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Author Archives: Kristin Moore

  1. Complex Custom Rubber Extrusions Simplified

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    A complex rubber extrusion made to specification is no simple task. Because of the special shapes and features required for optimum performance, complex extrusions take more time and diligence to create. Complex Rubber Extrusions by Aero Rubber Company Having the right tools and knowledge is crucial to success. Eliminate delays and orders that fail to meet spec. They can leave your business at a halt while you wait for the parts you need.

    Material Selection, Hardness, Dies & Quality Checks

    From aerospace to appliances, some machines rely on complex extrusions for optimal performance. Don’t compromise that performance with out-of-spec parts. Ensure that your extrusion manufacturer follows best practices and checks for quality before it’s delivered to you. Benefit from Aero Rubber’s years of experience manufacturing complex rubber extrusions and receive consistent, quality parts made to spec. Each step from material selection to overseeing production and final quality checks is equally important in the process.

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      Material Selection

      The first step to getting a complex extrusion right is selecting an appropriate material. Materials play a key role in the design of a complex profile. From the ease of creating the extrusion down to the function of the final piece, the rubber compound affects the result. Some elastomers, such as silicone, lend well to more intricate shapes because certain physical properties allow the material to flow more easily. Others, like Viton, are more challenging to extrude because of factors like complex structure. Forcing dense material through a narrow space causes an increase in friction. Excessive friction during the extrusion process can lead to the die overheating, causing disruptions in the flow of material. If this happens, there may be distortions in the final extrusion. You may see pockets where the material has broken off or excess bits that have become stuck to the profile surface.   At Aero Rubber, our sales engineers’ vast knowledge of rubber materials helps them discuss with you the best material options for your design. Through collaboration with you, our engineer learns about your needs for the final part and makes suggestions about materials to meet those needs.

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      Rigidity Vs Flexibility

      The next important step after settling on a material is choosing the correct durometer, or hardness. Are you looking for your product to be very rigid or very flexible? Striking the right balance with durometer is key. This makes sure you get the function you need from your rubber extrusion. Measuring durometer of tubing with durometer gauge A higher durometer material requires more force to move it through the die. However, too high of a durometer makes it difficult to feed the material into a more complex shape. Heat buildup from the extra energy needed to move the material through the die can cause the profile to start curing prematurely. Skin curing can occur when excessive heat buildup within the die causes the surfaces of the profile to cure before the rest of the material. With Aero, our production technicians monitor the heat within the extruder. This makes sure it stays at an appropriate level so problems like skin curing won’t occur. On the other hand, too low of a durometer can cause other types of structural deformities. Since the material would have a softer structure, it would ultimately mean less support and stability for the profile. Low stability in the final product can cause your extrusion to lose its shape or collapse entirely before it can be cured. To avoid material mishaps like these, we recommend considering the use of the final product, its environment, and the properties your part needs for its best performance when making your selection.

      Don’t commit to a material too soon. It’s important to ensure that whichever elastomer and durometer you choose can perform to your satisfaction. When you use Aero Rubber for your complex rubber extrusions, we’re always available to answer your questions. Our Consultative Sales Engineers have decades of rubber industry experience to help you find optimal materials for your design.

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      Creating The Die

      Once you have the right material for your extrusion, the die must be made. Creating the right die for a complex extrusion can be an intensive process with several challenges along the way. One of the benefits of working with Aero Rubber for your custom rubber extrusion is our team’s depth of knowledge. We help spot potential issues and recommend steps to prevent them. Extrusion profiles with small details mean little room for error and more intricate dies. A process called Electrical Discharge Machining (EDM) is used to cut through steel. It uses electricity-infused wires to create a die based on the profile’s design and expected swell of the material. These dies take much more time to create but can produce amazing results. four custom rubber extrusions Through extensive experience, Aero Rubber considers your design before your order is placed. To eliminate unexpected changes, your Sales Engineer may make recommendations. Following these suggestions can reduce late design changes, saving time and money, but all final decisions are up to you. Once the die is created and the extrusion process begins, careful monitoring is important to ensure a balanced flow. This creates a uniform extrusion. Other factors such as swell, extreme heat, or unbalanced flow can affect the outcome. Our adherence to strict quality guidelines during the extrusion process means that we’re monitoring your extrusion’s production closely. Aero Rubber has nearly five decades of rubber production experience. This has helped us develop best practices for trial runs with the die to minimize time spent on adjustments.

