1. 1
In-Plant-Materials
Optimization
Presented By
Specialty Elastomer Recovery, Inc. (SERI)
SERI

2. 2
PRESENTATION
 Guiding Principals
 Process
 Polymers Processed
 Quality Assurance
 Additional Capabilities & Process
Development
 Suggested Procedure for In “In Process
Materials” (IPM) Optimization Practice
 Summary

3. 3
Who is SERI?
 Leader in Fine Elastomeric Powder
Technology
 Process Recovered FKM and High-end
elastomeric Materials to a 325 Mesh Powder
 ISO Certified
 Excellent R&D, Pilot Plant, Laboratory and
Customer Support
 Unique and Proven Technology
 Continual Process and Product
Improvements

4. 4
SERI Manufacturing Facility

5. 5
SERI

6. 6
SERI FKM Procesing Line

7. 7
SERI Warehouse


8. 8
Guiding Principles
 Assist Material Approval Process
 Assist In Collection, Optimization and
Implementation
 Demonstrate Economic and Value
 Successful Long Term Relationship

9. 9
Objective
 Objective is
 to Recover,
 Reduce,
 Reuse,
 and fully Recycle IPM Materials in a cost
effective, viable, and environmentally
sound manner.

10. 10
CAPABILITIES
 Process many cured polymers into precise gradations
and surface morphologies.
 Strict adherence to QC measures which insure zero
contamination.
 Includes both virgin and recyclable elastomers.
 Finished particle size tailored to customers specific
needs.
 Finished powder down to a minus 325 mesh particle.
 Process is energy efficient, environmentally sound.
 Produces highly uniform products with high yields.

11. 11
The Process
1
Receive
Sample(s)
2
Process
to a
Gradation(s)
3
Lab
Evaluations
4
Make Process Adjustments
If Necessary
5
Feasibility
Finalize Parameters
At Mfg. Facilities
6
Begin Collection
&
Processing
7
Continue ongoing
Product/service
improvements

12. 12
Process Quality Assurance– Multi
Elastomer Processing
 Two manufacturing lines.
 Line 1 – Strictly FKM Materials (Black and Colors)
 Line 2 – Other High-end Elastomer Materials
 Specialized high-pressure rotating steam cleaning
system for all pipes in system.
 Water flush through grinding and dewatering system.
 Optimal equipment engineering design to
accommodate thorough and efficient cleanout
between every material produced.
 Line 1 and Line 2 are contained in separate areas
divided by a concrete wall with individual packaging
systems.

13. 13
“In Process Material” (IPM)
Optimization
Closed Loop
IPM
Methodology
Materials Products
Manufacturing Operations
IPM Loop
Manufacturing
Plant Site

14. 14
Merits of an “IPM” Practice
 Waste streams become resources
 No Chemistry Changes
 No Process Modification
 No Material Alterations
 Utilization of Existing Resources & Procedures
 Internal Cost Savings
 Competitive Cost Advantage
 Improved Production Performance
 Eliminate landfill burdens (cost & liability)

15. 15
Goal → Recapture “In Process
Materials”
Present
Practice
Landfill
> In ↓ Out $ IPM
Practice
IPM Optimization
< In ↑ Out $

16. 16
THE PROCESS
 The basic grinding process is called –
UltraFineTM
 The uniqueness is grinding in fluids,
preferably water, with or without additives
to achieve precision gradations, uniform
chemistry, and surface morphologies
 The process when used as a compounding
system then becomes an IPMTM process

17. 17
The UltraFine “IPM” Process
Feed Hopper
Milling
Rare Earth
Magnets
Conveying
Conveying
Rare Earth
Magnets
Slurry Hopper
Filtration
Conveyor
Conveying
Packaging
Rare Earth
Magnets
Screening
SHIPPING
Customers
Custom
Fine Ground
Elastomeric
Powders
Feed Hopper
RECEIVING
Customers
“IPM”
Drying
Pollution Control
Water Make-up
Pump
Pump
Wet Grinding
Note: Heavies & Light
Contaminate Ends
Removed
C
o
n
v
e
y
i
n
g
Conveying

18. 18
Nature of UltraFineTM Powders
High Surface Areas
Uniform Chemistry
Uniform Gradations
Clean
Flowable
Replaces Costly
Polymer Equivalents
High Yields
Energy &
Environmentally Sound

