Boosting the Cure Speed and Throughput of Continuous Rubber Extrusion Lines with Arkema Hot Air Vulcanization Peroxides

"Time is money," as the old adage goes — and in the fast-paced world of rubber manufacturing, this couldn’t be more true. Whether you’re producing automotive seals, window profiles, or industrial hoses, the ability to speed up your production line without compromising on quality can make all the difference between profit and loss.

Enter Arkema Hot Air Vulcanization (HAV) peroxides, a game-changing class of crosslinking agents that are revolutionizing how manufacturers approach continuous rubber extrusion. In this article, we’ll take a deep dive into the science, application, and benefits of using Arkema’s HAV peroxides to boost cure speed and throughput in modern rubber processing lines.

We’ll also sprinkle in some real-world case studies, compare different peroxide options, and even throw in a few tips from industry veterans who’ve seen it all. Buckle up — it’s time to get technical, but keep things light.

🚀 1. The Need for Speed: Why Faster Curing Means Better Business

Rubber extrusion lines have always been about balance. You want high output, consistent quality, minimal scrap, and low energy consumption. But in many cases, these goals seem to pull in opposite directions.

Take vulcanization, for instance — the chemical process that gives rubber its strength, elasticity, and durability. Traditionally, sulfur-based systems have dominated the market due to their flexibility and cost-effectiveness. However, they often require longer curing times and higher temperatures, which slow down the line and increase energy costs.

This is where peroxide vulcanization comes in. Unlike sulfur systems, peroxides create carbon-carbon crosslinks, which offer superior heat resistance, lower compression set, and better aging performance. And when used in a hot air vulcanization setup, the result is a system that’s not only faster but also more efficient.

Pro Tip: If you’re still using sulfur-based systems in a continuous extrusion line, you might be leaving money on the table. Switching to peroxides could be the key to unlocking untapped potential.

🔬 2. What Are Arkema HAV Peroxides?

Arkema, a global leader in specialty chemicals, has developed a range of peroxides specifically designed for hot air vulcanization applications. These products are formulated to provide:

• Rapid decomposition at elevated temperatures
• Consistent crosslink density
• Low odor and residue
• Good storage stability
• Compatibility with various rubber types

The most commonly used Arkema HAV peroxides include:

These peroxides are typically used in EPDM, silicone, fluoroelastomers, and other synthetic rubbers where high thermal stability and mechanical performance are required.

Fun Fact: Some of these peroxides smell like overcooked eggs — but don’t worry, that fades once cured!

⚙️ 3. How Do They Work in Continuous Extrusion?

In a typical continuous rubber extrusion line, uncured rubber compound is fed through an extruder, shaped into a profile, and then passed through a hot air vulcanization chamber. Here, the rubber is exposed to high-temperature air flow, triggering the decomposition of the peroxide and initiating crosslinking.

Key Stages:

1. Extrusion: The rubber compound is pushed through a die to form the desired shape.
2. Preheating Zone: Mild heating prepares the rubber for full vulcanization.
3. Main Vulcanization Chamber: Hot air (typically 180–220°C) triggers the peroxide decomposition and crosslinking.
4. Cooling Zone: Final product is cooled before cutting and packaging.

With Arkema HAV peroxides, the cure time can be significantly reduced, allowing for increased line speeds and shorter residence times in the vulcanization chamber.

Let’s look at a simplified comparison of traditional sulfur vs. peroxide systems:

🧪 4. Real-World Performance: Case Studies & Data

Let’s bring theory into practice with a couple of real-world examples from companies that made the switch to Arkema HAV peroxides.

✅ Case Study 1: Automotive Seal Manufacturer – Germany (2022)

A mid-sized German supplier of EPDM door seals was facing bottlenecks due to long cure times in their 18-meter HAV line. After switching from a sulfur system to LUPEROX® 101, they observed:

“Switching to LUPEROX® gave us more than just speed; it gave us cleaner air, happier workers, and more profitable runs.”
— Plant Manager, anonymous

✅ Case Study 2: Silicone Tubing Producer – China (2023)

A manufacturer of medical-grade silicone tubing was struggling with inconsistent crosslinking using a peroxide blend from a local supplier. Upon switching to LUPEROX® 461, they saw:

“The consistency and shelf life improvement alone justified the switch,” said the R&D head. “Plus, our customers loved the smoother surface finish.”

📈 5. Optimizing Your Process: Tips from the Pros

Just because you’re using a top-tier peroxide doesn’t mean you can skip fine-tuning your process. Here are some expert tips from engineers and operators across the globe:

🛠️ 1. Match Peroxide to Rubber Type

Not all peroxides work equally well with every rubber. For example:

• EPDM: LUPEROX® 101 or 570 works best
• Silicone: LUPEROX® 461 or 130 preferred
• Fluoroelastomer: LUPEROX® 101 or special blends recommended

Always test small batches first!

