Production process
At Bekina® Compounds, we combine smart processes with versatile machinery to always create the ideal conditions for producing high-quality compounds. Our automated production lines, together with the expertise of our dedicated production team, form the foundation for safe, flawless manufacturing, smooth delivery and optimal processing of our compounds into finished products at our customers’ facilities.
This enables Bekina Compounds to produce a wide range of compounds, based on numerous polymers and in various delivery formats. In addition to automated batch-off installations, we also have granulation lines to produce granulate (mainly TPEs) of various sizes.
A major advantage is our iCOM® installation, where we can continuously and at high speed blend a masterbatch with the vulcanisation system and filter it into the final compound, complete with inline quality control.
We produce compounds for various processing techniques such as:
- Extrusion
- Injection moulding
- Compression moulding
- Transfer moulding
- Autoclave
- Calendering processes
Mixing line 1
Polymers
We mix synthetic rubbers and natural rubbers, but also TPEs
We mix synthetic rubbers and natural rubbers, but also TPEs
Our range of polymers includes:
Ethylene–propylene rubber (EP(D)M), natural rubber (NR), styrene–butadiene rubber (SBR), butadiene rubber (BR), isobutylene–isoprene rubber (IIR), nitrile rubber ((H)NBR), epichlorohydrin rubber (ECO), as well as various specialty polymers and certain types of thermoplastic elastomers (TPEs).
Thanks to this broad range of polymers, we can always formulate the right compound, perfectly tailored to your specific product requirements and production process.
Weighing and dosing
Automatic weighing of the fillers
Automatic weighing of the fillers
The mixing process starts with precise weighing and barcode scanning based on the recipe in our MES system. The fillers and oils, usually supplied in big bags or IBCs, are automatically dosed directly into the mixer via our AZO system. The rubber polymer is weighed directly from the pallet on a scale by the mixer operator, together with the small-component sachets that are pre-weighed by our offline automatic weighing system from Colourservice (see mixing 2 below).
The entire weighing and mixing process is digitally recorded and visualised in real time in our MES system. Batch reports with detailed weighing data are always available for maximum traceability and quality control.
Mix
The heart of Bekina Compounds: the internal mixer
The heart of Bekina Compounds: the internal mixer
Our 75 litre tangential internal mixer is the beating heart of our production. This powerful machine mixes rubber, fillers and oils quickly and homogeneously into consistent compounds. Downstream we continue on open mills with a stock blender. Depending on your requirements, we then send the compound to our automated batch-off installation or granulation line.
Cooling and packaging
High-quality compounds in the form that best suits your production process
High-quality compounds in the form that best suits your production process
Our compounds are ready-to-use and can be used directly in our customers' production processes. We also focus on close communication and customisation in terms of packaging: we tailor the packaging completely to the specific wishes and requirements of each customer.
This allows us to offer a wide variety of delivery forms:
- Endless strips (for injection moulding or extrusion)
- Plates or slabs (with or without film between)
- Pellets/granules
Treated with anti-tack and supplied in the required dimensions (width, thickness, sizes, weights, etc.) – always according to the customer’s specifications.
We offer flexible packaging options, such as disposable or Euro pallets, reusable (mesh/wooden) boxes or cardboard boxes.
Mixing line 2
iCOM®
Mixing a masterbatch into a final compound
Mixing a masterbatch into a final compound
Mixing line 2 is a separate mixing line for blending masterbatches into the final compound. Our unique patented iCOM® technology (integrated continuous mixing & straining) is there a continuous process for the final mixing and filtering (up to 180 mesh) of compounds. iCOM® is equipped with two Brabender feeders that dose the vulcanisation system gravimetrically. The combination of a cold-feed single-screw extruder and a gear pump provides excellent temperature control, a greatly increased throughput and a sharply reduced batch-to-batch variation compared with conventional final batch mixing on an internal mixer. In addition, the line is equipped with an inline quality control (rheometer) for optimal process control.
Extrusion & filtration
Two vacuum extrusion lines
For filtering compounds
For filtering compounds
Bekina Compounds has extruders for profile extrusion of TPEs and rubbers, as well as filtration of rubber compounds. We regularly invest in optimising and expanding its production facilities to ensure high-quality finishing of even larger volumes. This led to the addition of a second vacuum extrusion line for filtering rubber compounds up to 180 mesh.
Automatic weighing installation
Fully automatic weighing
Of small components in dispersible sachets
Of small components in dispersible sachets
At Bekina Compounds, precision and efficiency go hand in hand. With our state-of-the-art Colourservice installation, we guarantee extremely high dosing accuracy and lightning-fast weighing of our small components, fully in line with the formulation. Each sachet contains exactly the right mix of multiple raw materials and is fully traceable thanks to the barcode and scanning system.