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Rubber Plants

PLANTS - ZEPPELIN
Rubber Tire Plants

Rubber Plants

Rubber and tire industry

Knowledge pays off

Zeppelin relies on its own first-class technology for rubber and tire plants. More than 500 systems that have been constructed around the world as well as a list of references with all the major companies from the industry also speak for themselves within this sector.

The operating success of companies in the rubber and tire industry depends on the exact mixing of raw materials and the reliable and high-precision supply and dosing. A decisive factor is the mixing – a task that requires special technologies, know-how and most importantly experience.

Zeppelin supplies complete plants from a single source from the receipt of raw materials and the storage and conveying technology, the weighing and dosing of carbon black, silica, oils as well as other additives and small components through to turn-key mixing rooms.

Our solutions

Pre-engineering


You don't make important decisions on your own

Constructing a new plant or expanding an existing one is a very complex project. All eventualities must be taken into account even prior to any investment decision. Planning processes should be designed in such a way that time and costs can be used effectively. We don't leave our customers to fend for themselves and ensure that they receive optimum project management with Zeppelin Value Engineering.

We are even an expert partner in the initiation phase, providing our customers with all the relevant data through Front-End Engineering & Design (FEED) so that they can make the best decision. We go into greater depth at the start of the project with a feasibility study with the aim of shortening the implementation phase and significantly reducing the effort for any modifications. A faster time-to-market, amongst other things, is the positive consequence of this approach.

We provide simulations and calculations for all project phases to give a better estimate of the costs incurred and check the performance of the system. We create PDF files or a complete 3D layout plan of the entire system, determine the energy requirements and support our customers in the sizing and specification of the main components.

The more accurate the costs, volumes, deadlines and workload, etc. can be, the more effectively the project can be driven forward so that investments pay off from the very outset.

Recycling

Closing the recycling loop

Around 630,000 tons of used tires are accumulated each year in Germany alone. There are 3.2 million tons within the European Union and even 4.4 million in the USA. In the European Union alone, 4% of these end up in landfill sites and 50% are used as fuel in furnaces within the cement industry – a huge waste of precious raw materials. Still, every car tire contains approx. 2 to 3 kg of carbon black.

Zeppelin is seeking to eliminate this waste and ensure sustainable business activities through recycling. Together with our project partner Pyrolyx AG we have succeeded in recovering oil, gas and high-quality carbon black in particular from tires on an industrial scale.

The quality of the carbon black is a decisive factor for the effectiveness of the process. As a leading manufacturer of systems for the tire industry, we enjoy a high reputation within this field with our process engineering know-how. With our turn-key recycling systems we want to close the recycling loop, conserve resources and play our part in ensuring that energy efficiency and sustainability are not just empty phrases, but instead have an effective impact in reality.

Carbon black and silica

A consistently good performance

Technical innovations, such as a patented slow conveying process for carbon black beads and silica that are considered a pioneering concept within the industry, underline the excellent reputation that Zeppelin enjoys within the rubber industry.

Raw materials in powder form must be conveyed pneumatically in hermetically sealed systems in order to ensure that there is absolutely no dust in the system and surrounding area. The lowest possible conveying speed is a decisive factor for the product-friendly conveying of sensitive products, such as carbon black or silica.

Very different qualities of carbon black and silica are used in modern rubber compounds. The conveying system must always be dust-free and work reliably and at a constant performance despite the different characteristics and flow properties of these raw materials. Our patented conveying processes ensure gentle and reliable conveying at all times.


Liquid additives

Liquid dosing without product loss

Accuracy has a new name: With Zeppelin’s new Liquid Dosing System (LDS), dosing is achieved accurately, without cross-contamination, and in a closed system for up to 24 or 36 liquids depending on the mixer. Temperature control up to 80°C. Now that’s technological lead!

New, fully automatic small ingredients system
Safer. Cleaner. More accurate – fully automatic. Direct dosing of small ingredients into the bag – highest recipe accuracy without cross-contamination. This system ensures highest operational safety and availability with constant maximum dosing and weighing quality of the recipe as well as complete traceability of the raw materials used.

Advantages you can rely on

    • Precise and reliable injection of low or high viscosity liquid into the mixer
    • Injection valves for all mixer types
    • Connection of up to 4 different liquids in one dosing cylinder
    • Closed system – high safety process
    • Modular system – can be retrofitted in existing plants and easily expandable
    • Minimum cross-contamination, Full automatic control and recipe management
    • New 6-port injection valve – One step ahead: One single valve can inject up to 6 oils
    • Minimal cross-contamination, minimal size, maximum efficiency