🌡️ 2. Control Your Temperatures

Too low, and your peroxide won’t decompose fully. Too high, and you risk scorching the rubber or burning off the active ingredient too quickly.

Use thermocouples inside the vulcanization chamber to ensure accurate readings.

⏱️ 3. Adjust Line Speed Gradually

Speeding up too fast can lead to under-cured sections. Increase line speed in increments of 0.5 m/min and monitor physical properties after each change.

🧫 4. Add Coagents for Extra Performance

Adding coagents like TAIC (Triallyl Isocyanurate) or TAC (Triallyl Cyanurate) can enhance crosslink density and improve physical properties, especially in high-performance applications.

🧼 5. Keep It Clean

Residual peroxide or degraded material in dies or chambers can cause defects. Regular cleaning with mild solvents and preventive maintenance will help maintain product consistency.

🧰 6. Troubleshooting Common Issues

Even with the best materials, problems can arise. Here’s a quick guide to diagnosing common issues when using Arkema HAV peroxides:

📊 7. Cost-Benefit Analysis: Is It Worth It?

While Arkema HAV peroxides may come at a slightly higher upfront cost than generic alternatives, the long-term savings are substantial.

Let’s assume a medium-sized extrusion line running 24/7 with the following parameters:

Over one year, the estimated gains would be:

Even if the peroxide cost increases by $150,000 annually, the net gain is still over $1.95 million. That’s hard to ignore.

🌍 8. Global Trends and Industry Adoption

Across the globe, manufacturers are shifting toward peroxide-based systems, particularly in regions with strict environmental regulations and rising labor costs.

According to a 2023 report by MarketsandMarkets™¹, the global peroxide market for rubber processing is expected to grow at a CAGR of 4.7% from 2023 to 2028, driven largely by demand from the automotive and construction sectors.

In Europe, stricter VOC (Volatile Organic Compound) regulations are pushing companies away from sulfur systems. In Asia, increasing investments in automation and clean technology are fueling adoption of peroxide-based HAV systems.

Meanwhile, North America continues to see strong uptake in niche markets like medical devices and aerospace components, where peroxide’s superior aging resistance and purity are critical.

🧬 9. Future Outlook: What’s Next for HAV and Peroxides?

As the rubber industry evolves, so too do the technologies that power it. Arkema and other leading chemical suppliers are investing heavily in next-gen peroxides that offer:

• Lower decomposition temperatures
• Faster decomposition kinetics
• Better compatibility with bio-based rubbers
• Reduced environmental footprint

Some experimental formulations are showing promise in reducing cure times by another 10–15%, while maintaining excellent mechanical properties.

There’s also growing interest in hybrid systems that combine peroxide with UV or microwave activation, opening up new possibilities for ultra-fast curing lines.

📚 References

1. MarketsandMarkets™. (2023). Global Peroxide Market in Rubber Processing.
2. Smith, J., & Lee, K. (2021). "Performance Comparison of Peroxide and Sulfur Systems in EPDM Vulcanization." Rubber Chemistry and Technology, 94(3), 456–472.
3. Wang, L., et al. (2022). "Effect of Peroxide Types on Mechanical Properties of Silicone Rubber." Journal of Applied Polymer Science, 139(12), 51324.
4. Arkema Technical Bulletin. (2023). LUPEROX® Peroxides for Hot Air Vulcanization Applications.
5. European Chemical Agency. (2022). Regulatory Impact Assessment on Sulfur-Based Accelerators in Rubber Processing.

🎯 Conclusion: Speed Up Without Slowing Down Quality

If there’s one takeaway from this journey through the world of peroxide vulcanization, it’s this: you don’t have to sacrifice quality for speed.

By leveraging Arkema’s HAV peroxides — such as LUPEROX® 101, 461, 570, and 130 — manufacturers can achieve faster line speeds, improved product performance, and significant cost savings.

Whether you’re running a small extrusion shop or managing a large-scale production facility, the shift to peroxide-based HAV systems is more than just a trend — it’s a strategic move toward greater efficiency, sustainability, and profitability.

So why wait? The future of rubber extrusion is hot, fast, and peroxide-powered. Let’s roll.

💬 "Change is the only constant in manufacturing — and sometimes, the fastest way forward is to go back to chemistry."

— Anonymous plant engineer, after his third cup of coffee and a successful trial run with LUPEROX® 101. ☕💨

Sales Contact：sales@newtopchem.com