Creating markets for recycled resources

Fine Rubber Powders from Rubber Crumb & Buffings

Project code: TYR0009-26 Date of commencement of research: 25 December 2005 Finish date: 19 February 2006

Written by:

Anne & Russ Evans

Published by:
The Waste & Resources Action Programme The Old Academy, 21 Horse Fair, Banbury, Oxon OX16 0AH Tel: 01295 819900 Fax: 01295 819911 www.wrap.org.uk WRAP Business Helpline: Freephone: 0808 100 2040

May 2006

Tyres Report

1.

Summary

Generally, the finer the crumb rubber, the higher the value. Also, the more difficult it is to manufacture, using sophisticated, and expensive, equipment. So, what does it take to make really fine crumb rubber, and what is it used for? This report seeks to answer these questions. Edge Rubber is a small manufacturing company in the East-central Pennsylvania USA city of Chambersburg that makes fine rubber powders for use in new tyres, brake linings and pigments. These three markets are extremely difficult to penetrate successfully, even though environmental consultants globally assume that post-consumer tyre materials are an easy fit into products of these industries.

2.

The Edge Rubber Story

Numerous customers, including Goodyear Tire & Rubber Company, Cooper Tire & Rubber Company (and its Oliver retreading division), Bridgestone-Firestone, Titan Tire Corporation, Federal Mogul Corporation and Carlisle Motion Control Industries, Inc, are supplied by Edge Rubber of Chambersburg, Pennsylvania USA. The company began as a division of Baker Rubber, and passed through ownerships by NRI Industries (1996-2000), Polytek Corporation (2000), and Landstar Industries (2001-2003), before becoming independent in 2003.

The company is a producer of high quality rubber powders. It manufactures qualitycontrolled medium and fine powders, primarily for use by other manufacturers as component materials. Its customers have a choice of either whole tyre-derived rubber or tread only-derived product. All of the companys products meet demanding standards for purity, size distribution, and packaging. The company's factory is the longest running, most successful rubber powder facility in the United States. It is the only rubber powder manufacturer using wet-grind technology to produce a premium, fine grade product providing recycled content for the automotive industry. Fine Rubber Powders from Rubber Crumb & Buffings

Page 2

3.

Products

The company is a reprocessor, supplying rubber granulates and powders derived from whole passenger tyres, whole truck tyres, and retreaders buffings, as a feedstock for other products. Most of its finished products are rubber granulates and powders that are 10 mesh to 140 mesh, and most of its feedstock is 1/4" (6.4mm) rubber crumb or larger. The company can use 1" (25mm+) crumb rubber as feedstock, but prefers 1/4" (6.4mm) material if the price is competitive. Its primary products are rubber granulates and powders for the automotive industries, including materials for tyres to replace clays and other fillers (20 mesh, 30 mesh, 50 mesh & 80 mesh depending upon the tyre manufacturer) and for brake liners (20 mesh and 30 mesh depending upon the manufacturer). 140 mesh materials are supplied for roofing and to PPG Industries, a major paint supplier to the automotive industry. The company also supplies the bitumen crack and seal industry (10 to 20 mesh).

4.

Process

Raw material feedstock enters the plant at one side, and finished products leave the plant, packaged, on the opposite side (see aerial photograph above). The company uses two different processes to manufacture its products. The choice of processes depends upon the size and uniformity of the product being manufactured to meet the customers specifications. There are two ambient process lines, and one wet grind process line.
4.1 Wet-Grind Technology

The company is the only wet-grind manufacturer in the industry. The wet-grind system produces a premium, fine grade material that meets the demanding specifications of the automotive industry. The surface characteristics and shape of the particles produced with this system enable the product to be more successfully integrated into other polymer materials. The unique wet process line mixes rubber crumb feedstock into a slurry, then grinds the slurry. Because of the friction of the grinding process, an immense amount of heat is given off, and some of the slurry evaporates into steam. A sophisticated extraction and drying system allows bagging the finished product at the end of the process line Rubber grinding generates large amounts of heat as rubber particles are torn apart. In the wet-grind process some of the water mixed with the rubber granulate to be ground is heated into steam and vented. Because the wet-grinder is not a pressure vessel, the entrained water prevents the material from overheating.

Fine Rubber Powders from Rubber Crumb & Buffings

Page 3

This is the companys wet process mill. The steam rising is a visual reminder of the heat given off when rubber is ground making plant design and safety important issues. Photo by Edge Rubber.

This Process Flow Diagram is a simplified explanation of the companys wet grind technology. Diagram by Edge Rubber.