19. 19
Rubber Material: FKM Compound with 25% SERI 170 mesh Regrind Material
PROPERTIES:
Unit Results Results
Test Pieces 214 Orings No Regrind 25% FKM Regrind
Original Hardness, Shore A (ASTM Slab) point 75 75
Properties Hardness, I.R.H.D. point 70 71
Tensile Strength MPa 14.0 13.9
Ultimate Elongation % 251 236
Modulus @ 100% Elongation,Mpa % 6.3 7.2
Heat Aging Change in Hardness, Shore A point 0 +1
Change in Tensile Strength % +39.9 +40
250°C x 70 hrs. Change in Ultimate Elongation % -19.1 -21.8
Immersion in Liquid Change in Hardness point -2 -1
Fuel C Tensile Strength % -7.7 -9.6
Ultimate Elongation % +1.9 -1.8
23°C x 70 hrs. Change in Volume % +2.8 +2.2
Immersion in Liquid
Methanol Change in Volume % +3.7 +3.0
23°C x 24 hrs.
Compression Set Compression = 25% % 17 16
175°C x 22 hrs.
SERI

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HNBR Compound with 25% SERI 170 Mesh Regrind Material
PROPERTIES: Unit Results Results
Test Pieces ASTM Dumbells No Regrind
25% HNBR
Regrind
Original Hardness, Duro A point 73 73
Properties Tensile Strength MPa 29.30 29.4
Ultimate Elongation % 225 238
Tear Die B kN/m 21.43 25.06
Heat Aging Change in Hardness point +1 +1
Change in Tensile Strength % +7.4 +2.7
120°C x 70 hrs. Change in Ultimate Elongation % +1.3 -2.1
Immersion in Liquid Change in Hardness point -10 -11
Fuel C Tensile Strength % -70.3 -61.0
Ultimate Elongation % -47.6 -42.4
30°C x 48 hrs. Change in Volume % +37.7 +37.3
Immersion in Liquid Change in Hardness point -10 -12
Fuel C +M10 Tensile Strength % -71.3 -75.0
Ultimate Elongation % -52.4 -53.5
30°C x 48 hrs. Change in Volume % +56.7 +56.9
Immersion in Liquid Change in Hardness point -10 -11
Fuel C +E20 Tensile Strength % -71.6 -72.3
Ultimate Elongation % -51.1 -54.5
30°C x 48 hrs. Change in Volume % +53.9 +53.7
Immersion in Liquid Change in Hardness point -8 -9
Fuel C +MTBE15 Tensile Strength % -67.9 -66.7
Ultimate Elongation % -48.4 -47.2
30°C x 48 hrs. Change in Volume % +36.0 +36.4
Compression Set Compression = 25%
% 10.6 11.0
120°C x 70 hrs. Plied Slabs
SERI

21. 21
Dynamics of the UltraFineTM
Wet Grind System
Precision
Intimate
Grinding
in a Fluid
System
Customer
Specialty
Polymer(s)
Precision
Tailored
Ground
UltraFineTM
Powder
Light End Contaminates Removed
Heavy End Contaminates Removed

22. 22
Custom Tolling - UltraFine™ “IPM”
Flow Loop
Customer –Facility
1. Collecting Source
Separated Materials
2. Labeling
3. Shipment
SERI RECEIVING
4. Receiving
5. Storage
6. Production
Scheduling
UltraFine PROCESSING
7. Primary Reduction
8. UltraFine Grinding
9. Precision Screening
SERI PACKAGING
10. Drying
11. Packaging/pre-weigh
12. Warehousing
SERI SHIPPING
13. Product Certification
14. Final QA/QC
15. Material Balance
16. Shipment (Round-Robin)

23. 23
Present to Future Practice
Customer IPM
Converted to CG-
FKM-170 UltraFine
Powder
Back to High Quality
New Parts

24. 24
The Benefit
Maintain Product Properties
EconomicValue,$
IPM Value, Time
Landfilling, $ Losses, Stop
Generally Improved Manufacturing
Experiences and Significant
Economic Benefit
Transition

25. 25
Future Improvements
FKM
Teflon
Aflas
FQM
New
Specialty
Development in Time
Savings/Profit

26. 26
SUMMARY OF SERI’S SERVICES TO
CUSTOMERS
 Established
 Certified For Quality and Methodology
 Professional Staff and Services
 Confidentiality
 Precision Grinding to Produce
Specified High Quality UltraFineTM
Powders
 Partnering for Future Innovation and
New Developments

27. 27
Result
 Reduced Material Costs
 Capture Lost Opportunity Value
 Improve Production
 Leading Edge Opportunity
 Improve Product Margins
 Maintain Competitive Edge

28. 28
Thank You
An “IPM” Partnership
SERI

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Shipping Area

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Receiving Area

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Back of Manufacturing Facility

32. 32
Manufacturing Facility

33. 33
SERI Manufacturing Facility

34. 34
Direct line to the power company