Sustainability through Testing - MSME Perspective BY DR. K. RAJKUMAR Indian Rubber Manufacturers Research Association Affiliated to DIPP, Ministry of Commerce & Industry, Govt of India B-88, Road No. 24, Wagale Industrial Estate, Thane West, Maharashtra 400604 Email : [email protected], [email protected]; website : www.irmra.org
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Sustainability through Testing - MSME Perspective
BY
DR. K. RAJKUMAR Indian Rubber Manufacturers Research Association
Affiliated to DIPP, Ministry of Commerce & Industry, Govt of India
MSME industries do not give importance to testing due to which they :
- face huge rejection
- face huge penalty
- unexpected loss
- not budgeted cost
Less competitive
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
COST OF POOR QUALITY • The rejection and rework - adds to cost of poor
quality i.e
• Rejection and reworks leads to big loss in terms of time and economy.
• The lack of inspection / testing and absence of control measures at appropriate stage, leads to not only financial loss but also delay in execution of order.
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Importance of testing to segregate quality
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Environmental hazard ??
• Disposal of rejected materials - an environmental issue and hence, the industry has to face several consequences.
• All these issues make industry less competitive / loss of business / loss of customer and finally to closure of Industry.
Solution :
• Testing of raw materials and in process materials at appropriate stage during manufacturing and will give benefit of becoming sustainable.
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Reduce the Cost of Poor Quality
• Importance of testing to minimise overall cost of poor quality.
• IRMRA conducts several skill development & training activities for MSME sectors emphasising the role of testing and its importance to become sustainable.
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Parameters to check
Basic chemicals”
– Appearance
– Volatiles content
– Ash content
– Solubility test
– Identity (IR spec)
– Assay ( GC/HPLC) or Chemical methods.
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Materials Function
Elastomer/raw rubber Basic components in rubber compounding
Fillers Used for reinforced or modified the mechanical properties
and also to reduced the cost
Plasticier To ease the processing, to modify the specific properties
and also as extender’
Anti oxidant To protect the rubber from ageing
Accelerator To increase vulcanization process and reduced the time of
vulcanization
Activator To increased the accelerator efficiency
Vulcanization agent Needed during vulcanization process to produced a
crosslinking
Other ingredients Used for specified purpose such as for coloring, as retarder
etc
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Chemical testing of Finished products
• Polymer Identification: Some of the basic polymer can be
identified easily by this technique.
• Burning characteristics
• Beilstein Test (copper wire test)
• Action of 80% Sulphuric acid
• Action of Conc. Nitric acid
• Pyrolysis test
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9/27/2018
Identification of Rubber by chemical test
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Acetone Extraction
• Test Apparatus : Soxhlet assembly.
• Test Method : ASTM D 297 –93
• Need for Testing :
• Determination of the following ingredients:
• Polymer identification.
• Free sulphur.
• Antioxidants.
• Accelerators.
• Waxes, mineral oils.
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Ash content
• Test Method : ASTM D 297-93.
• Need for Testing
• Quality control,
• Inorganic filler determination.
• Zinc oxide determination
• Elemental analysis.
• Test Procedure : The samples are heated in a muffle furnace at 550 ± 250C (direct method). 900 ±250 C (indirect method). All organic matter will be oxidized and inorganic ash will remain
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Sulphur Analysis
• Test Method : ASTM D 297-93.
• Types of Determination :
• i). Free sulphur.
• ii).Total sulphur.
• iii).Combined Sulphur.
• Free sulphur is determined by using extracted portion of acetone extract.
• Total sulphur analysis is carried out on an untreated sample.
•
• Combined sulphur =Total sulphur – Free sulphur
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9/27/2018
Liquid Swelling
• Test Method : ASTM D 471 –98.
• Methods of Testing : Gravimetric change.
• Volumetric change.
• Dimensional change.
• Parameter measured:
• 1. Change in mass
• 2. Change in volume
• 3. Change in hardness
• 4. Change in tensile
• 5. Color change of liquid
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Need for liquid swelling
• Rubber products in service are subjected to various types of
liquid environments.
• Due to absorption or extraction of rubber liquids, the rubber
component will either shrink or swell.
• By swelling, mechanical and functional properties of the
component deteriorate. Also dimensions of the component may
change.
• The component will not be serviceable
IRMRA - An accredited Lab for your Research & Testing needs
9/27/2018
Standard test oils
• ASTM oils, 1, (ap-124oC)
• ASTM oils 2, replaced by IRM 902 (ap-93oC)
• ASTM oils 3 replaced by IRM 903. (ap-70oC)
• ASTM oils 5(ap-115oC)
LOW ANILLINE POINT THE MORE SEVERE THE
SWELLING ACTION BY THE OIL
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9/27/2018
Standard test liquid
• Fuel A Iso octane 100
• Fuel B Iso octane 70 Toluene 30
• Fuel C Iso octane 50 Toluene 50
• Fuel D Iso octane 60 Toluene 40
• Fuel E Toluene 100
• Fuel F Diesel fuel
• Fuel G Fuel D 85 ethanol 15
• Fuel H Fuel C 85 ethanol 15
• Fuel I Fuel C 85 methanol 15
• Fuel K Fuel D 15 methanol 15
IRMRA - An accredited Lab for your Research & Testing needs