Fine Rubber Powders from Rubber Crumb & Buffings

Page 4

4.2 Ambient Grinding Technology

The company also uses ambient grinding technology to produce material for the moulded goods, sports surfacing and bitumen industries. The ambient grinding is done using granulators and cracking mills.

The factory is a tangle of chutes, conveyors and ducts, through which feedstock and products being manufactured flow from one machine to another. Photo by Edge Rubber.
4.3 Packaging and Shipping

After drying, fine rubber powder from the wet process is directed to a bagging station where the fine grind is put into SuperSacks, plastic bags or paper bags, depending upon the customers needs. Granulates and powders from the ambient lines are also directed to bagging stations. If the rubber granulates/powders are put into plastic bags, a small paddle with spikes is used to punch small holes in the sides of the plastic bags, after filling, so that any moisture in the granulates or powders can vent and dont fog up the bag causing caking.

Fine Rubber Powders from Rubber Crumb & Buffings

Page 5

This is one of the bagging stations where a SuperSack weighing about one tonne is being filled with rubber granulate or fine powder. Photo by Edge Rubber, Inc.

Fine Rubber Powders from Rubber Crumb & Buffings

Page 6

5.

Quality Control & Testing

The company is ISO 9001:2000 certified. Its internal testing laboratory provides all customers with reliable data on each product shipment. Most automotive customers require ISO 9001 certification and quality assurance, but independently test each batch received for consistency and to insure that what is received is within the very tight specifications of the tyre and/or brake industries. The companys laboratory tests assure that a product meets its customers requirements before it is shipped, improving the likelihood of customer satisfaction.

A lab technician prepares a sample for a sieve analysis, using ASTM standards and protocols. Each bath or customer shipment is checked for quality, consistency and adherence to the strict specifications expected by customers. Photo by Edge Rubber.

The laboratory is involved in the companys manufacturing operation. It is a full, state-ofthe-art rubber granulate/powder test facility, that performs all standard chemical tests and sieve analyses for rubber particulates using the latest technology and test equipment, including Thermogravimetric Analysis (TGA). The company produces rubber granulates and powders from various types of recycled tyre material. The lab tests feedstock, raw material streams and finished products to ensure that its rubber products meet all of its customers requirements all of the time. The company uses ASTM (American Society of Testing & Materials) test method D-5644 for performing sieve analyses on rubber granulates and powders.

Fine Rubber Powders from Rubber Crumb & Buffings

Page 7

6.

Contribution to Recycling

The company claims an annual output of approximately 35 million pounds (about 15,900 metric tonnes). This converts to about 1,040,000 whole post-consumer passenger tyres, 265,000 whole post-consumer lorry tyres, and buffings from 580,000 lorry tyre casings being retreaded (based on 40%, 40%, 20%).

7.
7.1

Why a Best Practice?

Establishing Markets, Standards & Protocols

The company has been in the forefront of establishing reliable, consistent and longterm markets for granulated rubber products and has worked with the tyre and rubber companies to develop protocols and products that are reliably consistent in meeting very tight specifications and expectations.
7.2 Testing for Product Quality

The companys on-site laboratory is among the best equipped and managed in the business, using it to guide the manufacturing process and assure compliance with tight customer specifications.
7.3 Manufacturing Innovation

The companys innovative use of the wet process to meet customers exacting needs, make this a Best Practice.
7.4 Supplier to New Tyre Manufacturers

The company supplies new tyre manufacturers which is extremely difficult to do because of the extremely stringent requirements. Yet the company has maintained a long-term relationship with most of the worlds largest new tyre manufacturers while broadening its product base to the pigment and friction industries so it is not totally dependent upon the tyre companies. The companys ability to satisfy these difficult industries makes this a Best Practice.

8.

Additional information:
Samuel E Kauffman, General Manager Edge Rubber 811 Progress Road Chambersburg, Pennsylvania 17201 USA Tel: +1 717 267-0599 Fax: +1 717 262-4909 Email: sfauffman@edgerubber.com URL: www.EdgeRubber.com

___________________________________________________________________________
Important Warning The information set out in the above is of a general nature only and not intended to be relied upon in specific cases. The information does not take account of environmental issues which should be discussed as a matter of routine with the regulatory authorities (the Environment Agency in England and Wales, the Scottish Environment Protection Agency in Scotland and the Department of the Environment in Northern Ireland). Consequently, the information contained in this website is provided only on the condition that WRAP and their sub-contractors will not be liable for any loss, expense or damage arising from the use or application of such information. Individuals and organisations proposing to utilise any of the practices and methodologies within these publications are advised to seek appropriate expert professional advice in respect to their specific situation and requirements. Any errors or omissions contained within the reports are the responsibility of the respective authors.

Fine Rubber Powders from Rubber Crumb & Buffings

Page 8