Rubber technology

Rubber sheet production lines

KraussMaffei Berstorff offers extensive know-how in the field of rubber sheet production – starting from extrusion technology and calendering all the way through to continuous vulcanization.

We deliver complete rubber sheet production lines as one-stop solutions to ensure professional project implementation, smooth processing and premium product quality. Benefit from our longstanding experience combined with comprehensive in-house technical expertise.

Rubber sheet production lines

Roller-head lines

Optimal solution for premium-quality products

 

Customized roller-head lines continuously produce blister-free rubber sheets of up to 20 mm thickness from natural or synthetic rubber with maximum productivity. These lines are designed for the entire range of rubber sheet applications – from floor coverings, uncured

conveyor belts, pressure blankets and roofing sheets up to semi-finished tire components.

All these roller-head lines for the production of rubber sheets are exclusively equipped with extruders and calenders developed by KraussMaffei Berstorff and stand out for excellent product quality and unparalleled productivity.

 

Additional technical benefits at a glance:

  • Mechanical interlocking of extruder and calender during operation
  • Extruder travel for servicing and retooling operations
  • Hydraulic opening and closing of the slot die for rapid cleaning

The automation of all process steps minimizes set-up times and enhances the productivity of roller-head lines. Thanks to the central master control station and the machine control system, line settings can be made conveniently and centrally. The innovative process-oriented operator guidance helps to shorten set-up times for product changes and to reduce manpower requirements.

Rubber sheet production lines
Cold-feed pin-barrel rubber extruder
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Cold-feed GE-SC Pinconvert® extruder
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Calender lines

High-performance calendering solutions for sustainable process optimization

With its calendering technology portfolio comprising calenders of “I” or “inverted L” or “S” design with 2, 3, 4 or 5 rolls, KraussMaffei Berstorff offers an extensive range of different solutions. The modular set-up and various accessories provide maximum flexibility and outstanding productivity.

Convincing designs for the most varied products – highly flexible and reliable solutions

KraussMaffei Berstorff offers a comprehensive

range of upstream and downstream auxiliary  equipment customized to your individual requirements.

This equipment includes different types of winders, contactless thickness gauges as well as laminating and cutting systems that are perfectly tailored to the specific process and ensure short retooling times and maximum production reliability.

Design features of KraussMaffei Berstorff

calenders at a glance:

  • Rolls made from premium quality materials with high concentricity and dimensional accuracy, unparalleled surface quality and hardness
  • Various calender heating options
  • Excellent concentricity owing to special roll bearings with oil circulation lubrication
  • Hydraulic roll gap adjustment gives short response time at maximum adjustment precision, uncompromising repeat accuracy and rapid roll gap opening
  • Hydraulic cross axis adjustment and roll bending device to compensate roll deflection
  • Calender drives of sustained premium quality for the most varied applications
Rubber sheet production lines
Slash calender
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Continuous vulcanization

Just as flexible and reliable as on the very first day

The KraussMaffei Berstorff AUMA is ideally suited for laminating or vulcanizing rubber sheets, printing blankets, conveyor belts and roofing sheets in a thickness range from 0.5 to 20 mm. The advantages of this continuous process are low operating costs, short retooling times, low wear and spare parts requirements and easy operation and servicing.

The functional principle of the automatic mat vulcanizing system (AUMA) is largely based on the heating drum, deflector rolls and the pressure belt. The pressure belt wraps around the heating drum over the largest part of its circumference and presses the material to be vulcanized, welded or compressed against the heating drum while under high tensile stress. A drive on the upper deflector roll continuously controls the speed depending on the specific application. Constant production conditions provide for a reproducible product with premium quality in longitudinal and transverse directions.

Used in combination with a roller-head line, the AUMA offers outstanding economic benefits in particular in the rubber industry. The heat produced in the extruder during the production of the rubber sheets is used for subsequent vulcanization in the AUMA.

Rubber sheet production lines

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.

Profile manufacturing systems

Rubber profile manufacturing systems

Reliable and cost-effective rubber seal production

KraussMaffei Berstorff rubber profile production lines are designed for the most different types of premium-quality profiles: hollow or solid, with smooth or rough surfaces, with individualized contours and with or without steel reinforcement.
Our profile production line configurations are tailored to the specific requirements of your product. Equipped with perfectly combined extrusion and vulcanization systems, cutting and winding machines and the most varied measuring equipment, they stand out for high productivity and uncompromising cost-effectiveness.

Profile manufacturing systems
Extrusion technology
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Vulcanization technology
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Salt bath systems
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Cooling duct
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TPE / hybrid profile production lines

Eco-friendly processing of future-oriented materials


Depending on the specific application, KraussMaffei Berstorff offers different line configurations composed of up to five single-screw extruders with screw diameters from 30 mm to 90 mm. These reliable lines are designed for processing polypropylene (PP) or thermoplastic elastomers (TPE) with different degrees of hardness. A wide variety of extrusion heads and profile dies of special design provide the basis for premium-quality foamed or compact hybrid profiles.
Owing to the innovative injection system, environmentally friendly blowing agents can be used for foamed profiles.
The modular design ensures flexible, customized machine configurations: from conventional mono-profile to hybrid profile solutions 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 as well as cooling basins with closed water circulation substantially enhance the line energy efficiency. A central control panel is used to control all line components and auxiliary units. KraussMaffei Berstorff delivers the complete turnkey composite profile line with run-in extrusion tool – from the metering system to the depositing table for the finished profiles.