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        The Finishing Touches

        What happens at the end of the process is as vital as the planning beforehand. If an extrusion has complex features paired with a thin wall or a low durometer, it will need support to maintain its extruded rubber shape as it cures. Otherwise, the profile can collapse, droop, or lose its shape by the time it’s completely cured. Sometimes a form is necessary to prevent shape loss. The profile rests on the form to maintain its shape as the material cures. This process is known as form curing. Your extrusion is only a success once it matches your original design and meets our quality standards.

      High Quality Rubber Extrusions

      Having a reliable, knowledgeable team in place to handle all the what-ifs of custom extruded rubber production is essential. Aero Rubber has both the right resources and knowledge to make your complex extrusions to spec. Our ISO 9001:2015 certification means that you can count on our team. We hold every product we make, especially our most complex products, to the highest standard. Our inspection process evaluates the appearance, physical properties, and dimensions of the parts we make. This ensures that your product conforms to the specifications you need. Within our trusted network, we ensure only high-quality extruded rubber profiles make it into your hands. We bring together the right materials, equipment, and people for success.

  2. Is Your Rubber Tubing Failing? Tips to Help You Succeed

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    Whether you use tubing for seals, connections or liquid transport the last thing you need is for your tubing to fail. The safety of your employees and customers depends on it. And, not all tubing is created equal. It’s important to consider several factors before you order tubing. We’ll go over some of the most common considerations below, but it’s always a good idea to get an individualized consultation before proceeding.

    Rubber Tubing in a variety of Sizes and Colors Aero Rubber

    Tubing Vs Hose – What’s the Difference

    While sometimes used interchangeably, hose and tubing are different. Tubing is used for low pressure applications. Hose is used in high pressure situations and is reinforced with fabric or wire.

    Tubing Performance Factors

    Do you struggle with extreme temperatures? Have tubing slipping off assemblies? Or find ozone, UV or chemical exposure is a problem? Any one of these factors could degrade rubber tubing and cause unneeded failures if an incompatible elastomer is chosen.

    • Environmental Factors

      • Temperature

      Where you store your tubing and external temperatures impact your choice of tubing. Not all rubber works well in every temperature. Too hot or too cold and the rubber tubing will need to be retired early. Consider outdoor temperatures or the temperature of liquids flowing through the tube when making tubing decisions.

      • Ozone & UV

      Just as sun and ozone levels can harm our skin, they can also deteriorate rubber materials creating cracks or dry rot. Take careful note when testing products inside, that will ultimately be used outside.

      • Abrasion

      Does your rubber tubing get dragged or does it rub against something? If so, you will need an abrasion resistant rubber to withstand erosion or mechanical wear. Higher durability means reduced maintenance.

    • Chemical Exposure

      Chemical contact, both inside and outside the rubber tube impacts performance. Always consider the factors your tubing will encounter before choosing a type of rubber. Using Ethylene Propylene Diene Monomer (EPDM) tubing for ozone or UV exposure is ideal. But, run petroleum products through the tubing, and it will quickly deteriorate and become fragile.

    • Special Standards

      As we said earlier, no one tubing meets all needs. . Dairy, food, medical and military manufacturers all have unique needs. And, Aero Rubber can provide the material you need. Spec grade materials such as 3A Dairy, ASTM, MIL SPEC, AMS and more are available in many different elastomers. And to further meet your needs we also provide Hi-grade, Mid-grade, and economy grade rubber formulations to ensure that your tubing choice can also fit your budget.

    • Sizing

      While the size of the tubing is always your choice, fit and function must work together to ensure the best performance. For instance, if the tubing needs to fit on an assembly, then the inside diameter (I.D.) must be sized correctly for a secure fit. In addition, the wall thickness (WT) will influence the flexibility, the bend radius and the degree of kinking.

    Fortunately, there are many good choices to extend the expected life of rubber tubing if you factor environmental factors, chemical exposure and size into your decision. By choosing the best rubber tubing for your needs you can improve efficiency, lower costs and provide safer conditions. Take a few minutes today to inspect your tubing. If it looks worn, has cuts, looks corroded or seems like it’s underperforming give us a call.

    Aero Rubber specializes in custom industrial bulk rubber tubing and can help. Our consultative sales teams can give you appropriate rubber choices for your needs, so you can make an informed decision about your rubber tubing needs. Aero will not engineer nor specify the total requirements for your tubing but will discuss the environment and use of the tubing to offer you a choice of materials, elastomers and specifications.

