Extrusion Equipment

for the Tire and Rubber Industry

Extrusion Equipment
for the Tire and Rubber Industry
04 Company Profile 20 Equipment for Manufacturing Profiles, Hoses
and Industrial Rubber Goods
06 Extrusion Lines for Tire Components 22 Hose Extrusion Lines
08 Tread/Sidewall Lines 24 Extruders for Rubber-Profile and Hose Extrusion
10 Innerliner Lines
12 Pin-type Extruder QSM 26 TROESTER Solutions by the Experts
14 Roller-Head/SRRD Systems 28 Project Management Support
15 Calender Systems 29 Research & Development
16 CoExtrusion 30 Manufacturing and Assembly
18 Downstream Equipment 32 Electrical Equipment, Line Control and PLC

34 TROESTER Worldwide
 »We are what we repeatedly do.
Excellence, then, is not an act but a habit.«
Aristotle (Greek Philosopher, 384 - 322 BC)
Company Profile

Foundation Year 1892

Managing Directors Dr. Peter Schmidt (Managing Partner)

Dipl.-Ing. Bernd Pielsticker

Staff approx. 500 employees in R&D and manufacturing, mechanical

and electrical design and administration

Subsidiary Companies TROESTER Machinery, Ltd./USA

TROESTER Machinery (Shanghai) Co., Ltd./PR China
X-Compound GmbH, Switzerland

Representative Offices in Russia and France

Representations in over 40 countries

04
Excellence in Extrusion

In 1892, the engineer Paul Troester struck upon the innovative idea of building
machines which could process unvulcanised rubber and guttapercha. He thus
laid the foundation for a name which is world-renowned and synonymous for
technological advancement, quality and outstanding performance in the fields
of rubber and plastics processing.

The essential feature of all machines and lines built by TROESTER is their
superior process technology. Highly qualified development engineers design
efficient extrusion lines with a long service life. The latest production processes
for the manufacture of tires, profiles, tubes, automotive rubber goods and
cables require customized system technology. TROESTER develops efficient
machine and equipment control systems which flexibly employ the hardware
components of leading manufacturers.

TROESTER developments will continue to set the milestones for rubber and
plastics processing in the future. In doing so, we are committed to the growing
demands for quality, efficiency and environmental compatibility.

05
Extrusion Lines for Tire Components

06
Lines for Manufacturing Tire Components

Tire manufacturers all over the world rely on TROESTER’s Expertise and Experience.
Wide ranging innovative and continual technical development have enabled
TROESTER to become one of the world-wide leading manufacturers of complete
extrusion lines for the production of car and truck tire components.

Compared to the lines made from individual machines, complete tire-component

lines from one supplier offer remarkable advantages. The control system is
developed, designed and programmed in-house by using the latest available electrical
components. All specifications are considered according to the individual needs of the
tire manufacturer. During the whole project the customer only has one contact partner,
who also coordinates transport, installation and commissioning: TROESTER.

This solution also offers advantages for the finished quality of tires. Car and truck
tire components which are produced on TROESTER lines are characterized by
high dimensional accuracy as well as extremely small positional tolerances between
the individual components.

Even when it comes to the development of new products, TROESTER offers our
customers comprehensive know-how and the solid reassurance associated with
“Made in Germany”.

07
Tread/Sidewall Lines

08
 >> High speed line (e.g. 45 m/min for tread, 60 m/min for sidewall)
>> Take away conveyor with shock cooling for sidewall components
>> E-house container on mezzanine
>> Special water treatment
>> Optimized material flow with winders close to the extruder area

high speed

09
Innerliner Lines

10
 >> Up to 70 m/min. line speed
>> Minimized floor space
>> Automatic calender sleeve change
>> Cloosed loop forced air cooling
>> High energy efficiency
>> Cold edge cutting
>> E-house container on mezzanine

air cooling

11
Pin-type Extruder QSM
The QSM Extruder

The QSM technology was substantially co-developed, in the mid 1970s,

by TROESTER. The continuous development of this technology allowed
tire manufacturers to extrude a wide range of rubber compounds, with
optimum plasticization, without the need to change the extruder screw.

The QSM pins, which are inserted externally through the barrel wall, con­
tinuously divide the stream of rubber compound. This intensive con­tin­uous
mixing achieves a thermally homogenised and gentle plasticization of the
compound at a low temperature.