Profile manufacturing systems

Silicon profile manufacturing lines

Silicone extrusion lines in KraussMaffei Berstorff quality

KraussMaffei Berstorff's product portfolio comprises complete extrusion lines for profiles and hoses made from solid silicone rubber.
The engineering and manufacture of these lines require a high degree of materials expertise and outstanding manufacturing quality. In order to achieve maximum output rates when processing solid silicone rubber, KraussMaffei Berstorff extruders are equipped with an innovative cooling system. The rubber temperature is thus reliably kept below the reaction temperature of the catalyst.

Extruder

  • Extruder sizes with screw diameters of 45, 60, and 90 mm at an L/D ratio of 10 to 12

Shock module

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

Hot-air systems

  • Short heat-up times and direct heating of the channel air
  • Recovery and reuse of the generated heat
Profile manufacturing systems

LabStar systems

High flexibility and ease of operation


The LabStar laboratory line offers a high degree of process flexibility and is at the same time extremely easy to operate. Owing to its modular design, the system can be quickly adapted to different process tasks.
Thanks to the low material consumption of only 8 kg/h, the profile production line is suited above all for research tasks and compound development, since it can be used to manufacture test pieces and sealing profiles with a cross-section of below 1 cm². Testing these profiles, rubber compounds can be optimized for the extrusion process and for a wide range of profile characteristics.
The configuration is based on a GE 25 x 18D rubber-processing extruder for continuous material shaping that is equipped with a mobile control panel. The subsequent profile pre-vulcanization 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-scale technology and scores by effective hot air routing that leads the energy to the product in the most efficient way. The easy-opening covers make it possible to insert the product easily during start-up and to clean the process chamber quickly.
Special emphasis was put on the machine's operating concept. A control panel and touchscreen on the vulcanization unit enable easy operation and excellent visualization. On-site operation of the system means that each setting can be checked visually at the same time.

Profile manufacturing systems

Tire lines

Solutions for cost-effective production and premium-quality products

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

  • High output rates at narrow dimension and weight tolerances and optimum homogeneity
  • Short retrofitting times for compound or geometry changes
  • Minimized start-up waste
  • Optimized screw geometry for each compound
Tire lines

Mulitplex extrusion systems with up to 7 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.

Tire lines
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 lines – Tandem solution for precision jobs

The KraussMaffei Berstorff roller-head technology provides a perfect combination of precision and cost-effectiveness: minimum 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 sheet exactly to the configured final thickness. Narrow tolerances over the entire sheet width and an unparalleled compound homogeneity ensure the production of inner liners and filler strips without any bubbles or pores.
All these roller-head lines for the production of rubber sheets are exclusively equipped with extruders and calenders developed by KraussMaffei Berstorff and stand out for excellent product quality and unparalleled productivity.

Additional technical benefits at a glance:

  • Mechanical interlocking of extruder and calender during operation
  • Extruder travel for servicing and retooling operations
  • Hydraulic opening and closing of the wide extrusion head for rapid cleaning

The automation of all process steps minimizes set-up times and enhances the productivity of roller-head lines. Thanks to the central master control station and the machine control system, line settings can be made conveniently and centrally. The innovative process-oriented operator guidance helps to shorten set-up times for product changes and to reduce manpower requirements.

Tire lines
Mini roller-head systems
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Calender systems
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CapStrip systems

CapStrip line - premium product quality and uncompromising production reliability

KraussMaffei Berstorff CapStrip line for the manufacture of jointless cap plies with nylon or hybrid cords for high-speed tires.
The line is designed for coating cords with different rubber compounds. 16 strips of nine threads each are produced in a single cycle.

Line components:

  • Creel with 144 spools to take nylon or hybrid cords
  • Pin-barrel extruder for plasticizing the rubber compound and for filling the gear pump
  • Gear pump for constant output and pressure build-up
  • Hydraulically locked cross-head for simultaneous coating of 16 strips with 9 cords each
  • Cooling drum assembly
  • Material accumulator
  • 16-station winding system

The substantial benefits of the CapStrip line give you a decisive competitive edge in terms of quality:

  • Optimum material homogeneity
  • Excellent cord coating quality without any damage to the cords
  • Constant output
  • Throughput rate of 40 m/min
  • 16 strips with 9 cords each in a single cycle
  • Short retooling times in case of compound changes
Tire lines

CompoundRework system 1000

For lower costs and high sustainability
Most extrusion processes inevitably involvethe production of a certain amountof recyclable scrap, i.e. residual material that remains in the extruder or in the extrusion head in the event of compound or extrusion tool changes. In order to maximize added value, tire producers strive to recycle this scrap material by returning it to the production process.
Tire lines
CompoundRework System 1000
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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 fabrication systems

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

Hose fabrication systems

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

Hose fabrication systems

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

Hose fabrication systems

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.
Hose fabrication systems
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.

Roll covering systems

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
Roll covering systems

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.

Roll covering systems

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
Roll covering systems

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.

Compound preparation

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.

Compound preparation

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.

Compound preparation

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.
V-belt systems

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.

AUMA