbles from natural or synthetic rubber with high productivity. They cover the entire process of rubber web manufacturing: of floors, conveyor belt rollers, printing blankets, roofing membranes and semi-finished tire products.

In the roller head systems for manufacturing rubber webs, the extruders and calenders developed by KraussMaffei Berstorff are used exclusively. They stand for excellent product quality with the highest productivity.

Additional technical features at a glance:

  • Mechanical interlocking of the extruder and calender during operation
  • Ability to move the extruder for servicing and retooling work
  • Hydraulic opening and closing of the wide extrusion die for quick cleaning

The automation of all process steps minimizes the set-up times and increases the productivity in the roller head systems. With the central master control station and the machine control system, settings for the system can be carried out conveniently and centrally. The innovative process-oriented operator guidance system aids in reducing set-up times when changing orders and makes it possible to use fewer personnel.

Extrusion technology
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Cold-feed pin-barrel rubber extruder
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Cold-feed GE-SC Pinconvert® extruder
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Calender

High-performance calendering solutions for sustainable process optimization

In calender technology, KraussMaffei Berstorff offers comprehensive solutions with the I, S and F models. The calenders are customer-specifically equipped with 2, 3, 4 or 5 rolls. The modular structure and various additional features stand for the highest flexibility and productivity.

Ideal concepts for various products – reliable, flexible solutions

For various applications, KraussMaffei Berstorff adapts the additional features upstream and downstream of the calender precisely to the requirements. This equipment adapted optimally to the production process — from various winders to the non-contact thickness measurement systems to doubling and cutting equipment — makes short retrofitting times possible and ensures reliable production.

The design characteristics of the KraussMaffei Berstorff calender at a glance:

  • Rollers made of high-quality, premium materials with high molding precision, high surface quality and hardening
  • Various heating methods for rollers
  • Extremely high concentricity due to special roll bearing system and circulating oil lubrication system of the roll bearing system
  • Hydraulic roller nip adjustments or fast reaction time with the highest positioning accuracy, absolute repeatability and fast opening of the roller nip
  • Hydraulic tilting and roll-bending equipment for compensation of roll deflection
  • Calender drives for every intended application in absolute premium long-term quality
Slash calender
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Continuous vulcanization

Just as flexible and reliable as on the first day

The ideal application areas of the KraussMaffei Berstorff AUMA are the doubling or vulcanization of rubber webs, printing blankets, conveyor belts, and roof tracks in a thickness range from 0.5 to 20 mm. The advantages of these continuous procedures are low operating costs, short times for retrofitting, little need for wear and replacement parts and simple operation and servicing.

The functional principle of the automatic mat vulcanizing system (AUMA) is largely based on the heating drum, deflector rolls and range of pressure components. The pressure belt winds around the heating drum at the largest part of its circumference and presses, while under high tensile stress, the material to be vulcanized, welded or pressed against the heating drum. A drive on the upper deflector roll continuously regulates the velocity, depending on the intended use. Constant production conditions provide for a reproducible product with high quality in longitudinal and transverse directions.

The AUMA offers economic advantages particularly in the rubber industry if used in combination with a roller-head system. In the process, the heat brought into the extruder for manufacturing the rubber webs is exploited for the vulcanization in the AUMA.

Profile manufacturing systems

Profile production systems – Create premium quality sealing for the automotive and construction industry

KraussMaffei Berstorff profile production systems are the globally leading technology for increasing productivity and efficiency when manufacturing profiles of rubber, TPE or silicon. Alongside extrusion technology, the optimal coordination of the different system components is critical.

Excellent quality and absolute reliability - in order to prove itself in continuous use and to add to the economic success of the company, a profile extrusion system has to be equipped as well as possible to meet the high requirements. From the system solution for monoprofiles to hybrid profiles with up to 5 different components, for every system, the same principles for success apply: the highest quality, maximum availability, a modular design that permits growth and flexibility.

Rubber profile manufacturing systems

Manufacture rubber seals reliably and economically

KraussMaffei Berstorff rubber profile manufacturing systems produce the most different kinds of profiles:

Hollow or solid, with smooth or rough surfaces, with individualized contours, with or without steel reinforcement, in the highest quality.

The profile production systems are put together entirely according to the requirements of your product. Equipped with extrusion and vulcanization technology optimally aligned to one another, cutting and winding machines and the most varied measuring equipment, our systems distinguish themselves through high productivity and cost-effectiveness.

