Cinco procesos distintos: Mezclado, Calandrado/Corte en láminas, Laminado, Curado e Inspección y embalaje del producto terminado.

Las distintas aplicaciones de los compuestos requieren una mezcla de compuestos personalizada.

Forech realiza pruebas periódicas con diversas materias primas para determinar su idoneidad según las necesidades del cliente; personaliza el procedimiento de mezcla y la fórmula para cumplir con los requisitos de la aplicación. A partir de ensayos de laboratorio y producción, se calcula la proporción ideal de materias primas, el tiempo de mezcla y los pasos necesarios.

Las líneas de mezclado automatizadas garantizan que el proceso de mezclado no se desvíe de la receta.

Cada lote que sale de la mezcladora lleva impreso un número de lote y se somete a pruebas de laboratorio antes de ser procesado posteriormente.

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.