Production Process
Butyl reclaim is mixed with a number of chemicals and other elements to form a compound for inner butyl tubes. Sheets of this compound are passed through a stainer to remove any foreign matter from the compound. It is then put through an extruder to give the circular shape as per the particular size of the tube. The circular tube is then cut as per the desired length and valve jamming as per the appropriate valve size is conducted. Post that the ends of the flat tube are sliced together to form a spliced flat tube. The spliced portion of the tube is kept on ice for cooling so to strengthen the joint of the tube. Further, they are inflated and put in desired moulds for curing. After the tube is cured, the core is inserted in the valve and is inspected by inflating it. After it is thoroughly checked, it is packed for dispatch.
The Butyl scrap is collected from a network of approved suppliers and is further segregated to ensure only the Butyl material is taken for reclaiming. The entire process is divided into two phases. In the first phase, the scrap is segregated to pick only butyl scrap.Then such scrap tubes are cut into 3-4 pieces and puncture patches are removed from these . Such segregated scrap is taken into cracker machine to convert these into crumb. Now these crumbs are washed in a big hub.Under these all processes heavy magnets removes any kind of iron part mixed with the crumb.
In second phase the material is devulcanized into an autoclave under 200 degree temperature, which converts crumbs into lumps and lumps are filtered with screens from 60 to 100 Mesh for metal impurities through straining and then further refined for high quality butyl reclaim at the end.