Extrusion technology
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Cold-feed GE-K rubber extruder
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Cold-feed pin-barrel rubber extruder GE-KS
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Cold-feed Pinconvert® GE-SC extruders
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Vulcanization technology
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Shock module
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Microwave systems
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Hot air systems
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Salt bath systems
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Cooling duct
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TPE / hybrid profile production systems

Future-oriented materials, processed in an environmentally friendly way


The production tasks correspondingly have various system concepts, with up to five single-screw extruders with screw diameters from 30 mm to 90 mm. The reliable systems are designed for processing polypropylene (PP) or thermoplastic elastomers (TPE) in the most varied degrees of hardness. A wide variety of extruder heads and specially made profile molds provide the basis for premium quality hybrid profiles, regardless of whether you would like to manufacture foaming or compact profiles.

With the use of an innovative injection system, you can produce foaming profiles with environmentally friendly propellants.

The modular structure allows flexible, customized machine configurations: from the conventional mono profile system to the hybrid profile system with flock-tape system or steel reinforcement. The upstream and downstream equipment such as vacuum conveyors for metering energy-optimized raw material pre-drying and heat-balancing channel and cooling basins with closed water circulation make a crucial contribution to the increase in the system's energy efficiency. A central control panel is used to control all of the system components and auxiliary units. KraussMaffei Berstorff provides the turnkey composite profile system with broken-in mold, from the metering system to the deposit tray of the finished profiles.

Silicon profile manufacturing systems

Silicon extrusion systems in KraussMaffei Berstorff quality

For the extrusion of solid silicon rubber, KraussMaffei Berstorff provides complete systems for manufacturing profiles and hoses.

The design engineering and manufacturing of these systems demands a high degree of materials expertise and manufacturing quality. In order to achieve the highest output when processing solid silicone rubbers, the KraussMaffei Berstorff extruders are equipped with an innovative cooling system. The temperature of the rubber thus stays reliably below the response temperature of the catalyst.

System configuration

Extruder

  • Extruder sizes 45, 60, and 90 mm screw diameter at a L/D ratio of 10 to 12

Shock module

  • Pre-vulcanization at 600 °C with ceramic infrared radiant heaters, alternatively with NIR heaters

Hot air systems

  • Short heat-up times and direct heating of the ducted air
  • Regaining and reusing the generated heat

LabStar systems

High flexibility and ease of operation


The LabStar lab system offers a high degree of process flexibility and is at the same time markedly easy to operate. Due to its modular design, the system can be quickly adapted for different tasks.

Due to its low material consumption of only 8 kg/h, the profile production system is suited above all for research tasks and compound developments, since it can be used to manufacture test bodies and sealing profiles with a diameter less than 1 cm². Rubber compounds for the extrusion process and for various profile characteristics can be optimized in further practical trials using the profiles.

The machine is built around a GE 25 x 18D rubber extruder for continuous material forming, and is equipped with a mobile control panel for operating the system. The subsequent pre-vulcanization of the profile is carried out by a shock module with short-wave infrared emitters.

The compact combination of microwave and hot-air channels is based on production system technology and scores points due to an effective hot air channeling system which conducts the energy to the product in the most efficient way. The easy-opening covers make it possible to position the product easily during start-up and to clean the process chamber quickly.

Special emphasis was also given to the machine's operating concept. A control panel and touchscreen on the vulcanization unit enable easy operation and excellent visuals. Operating the unit on site means that each setting can be checked visually at the same time.

Tire lines

Solutions for effective production and excellent products

Tire lines from KraussMaffei Berstorff are economical solutions for continuous manufacturing of tire components at a high quality level. Through the special machine designs, the systems stand out due to:

  • High throughput at low dimension and weight tolerances and optimal homogeneousness
  • Short retrofitting times during mixture or geometry change
  • Low start-up waste
  • Optimized screw geometry for each mixture

Mulitplex extrusion systems with up to 6 extruders

KraussMaffei Berstorff extrusion systems are conceived for high product quality and the highest output and are equipped with extruders of various models (GE-SC or GE-W, GE-KS) and sizes. Through the modular construction, the system configuration, corresponding to the desired profile cross-sections, is relatively simple to establish as a double, triple, quadruplex, quintuplex, and hexaplex unit.

KraussMaffei Berstorff multiplex systems are conceived to be stacked in the piggyback design, in order to achieve the highest product quality through the symmetric material flow in the extrusion head. Additionally, the compact design results in a significant gain of space. An additional feature in order to fulfill the high quality requirements is the special design engineering of the flow channels in the extrusion head. They create a very soft and non-invasive transition for the extrudate of round diameter from the screw zone to a rectangular, flat profile form. Additionally, the deflection of the mass flow in the channel is reduced to a minimum.