  3. Can A Rubber Band Change The Way You Work?

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    Yes! Custom Rubber Bands Key to Bloom2O

    • The Challenge

      Bloom 20 Steps for Ebay CR

      To find an innovative rubber band that could change flower delivery expectations for KaBloom Flowers, Gifts and More®! Traditional floral plastic tubes delivered poor results. They leaked when shipped, leaving damaged packaging and wilted flowers. Founder and former CEO David Hartstein knew there had to be a better way. Changing systems wouldn’t be easy, but he wanted his customers to love his flowers as much as he did. As early as 2005, David Hartstein turned his focus to keeping flowers hydrated longer without the mess. In response, David introduced the Moses Miracle (now called Bloom2O)- a hydration system packaged in water that keeps flowers constantly hydrated regardless of the position of the bouquet, lying down or standing up. The Moses Miracle called for a hydration balloon, a foam spacer, a special balloon and a rubber band to hold it all together. But like most new systems, the first try isn’t always the last. In trials, he quickly realized standard rubber bands weren’t dependable. All too often the rubber bands broke as the balloon filled with water. KaBloom was using too many rubber bands and without their desired outcome. However, in 2013 when Amit Gupta stepped in as the new CEO, Gupta brought renewed enthusiasm for the Moses Miracle. He rebranded as Bloom2O and made moves to improve the rubber band they used.

      “The fit is important because it keeps the foam tight and keeps the flowers receiving water,” explained Ariel Hartstein the Marketing Coordinator at KaBloom. “The continuous compression provides continuous hydration.”

    • The Fix

      Bloom2.0 Rubber Band

      Having heard of Aero’s reputation with custom projects, Gupta called to discuss their issue. Based upon his desired stretch and resistance, the Aero team determined he needed a custom rubber band thicker than the previous bands. Although this was contrary to traditional wisdom that thinner rubber bands stretch more easily due to less material, Aero assured him they could make a suitable rubber band. “The fit is important because it keeps the foam tight and keeps the flowers receiving water,” explained Ariel Hartstein the Marketing Coordinator at KaBloom. “The continuous compression provides continuous hydration.” Upon testing, the new thicker rubber band stretched enough to allow the water into the balloon during the filling process, without breaking and retained a tight fit when full. This paired with a special foam within the balloon that prevented the water from leaking created an ideal system.

    • The Benefit

      7 Sunflowers B2O

      With a new more efficient system in place, KaBloom is confident the flowers they deliver are as fresh as possible. “Hydration was the key.” Ariel continued, “We found that under the old system using generic flower tubes, flowers had a maximum of 5 days before they started to turn. Now, we provide a 7-day freshness guarantee.” The system allows them to send high quality flowers across the country without charging more. “Using the rubber bands doesn’t cost more to the recipient nor the distributor than the water tubes especially at wholesale prices.” Ariel explained.

      Now, 5 years later, KaBloom continues to use the custom band and reports they’ve seen sales and customer satisfaction increase. KaBloom has enjoyed their experience so much when asked if there was anything else she would like to add about the Bloom2O process, Ariel added, “We couldn’t be happier. The team at Aero is great.”

    Aero Rubber Company® can take on your toughest rubber band challenges.

    Bring Aero to your office and find the best in rubber bands. From standard rubber bands, to custom Aero provides quality rubber bands to fit your needs.

    See what Aero Rubber Bands can do for you.

    Explore Rubber Bands

    Questions? Call 800-662-1009.

  4. Did You Know?

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    What was used to erase before rubber was invented?

    People tried anything from soft bread, wax or bits of rough stone to remove mistakes from paper (aka papyrus). It wasn’t until 1770 that an English Engineer used rubber and found that it worked well. But it wasn’t until 1839 that it became a household item thanks to Charles Goodyear. Eraser History

    How many types of products does Aero Rubber sell?

    While you could say we sell over 20 products, you could also argue we sell an infinite number of products since all of our rubber parts are custom and we do custom rubber bands as well. We specialize in providing large production runs of custom rubber products. Our major categories include:

  5. Fastmile Saves with Pallet Bands

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    Better Results & Lower Costs Lead Fastmile Logistics to Use Rubber Pallet Bands

    • The Challenge

      Cabinets with Pallet Bands

      With plastic wrap costs averaging $14,000 a year, Fastmile Logistics, a solutions company, looked to reduce their packaging material and disposal costs. Historically, as loose shipments of cabinets arrived at their storage facility, they wrapped the pallet load in plastic wrap. However, each time they needed to load an outgoing truck they had to unwrap and re-wrap the pallet loads due to the product mix. This was a time-consuming and costly task. Aero Rubber helped Fastmile find an alternative.