The screw of a QSM extruder is usually made from nitrided steel. In some
cases, where required, special steels are also used. When processing
particularly abrasive compounds, that cause excessive wear on the outside
flight tips, a special hard coating can be applied. TROESTER also has
special screw coatings in its delivery programme.

The QSM Extruder at a Glance

>> Universal for all rubber compounds

>> High throughput, whilst maintaining optimum production quality
and extrusion temperature
>> 60 – 300 mm screw diameters
>> Self-cleaning
>> Also available as vacuum-version
>> Individual adjustment of the extruder performance by
modification of the pin configuration

12
Schematic view of the
cross flow mixing barrel

QSM compound cross

section: flow division
obtained by the pins of
the pin-type mixing barrel

13
Roller-Head/SRRD Systems

Roller-Head, Single-Roll Roller Die

and Calender Systems

Roller-Head Systems
Roller Head Systems are typically used in tire industry to produce innerliner
materials. As opposed to multi-roll calenders the rubber compound is fed
through the roll gap directly from a wide base extrusion head to achieve
porosity free rubber sheets/profiles.

14
 Calender Systems

Single-Roll Roller Die Systems

The Single-Roll Roller Die System is a multipurpose system for various
applications producing high-quality profiled rubber sheets, for example
sidewalls, treads apex strips and innerliners.

Calender Systems
When producing high-quality articles made from rubber compounds,
calenders play an important roll. Due to the variation of roll dimensions, the
number of rolls and their arrangement, there are so many possibilities that
it would exceed the scope of this brochure to thoroughly describe them all.

15
CoExtrusion
CoExtrusion

TROESTER offers a broad variety of CoExtrusion aggregates starting from

extrustion heads with 2 extruders TROESTER CoEx® 2 up to multiple extrusion
systems enabling the extrusion of up to 6 different rubber compounds with
TROESTER CoEx® 5plus1.

The portfolio includes the C-Clamp Head as well as the patented Hammer-
Head and Y-Head all available in multiple opening sizes for optimum adaption
to the customers’ needs. The chosen clamping system depends on the require-
ments and on the individual production routine of the tire manufacturer.

The flow channels are matched to the customers’ individual requirements

and their products with the use of Finite Element Flow Simulation. The
flow history for the rubber in the head is analysed and adopted in order to
achieve a constant swelling behaviour at the head outlet and a uniform flow.

The general goal is a material-independent flow channel design in order to

allow an easier design of the subsequent flow-segments.

Besides an appropriate forming of the extrudate, the flow channels are

designed with the lowest possible pressure consumption. This helps to
reduce the compound temperature at the outlet and to increase the
extrusion speed.

The features as a whole meet the demand of the tire industry for flexible
manufacturing equipment to achieve a high productivity of the line at an
increased variety of products with the best price/performance ratio.

CoEx ® is a registered trademark of TROESTER GmbH & Co. KG in Germany

16
Design advantages Flow Channels

Chimney extrusion – > Proven technology adapted to the new design

pre die (example)
> No narrow channels or undercuts
Single piece tools
> One overlapping piece can be used for chimney
and non-chimney profiles (only exchange of Modular tools
Tread Sidewall
middle part required)
> Exchangeable middle part for overlapping piece
allows easy lateral positioning of chimney
> Considerable production cost optimization by
– minimizing the required number of extrusion tools
– reducing the changeover times

17
Downstream Equipment

Downstream Engineered in Germany

The downstream of an extrusion line is an integral part of a successful

extrusion line. The seamless interaction between extrusion unit and
subsequent line components assure a high line performance including
remarkable product tolerances at high line speed.

TROESTER has a broad and unique experience with tailor made extrusion
lines. The more challenging the more thankful tire manufacturers are for
the special skills of our engineering team. Together with our customers, we
established several milestones in rubber extrusion in regard to line speed,
accuracy, cooling and winding technology, etc.

18
Downstream Equipment Portfolio

>> Take away and shrinkage conveyors

>> Bottom and/or edge cementing
>> Cooling technology
>> Auto-threading
>> Product assembly
>> Cross skiver
>> Tread cutter
>> Winding technology with cassette handling devices
>> Booking technology
>> Measuring systems
>> Line control

19
Equipment for Manufacturing Profiles, Hoses and Industrial Rubber Goods

20
Equipment for Manufacturing Profiles, Hoses
and Industrial Rubber Goods

Permanent technical further development in collaboration with TROESTER customers

from all over the world provides a security for economically working machines and
lines that stand out for their excellent product quality.

