Netzsch optimises elastomer processing with real-time data

Selb, Germany – Polymer machinery maker Netzsch Process Intelligence GmbH has advanced elastomer processing with the use of real-time sensor technology and AI-based analysis.

The company's sensXPERT system uses dielectric sensors built into the mould to track molecular movement in real time, Netzsch said in a 7 May statement.

This allows processors to monitor temperature, pressure and the degree of vulcanisation during curing, delivering precise data on when a part is ready.

According to Netzsch, this feature reduces dependence on estimates or safety margins and enables consistent process control.

The technology can monitor each elastomer type, including EPDM, NBR, silicone and LSR, individually, with the system adapting to specific material behaviours.

The data is used to adjust the process in real time, helping to avoid typical issues such as short fills, bonding problems or uneven curing.

In one example, a manufacturer of high-voltage conductors that overmoulds with EPDM was struggling with electrical breakdown faults.

Using sensXPERT, the manufacturer was able to detect and correct critical deviations in flow and curing behaviour at an early stage, according to Netzsch.

The more stable process led to fewer rejects and “a significant reduction in the time and effort required for failure analysis.”

The technology is particularly claimed to help shorten cycle times, reduce energy consumption and avoid material waste.

In another example, a pump manufacturer using the system for the production of rubber stators reduced average cycle times by 23%, and in some cases by up to 32%, "without compromising product quality."

The system can be operated manually or adjust automatically based on live data.

Operators receive instructions based on "calculated vulcanisation levels," which Netzsch said improves consistency across batches, tools and materials.

The system records all process data and links them to individual parts, providing full traceability and supporting quality assurance.

This feature can particularly help manufacturers in regulated sectors such as automotive, medical and sealing technology.