    • The Fix

      After evaluation, Fastmile found rubber pallet bands not only cost effective but also a time saver. “We have been using the bands since 2014 and found that in plastic wrap product cost alone we are saving around $5,000 a year,” claims Brad Ward the general manager at the Orlando location.

      Fastmile uses a pallet size larger than your typical pallet to hold the cabinets. “Using custom pallets for the cabinets, the size of the rubber bands was just as important because they had to fit with our custom pallet size.”

      We use two bands one at the top and one at the bottom to keep the load stable and have found no problems with the bands stabilizing our loads,” Ward answered when asked about how well the bands have worked for them.

      “They work so well, we use them at our other locations when those locations have had the same application.”

      He noted the pallet band elasticity was instrumental to secure palletized loads.

    • The Benefits

      Aero’s rubber pallet bands were not the only alternative Fastmile tried, but it was the most efficient. “We tried the polyurethane with metal clasps but the clasps were time consuming and if you over tightened them, it could lead to product damage,” Ward explained. The other obstacle was the size of the pallet. After seeing how tightening the metal clasps led to difficulties, he enjoyed the way the bands snap into place after being applied to the pallet. No extra steps were needed.

      Pallet Band Application
      Learn More About Pallet Bands

      He went on to explain the savings is not counting trash costs which he estimates at another $200 yearly. Now, four years later Fastmile continues to be happy with the bands and has expanded their use to other facilities. Ward believes the other locations have seen similar savings.

      The bands do have a very specific use inside their warehouse and are not seen on every pallet. “Most of our pallets come in wrapped and leave with the same wrap on them which doesn’t give us the opportunity to use the bands,” Understanding the bands are not for every warehouse application, Ward would still recommend the bands to anyone looking to make changes where wrapping and re-wrapping take place.

      The strategy to switch from plastic wrap to pallet bands, which are reusable, led to yearly savings of more than $5,000 while keeping or improving efficiencies because they no longer had to deal with the wrapping and unwrapping every time they needed to unload and re-load the cabinets. The bands fulfilled Fastmile’s objective of lowering the amount spent on plastic wrap and reducing their trash costs.

     

    Find Out How Pallet Bands Can Work in Your Warehouse

    Call (800) 662-1009 and speak to one of our pallet band specialists.
    Read more about how Reusable Rubber Pallet Bands Help Stretch Budget.
    Download a Size Chart & Brochure.
    Watch how to use pallet bands.

     

  6. Oil Lid Rubber Seal Redesign Creates Cost Savings & Flexibility

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    One size does not fit all. Creating multiple sizes of rubber seals and rubber gaskets quickly and economically doesn’t have to be a challenge. Discover how one company benefited from a change in how their rubber seals are produced.

    Rubber Seals for Rail Car Oil Tanks

     

    Why switch from molded to extruded rubber seals?

    In search of a cost-effective way to produce oil lid rubber seals that would meet their size needs, a manufacturing company looked to Aero Rubber Company®, Inc. for assistance. While their molded rubber seals were functionally satisfactory, they could not easily and economically produce additional rubber gasket sizes from that mold. Each new rubber gasket size required a new mold. Molds take time to produce and each can be a costly option.

    When switching from molded rubber parts, there are two options – extruding or die cutting. Knowing die cut was not a viable option due to the cross-section, Aero presented the option of a custom extrusion, cut to length, and then spliced to the customer requested diameter. With samples in hand, the customer experimented with cold bonded splices, without much success. The cold bond process they experimented with employed a chemical bonding agent to seal the bond, which couldn’t hold up to their functional demand. Aero presented another option the customer hadn’t considered – hot vulcanized seals which would produce a much stronger splice than the cold bond method.

    What the company learned changed everything.

    Tests went well and new vulcanized spliced seals quickly replaced the original molded style. The customer realized they gained more than just cost savings. Without dependence on the molds, they could adjust the developed diameter of the rubber gasket with ease. No longer at the mercy of one seal size per mold, the customer began producing other seal sizes with the extruded and vulcanized splice method.

    Oil Tank Rubber Seals Gaskets

    Every rubber gasket or seal can have its own challenges. Not all seal sizes and cross-sectional designs can be extruded and vulcanize spliced. Molding may be required based on need.

    Let Aero Rubber help you meet these challenges. We believe in helping companies get quality advice and rubber parts to meet your needs. We care about your success and we work with you to make sure your needs are met. Explore all of our gasket & seal capabilities. Or, call one of our knowledgeable Consultative Sales Engineers at 800-662-1009 to find out how we can help with your project.

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