Equipment for the manufacture of profiles, hoses and other technical rubber goods
offer these advantages. From the design work to the manufacture and transport to
the installation and commissioning there is a competent partner for this kind of
equipment: TROESTER.

The large number of worldwide installed equipment for tubes and profiles as well as
the great customer satisfaction with TROESTER as supplier has of course many more
reasons. For example the superior process technology resulting from the development
of efficient machines and lines with a long service life. Further the perfected system
technology for machine and line control play a decisive roll. Another criterion is the
qualified TROESTER service and support which provides customers with the exact
support required, enabling them efficiently to produce high-quality rubber goods after
the starting phase.

21
Hose Extrusion Lines

22
 >> Multi-layer hose line
>> Tailor made design
>> Modular arrangement

flexible

23
Extruders for Rubber-Profile and Hose Extrusion

Extruders for Rubber-Profile and

Hose Extrusion

Key components of profile and hose production machinery are extruders

that are tailored to requirements, combined with gear pumps and/or
extrusion heads.

Extruder gear-pump systems are used to extrude profiles in small sizes

and with narrow tolerances and to process the rubber compound carefully.
The addition of strainer heads allows processing of vast quantities of rubber
compounds, for example in the mixing room.

Special requirements on machine technology, both with regard to the process

and the product, can be paired with tailored solutions. These include the
compact extruder with temperature-control devices integrated into the
machinery and all the electrical drive and control components required.

24
The cross head with hydraulic tool centering enables the extrusion of hoses
to high standards of quality and the minimization of losses when production
starts. The ROTOMEX gear extruder allows the rubber component to be
strained as closely as possible to the extruder.

25
TROESTER Solutions by the Experts

26
TROESTER Solutions for the Tire and
Rubber Industry by the Experts

The key feature of all TROESTER machines and systems is their superior process
technology. Highly skilled development engineers create durable and highly efficient
machinery which fully responds to customers’ requirements for top levels of production
efficiency and quality.

High-tech production processes for the rubber-processing industry are based on

sophisticated system technology. TROESTER develops efficient machinery and systems
concepts, as well as controls, where leading manufacturers’ hardware components are
used flexibly.

Skilled service and support personnel guarantee that equipment is available. At the
design stage already, emphasis is placed on making our products easy for customers’
on-site personnel to use. Detailed and in-depth training of our customers’ staff, help
in the initial phases and an extensive spare-parts service round out the support.

When it comes to advanced solutions for the tire and rubber industry, the TROESTER
Group has the experts.

27
Project Management Support

Outstanding Project Management

Management for Your Success

Individual projects require individual support as well as distinct technical
skills: TROESTER project management goes even further.

TROESTER project managers are customer’s link to technical and

commercial departments. With broad engineering know-how they are
able to provide a customer-oriented realization of the projects.

Worldwide Installation Competence

Complete planning and realization of installations, also for demanding factors
TROESTER finds appropriate solutions. With its global settlements, the
TROESTER Group is flexible and experienced to send out service engineers
short-termed worldwide.

Servicing the Future

TROESTER’s experts analyze required wear parts and consult about
system technology upgrades to maintain an up-to-date production.

Reliable Partner in Supply Chain

With a short-termed reaction time and an extensive stock of spare parts,
TROESTER enables an uninterrupted operation of the customer’s
machinery.

28
 Research & Development

Shaping the Future

Because development is an on-going process, we optimize our machines

and systems continuously to offer our customers maximum functionality
and quality. We use state-of-the art tools to include the latest findings and
innovations in our products and collaborate with a range of different partners
from industry and the world of science.

To implement specific solutions and concepts, TROESTER has a well-

equipped pilot plant where trials and ideas can be put into practice and
carried out. In addition to extruders with different extrusion heads and in
key dimensions, we can offer a wide variety of extruder screws to suit
virtually any application. TROESTER also has roller head machinery to
create rubber sheets as required under production-related conditions.

To produce the often tailor-made solutions in time, TROESTER uses

databases, process expertise and simulation tools, all of which is
underpinned by a highly qualified and dedicated team of people. We liaise
with our customers to develop tailored solutions to meet all requirements
wand specifications.

