COMERIO ERCOLE is proud to constantly provide innovative technological solutions that enhance end-user processes with significant productivity advantages. Our most important innovation in the steel cord rubberizing process is the FASTEEL® system, a revolutionary solution enabling automatic steel cord thread changeover.
The key benefit is the reduction of setup time. While steel cords are being produced on Creel #1, the steel cords from Creel #2 can be inserted and locked into the grooves of the pressing and guiding rolls of Application Device #2. This device will then slide on linear guides, allowing the grooved rolls to move into the production position while maintaining uniform tension on the cords, facilitating a quick production changeover.
Previously, changing over the steel cord production line would take 2-4 hours. With the new FASTEEL® system developed by COMERIO ERCOLE, downtime is reduced to just 10-20 minutes. To further minimize setup time and maximize the production efficiency of the calendering line, COMERIO ERCOLE has implemented the innovative FASTEEL® system, which allows each steel cord to be inserted into the grooves WHILE THE LINE IS RUNNING.
There is no other technological solution available worldwide in the tire industry that offers the same real process advantages as FASTEEL®.
August 2024 has been an incredibly busy and fulfilling month for us, despite it typically being a holiday period in Italy. We have successfully delivered at least three major calendering plants from our factories to the loading ports, involving an impressive number of trucks. Additionally, we have signed an important new agreement with a qualified partner for the “de-vulcanization process,” completing the circular economy loop where non-vulcanized scrap recovery is already supported by several project configuration alternatives.
COMERIO ERCOLE is now positioned to supply “turnkey” rework plants, such as REWTIRE®, based on various technologies to recover all types of non-vulcanized scraps and defective components of the rubber manufacturing process. Typically, extrusion processes produce a certain amount of recyclable non-vulcanized scrap, which is the residual material left in the extruder or extrusion head during compound or extrusion tool changes. To achieve sustainability and maximize added value, producers are committed to recycling this non-vulcanized scrap material by reintroducing it into the production process in line with the circular economy concept.
COMERIO ERCOLE has developed the BABYMILLS® MGS series specifically to rework 100% of all types of non-vulcanized rubber scraps, returning them to the production process. We have also introduced a new hydraulic gap adjustment system named HYDROFIT® PLUS, which uses proportional valves in the hydraulic actuators to ensure better bearing block position accuracy and repeatability. In addition to its technical features and performance, HYDROFIT® fully complies with the latest revision of EN 1417:2015, the European Safety Standard for two-roll mixing mills, which requires the automatic separation of the mill rolls to achieve a gap of at least 50 mm within 5 seconds.
IN SHORT Work continues even in August, which is typically a month marked by summer holidays in Italy. At least three major plants are being shipped during this period, with a significant movement of trucks headed to the ports for loading. Additionally, an important agreement has been signed in the rubber waste regeneration sector, involving an innovative “devulcanization” process. This will complement the ongoing project in the field of unvulcanized rubber waste recovery, which has already seen its first implementation for a major European producer.
