Fünf verschiedene Prozesse: Mischen, Kalandrieren/Plattieren, Laminieren, Aushärten und Endproduktprüfung & Verpackung

Unterschiedliche Anwendungsbereiche von Verbundwerkstoffen erfordern eine individuelle Mischung der Verbundwerkstoffe.

Forech prüft regelmäßig verschiedene Rohstoffe auf ihre Eignung für die Kundenbedürfnisse und passt Mischverfahren und Rezeptur individuell an die jeweiligen Anwendungsanforderungen an. Aus Labor- und Produktionsversuchen werden das optimale Rohstoffverhältnis, die Mischzeit und die einzelnen Schritte ermittelt.

Die automatisierten Mischanlagen gewährleisten, dass der eigentliche Mischprozess nicht vom Rezept abweicht.

Jede aus dem Mischer kommende Charge wird mit einer Chargennummer versehen und im Labor getestet, bevor sie zur Weiterverarbeitung freigegeben wird.

The compound that we get from our mixing line is in thick slabs of a small width. To get it into the desired width, thickness, and to coat it onto fabric if necessary, we pass it through either a calender or an extruder.

The sheeting lines control and adjust temperatures, speed, and gauge to ensure that the finished sheet or rubberised fabric is uniformly thick and free from bare patches. During every setup, a human supervisor will also double check the width and thickness to make sure that there is no deviation.

Forech is also capable of producing cover rubber in thicknesses up to 8 mm in a single pass, which reduces the risk of blister formation or delamination during operation.

For fabric belts, we take individual rolls of rubberised fabric to a building table, and lay them one on top of the other, and apply slight pressure to create the carcass of the fabric belt.

The top cover and bottom cover are also laid on to the fabric carcass in this machine.The building table is also the equipment which we use to assemble very thick rubber covers or rubber lining sheets from thinner sheets taken from the calender. Breakers, sensor loops, or any other additions to the cover are also assembled into the belt at this stage of manufacturing.

For steel cord belts, the laminating happens inline, in a compacting station which lays rubber on the top and bottom of steel cords which are kept under tension.

Moulded items are assembled in the mould itself.

After assembly, the assembled sheet, conveyor belt, or moulded part is brought to a rotocure or press.

Heat and pressure is applied to ensure that the raw rubber goes through a vulcanisation reaction to take its finished shape.

Forech has specialised presses and moulds based on product, thickness, width, and shape for its different product lines including rubber sheets, profiled rubber lagging, flat conveyor belts, profiled conveyor belts, ceramic lagging and pads, sidewalls and cleats, and idler rings.

On every line, curing time, temperature, and pressure are monitored and controlled to ensure the best possible surface finish and a defect free product.