29
Pin-type Extruder
Manufacturing andQSM
Assembly

Manufacturing and Assembly

Customers have come to expect a high degree of quality from TROESTER

because the true efficiency of machinery only becomes apparent during
a long product life cycle. To meet these expectations TROESTER places
huge emphasis on in-house manufacturing. In the past few years, the level
of in-house manufacturing of TROESTER machinery has steadily increased.
Insourcing instead of outsourcing is the roadmap pursued.

The cornerstones for increasing production and enhancing product quality

were substantial investment in TROESTER’s machinery, CNC-driven
production processes and stepping up training of all personnel.

30
The drive to manufacture products made in Germany has given an
enormous boost to TROESTER employees’ identification with the company.
TROESTER’s well-trained personnel works in three shifts and takes its
responsibility towards customers very seriously. As a result, personal store
is set by checking the quality of machinery made in-house.

>> Screw milling

>> Hard-facing of screws
>> CNC controlled machining
>> Final finishing of process
relevant surfaces
>> Thorough inspection process

31
Line Control and PLC
Electrical Equipment and Line Control –
Solutions from One Source

The extrusion line control systems as well as the design of electrical

components are significant elements of TROESTER’s equipment portfolio.
The extrusion unit works with the downstream equipment as a functional
unit enabling constant product dimensions in the various production stages.
The control is developed, designed and programmed in-house, specialists
for several control-, drive- and measuring-systems are available. Electrical
components can be delivered according to customer’s requirements.

Typically the line control consists of a PLC-PC architecture. In the field area
up to 100 electrical devices like drives, sensors, measuring equipment,
identification and marking systems are usually linked by an Ethernet
based fieldbus system and controlled by the PLC. The Line-PC is used
for visualization and process trending, recipe handling and the long-term
production and quality protocol. For each production run the production
parameters as well as the quality results will be stored. Such production
results are summed up in statistically evaluated parameters like CPK-values
(statistical process ratio).

A configuration with the PC as a redundant system is available, to ensure that

quality documentation and production reports are provided without any lag.

32
 Electrical Equipment

Ready for Industry 4.0

>> Remote access for PC, PLC, drives and further control and
measuring systems
>> Customized MES interfaces for production schedule, recipe data,
quality data, material validation, production data and further
information
The container construction allows for an extensive pre-assembly and
>> Quality-, process- and machine data collection and storage (for the pre-acceptance by the manufacturer and thus results in shorter
commissioning times on site.
analyzing on external systems)
>> Integration of Barcode- and RFID-systems
>> Maintenance schedule and protocol
>> Web interface for machine visualization (machine operation blocked)
>> Development of further service and support tools in cooperation
with customers

33
TROESTER Worldwide

TROESTER GmbH & Co. KG, Germany

TROESTER Machinery Ltd., USA

TROESTER Machinery (Shanghai) Co., Ltd.
X-Compound GmbH, Switzerland

34
TROESTER GmbH & Co. KG
Am Brabrinke 1-4
30519 Hannover, GERMANY
Phone +49-511-87040
Fax +49-511-864028
E-mail innovations@troester.de
www.troester.de

TROESTER Machinery, Ltd.

300 Loomis Avenue
Cuyahoga Falls, Ohio 44221, USA
Phone +1-330-928-7790
Fax +1-330-928-7239
E-mail info@troester-usa.com
www.troester-usa.com

TROESTER Machinery
(Shanghai) Co., Ltd.
Workshop No. 1, Area C
No. 6999 Chuan’sha Road, Pudong
Shanghai 201202, PR CHINA
Phone +86-21-58598308
Fax +86-21-58598310
E-mail info@troester.cn
www.troester.cn

TROESTER Moscow
Representation Office
2nd Sinichkina St. 9A, Bldg 3
Moscow, 111020, RUSSIA
Phone +7-495-7601423
E-mail lusia13710@mail.ru

X-Compound GmbH
Hardmatt 932
CH -5082 Kaisten, Switzerland
Phone +41-62-869 10 30
Fax +41-62-874 32 08
E-mail info@x-compound.ch
www.x-compound.ch
© TROESTER GmbH & Co. KG 2019. CoEx ® is a registered
trademark of TROESTER GmbH & Co. KG in Germany.

The particulars in this catalog are for general information

only. TROESTER GmbH & Co. KG assumes no liability for
errors or omissions and reserves the right to make changes
in design or specifications of the products at any time
without prior notice.
www.t roest er.de