All process sequences are continuously checked by a monitoring system. Through it, a high operating reliability is guaranteed.

Throughputs of up to 10,000 kg/h or approx. 30,000 car treads per day are achieved with the state-of-the-art systems.

Cold-feed pin-barrel rubber extruder GE-KS
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Cold-feed Pinconvert® extruder GE-SC
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GE-W hot-feed extruders
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Multiplex extrusion heads
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Solutions for effective production and excellent products
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Control system and automation
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Roller-head systems

Roller head systems – Tandem for millimeter work

The KraussMaffei Berstorff roller-head technology provides a perfect combination of precision and cost-effectiveness: the lowest tolerances in the production of inner liners and carcass fillers or squeegee strips.

The rubber compound plasticized in the extruder is conveyed via a wide extrusion die directly into the roll nip of a two-roll calender. The calender calibrates the web exactly to the configured final thickness. The lowest tolerances over the entire web width and an optimal mixture homogeneity guarantee the production of inner liners and filler strips without bubbles or pores.

In the roller head systems for manufacturing rubber webs, the extruders and calenders developed by KraussMaffei Berstorff are used exclusively. They are responsible for excellent product quality with the highest productivity.

Additional technical features at a glance:

  • Mechanical interlocking of the extruder and calender during operation
  • Ability to move the extruder for servicing and retooling work
  • Hydraulic opening and closing of the wide extrusion die for quick cleaning

The automation of all process steps minimizes the set-up times and increases the productivity in the roller head systems. With the central master control station and the machine control system, settings for the system can be carried out conveniently and centrally. The innovative process-oriented operator guidance system aids in reducing set-up times when changing orders and makes it possible to use fewer personnel.

Mini roller-head systems
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Calender systems
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CapStrip systems

CapStrip line - the highest product quality and reliable production

The KraussMaffei Berstorff CapStrip Line for manufacturing jointless bandages with nylon or hybrid cords for high-speed tires.

The system is designed for coating cords with different rubber compounds. 16 strips with 9 threads each are produced in a single pass.

System components:

  • Creel with 144 spools for holding nylon or hybrid cords
  • Pin-barrel extruder for plasticizing the rubber compound and for filling the gear pump
  • Gear pump for uniform output and pressure build-up
  • Hydraulically locked cross-head die for simultaneously coating 16 strips with 9 cords each
  • Cooling drum assembly
  • Accumulation system
  • Spooling system with 16 stations

The superior benefits offered by our Cap strip line give you the quality edge you are looking for:

  • Optimal extrudate homogeneity
  • Excellent cord coating quality without damage to the cords
  • Uniform output
  • Throughput of 40 m/min
  • 16 strips with 9 cords each in a single pass
  • Short retooling times in case of compound changes

Hose fabrication systems

Hose extrusion systems - proven technology for the highest standards

Hydraulic hoses, automotive hoses or industrial hoses: Here, you will find the optimum system solution for hose fabrication for your company. The extrusion systems from KraussMaffei Berstorff set new benchmarks with their productivity and their innovative detailed solutions in hose fabrication. As a general contractor, KraussMaffei Berstorff provides all services for the construction of a high-performance extrusion system: Conception of the system and of the testing lab, design engineering, manufacturing and installation of the machine technology, training of the machine operators and commissioning, all from a single source. With complete solutions, alongside the economical advantages, we offer you, above all, the guarantee of the best possible technical matching of all individual components. In this way, even in the project planning phase, you can be sure that there will be no problems later.

Hose systems for high-pressure hoses

Highest standards in hose production

With the extrusion systems from KraussMaffei Berstorff to manufacture high-pressure hydraulic hoses, you can fulfill even the most varied customer wishes.

The hose extrusion systems unite innovative solutions of extrusion technology with the state-of-the-art downstream equipment technology. The result is a highly modern system, with which you are best equipped for the increasing challenges of the market.

The systems for production of hydraulic hoses are designed specifically for the customer and its process technology. They allow the manufacturing of various hoses with multiple layers of tensile steel braiding for working pressures of 70 bars up to 420 bars and bursting pressure over 1000 bars, depending on hose diameter.

Typical materials: EPDM, NBR, SBR; reinforcement with stainless steel and textile cords

Typical products: 1SN, 2SN and 4SH high pressure hydraulic hoses

Systems for automotive hoses

Hose extrusion systems made to measure

Innovative ideas connect themselves to advanced technology to create a maximum of efficiency and reliability. KraussMaffei Berstorff hose extrusion systems form a unique, one-of-a-kind performance class for the highest quality and productivity requirements in the manufacturing of automotive hoses and shaped hose sections.

From the preparation of rubber compounds to the development of the finished end products, the systems fulfill all requirements for perfect operability and the shortest setup times for product changes and high machine availability.

The wide variety product requirements and requirements from a process technology standpoint are met by KraussMaffei Berstorff with an absolutely customer-specific flexibility during system planning and design. Well-founded knowledge across the complete production process makes KraussMaffei Berstorff a reliable partner for manufacturing automotive hoses.

Tailored to your requirements, the systems can, for example, be equipped with different extrusion procedures, fully integrated manufacturing of the reinforcement and Programmable Logic Controller-run control system. With this, the systems give you almost everything you could want in a state-of-the-art manufacturing system. Regardless of which automotive hoses you want to produce, hose extrusion systems from KraussMaffei Berstorff define the highest benchmarks in all areas – now and in the future.

Typical materials: EPDM, NBR, SBR; reinforcement with stainless steel and textile cords

Typical products: Automotive hoses for exhaust systems, drive train, oil cooling, coupling, brakes, air conditioning and heating system, fuel, steering, hydraulic chassis stabilization, air flow and intake hoses

Systems for industrial hoses

Proven technology and high production reliability

Hose extrusion systems from KraussMaffei Berstorff always provide an optimal economical solution for your hose fabrication.

The systems prove themselves in daily use in manufacturing various tissue-reinforced hoses, which are used for a wide range of applications in industry. Depending on hose type, the systems offer the highest capacity with the lowest personnel usage and, with that, set the benchmark in the fabrication of industrial hoses. This is further supported through the shortest set-up times and a high degree of reliability. In conjunction with the most varied machine components, the highest accuracy and quality is achieved. Thanks to the wide range of extruders and the various machines for manufacturing the reinforcement, they are suitable for every application.

Typical materials: EPDM, NBR, SBR; reinforcement with stainless steel and textile cords

Typical products: Water hoses, hoses for foodstuffs, beverages, cosmetics and the pharmaceutical industry, oxyacetylene hoses, construction and conveyor hoses, chemical and fueling hoses

Manufacturing perfect rubber hoses

Economical hose production demands throughput capacity with consistently excellent hose quality. Costs can be reduced and quality improved by automatic hose centering heads synchronized with an X-ray measuring system that continuously measures the wall thickness,  the eccentricity and the outer diameter of the rubber hoses.
Automatic hose centering heads
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Roll covering systems

Achieve higher coating quality.

With the extrusion systems from KraussMaffei Berstorff, you can easily coat rolls, sleeves or pipes for the most varied industries. The systems, with our high-performance rubber extruders, process every common rubber compound and coat them in the highest quality.

The coating systems from KraussMaffei Berstorff distinguish themselves with short set-up times, maximum productivity and high coating quality. In order to achieve that, all components of the systems are optimally adapted to each other.

Covermatic systems: The coating specialists

High quality is always well received.

As long as the coating was applied with precision.

The advantages of the Covermatic systems at a glance:

  • Coating of roller cores, tubings, pipes and other round bodies of 5 - 310 mm diameter and lengths of up to 6,000 mm with rubber quality from 20 to 110 mooneys
  • 3 machine models with feeder extruders of the GE-K, GE-KS or GE-SC series can be selected for covering capacities from 200 - 550 kg/h
  • Excellent coating quality through special degassing of the mixture and non-invasive processing
  • Low personnel levels due to automatic coating process and simple, fast dimension and mixture change
  • Central control panel with memory storage for process and manufacturing data

Crosshead extrusion systems

Crosshead extrusion systems – the perfect combination!

Crosshead extrusion systems consist of perfectly matched components to ensure reliable and precise operation. Our systems are ideal for direct coating of roll cores and other round parts with core diameters between 5 and 200 mm and layer thicknesses of 2 to 20 mm. Depending on the crosshead size and the required output capacity, these systems can be equipped with vacuum rubber processing extruders with screw diameters of 60, 90 or 120 mm.

Strip winding systems

Strip winding systems: No compromises

Whether for flat or diagonal coating, the systems persuade in terms of cost-effectiveness and quality. Rolls up to a core diameter of 2,800 mm and in any face length can be equipped in a single pass with rubber layers from 0.5 - 70 mm.

Through the use of the various rubber extruders from KraussMaffei Berstorff, the covering systems provide an economic system concept for practically every commercially available rubber compound. That creates the basis for your success.

The cost-effectiveness is based on an optimal cooperation of numerous factors:

  • Reliable prevention of entrapped air during the covering process through rheologically optimized flow channels
  • Simple operation via a central control panel and the quickly replaceable final dies simplify frequent mixing changes and decrease the use of personnel
  • High covering accuracy through fully automatic feed control and a highly dynamic and precise base frame drive
  • Option for saving recipe data
  • Optional with system visualizationMaterial savings by layer thickness inspection
  • Quality and productivity improvement through retrofittable mini roller head

Compound preparation

Preparing rubber compounds

Excellent quality and absolute reliability - in order to prove itself in continuous use and to add to the economic success of the company, systems for preparing rubber compounds have to be prepared as well as possible to meet the high requirements. From the strainer solution to the rolling mill technology, the same principles for success apply to every system: the highest quality, maximum availability and flexibility and perfect integration into the workflow of rubber article production.

Strainer systems

Clean compounds and high efficiency

Strainer systems are the ideal investment for the future for many manufactures of rubber articles; they reliably remove contamination from rubber compounds. The result: Clean compounds for manufacturing premium quality sealing profiles, hoses or sheets.

KraussMaffei Berstorff strainer systems are outfitted with innovative components to reduce setup time and increase productivity. The various mesh sizes provide the compound with highest possible purity.

Sieve changer with hydraulic feed system – for easily replacing sieves.

GE-W hot-feed extruders

High-performance extruders with proven technology

Hot-feed KraussMaffei Berstorff GE-W series extruders have proven themselves in manufacturing a wide assortment of natural and artificial rubber products. They are fed as units downstream of roller mills, either continually with strips or intermittently with rolls of uncured rubber. They evenly shape the preheated plasticized rubber. In addition, they can be arranged as discharge extruders directly below internal mixers. In this form they receive screws with larger diameters and tamping dies as a means of facilitating infeeding.

V-belt systems

Customized technology for the best reliability

For V-belt manufacturers that would like to meet increasing customer demands at a professional level, the V-belt systems from KraussMaffei Berstorff are the ideal systems for coated, open-flank V-belts or V-ribbed belts. Their customized technology lets them offer production and investment security thanks to high product quality and reliability. Depending on the requirement, systems with different system components can be equipped for semi-finished products, assembly, vulcanization, cutting, grinding, measuring, inspecting and stamping. The result is a system optimally tailored to the product. A system whose versatility speaks for itself and makes it easy to have profitable production.

Coated V-belts - system design features:

  • Build-up in layers on separating drums in a separating drum building up machine
  • Profiling and scooping out sections for unfinished belt parts
  • Coating unfinished belt parts in a coating machine
  • Vulcanizing and stabilizing V-belts in a V-belt AUMA

Open-flank V-belt and V-ribbed belts – system design features

  • Build-up in layers on smooth or cogged separating drums in a separating drum building up machine
  • Vulcanization in autoclaves with freely movable vulcanization sleeves
  • Cooling the belt winding and drum in a cooling water pool.
  • Removing the belt winding from the drum in a stripper
  • Cutting the belt winding into individual belts using a cutting machine (VBC or drum cutting machines)
  • V-ribbed belts manufactured in a similar process to smooth belts
  • Special grinding machine for profiling.

AUMA

Just as flexible and reliable as on the first day

More than 80 years after its market launch, the KraussMaffei Berstorff AUMA stands for quality and long-term productivity. In the production of floor coverings, wall panels, and conveyor belts made of PVC, or when pressing chipboards and fiberboards, it remains a synonym for flexibility, product quality, and reliability.

The functional principle of the automatic mat vulcanizing system (AUMA) is largely based on the heating drum, deflector rolls and range of pressure components. The pressure belt winds around the heating drum at the largest part of its circumference and presses, while under high tensile stress, the material to be vulcanized, welded or pressed against the heating drum. A drive on the upper deflector roll continuously regulates the velocity, depending on the intended use. Constant production conditions provide for a reproducible product with high quality in longitudinal and transverse directions.

For manufacturing floor coverings made of PVC or polyolefin granulate, chips and films, KraussMaffei Berstorff has the two-drum AUMA V. It is equipped with a heating drum with additional infrared radiation heating and a cooling drum. The product is heated, formed and cooled between the two steel bands in a single process. A smooth surface and high quality of the product are guaranteed at all times.