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Figure 2. Sydney Metro Trains, one of the many applications of Jehbco's silicone extrusions.

From Material Properties to Applications: The Role of Silicone Rubber Extrusions in Modern Industries 

Silicone rubber is one of the most versatile and widely used materials in modern manufacturing and engineering. Its exceptional physical, chemical, and thermal properties make it indispensable across industries such as construction, defence, medicine, electronics, food processing, and more. Silicone rubber has numerous advantages over natural rubber, including superior temperature resistance, chemical inertness, and durability, making it the material of choice for demanding applications. 

This article explores the unique material properties of silicone rubber, its advantages over natural rubber, and the diverse applications of silicone extrusions across industries. 

Material Properties of Silicone Rubber 

Silicone rubber is a synthetic elastomer made from a polymer backbone of silicon, oxygen, and organic groups. Its structure gives it a unique combination of properties that set it apart from other materials. Below are the key properties of silicone rubber: 

1. Temperature Resistance

Silicone rubber can withstand a wide temperature range, from as low as -60°C to as high as 230°C (and even higher for specialized grades). Unlike natural rubber, which becomes brittle at low temperatures and degrades at high temperatures, silicone rubber retains its flexibility and performance across extreme conditions. This makes it ideal for applications in environments with temperature fluctuations, such as automotive engine bays, industrial ovens, and aerospace components. [1] 

Figure 1. An autoclave with a silicone extrusion door seal, used to sterilise surgical instruments. Silicone rubber’s excellent material properties make it ideal for applications such as these.

Figure 1. An autoclave with a silicone extrusion door seal, used to sterilise surgical instruments. Silicone rubber’s excellent material properties make it ideal for applications such as these.

2. Chemical Inertness

Silicone rubber is highly resistant to a wide range of chemicals, including oils, solvents, and many acids and bases. This chemical inertness ensures that it does not degrade or react in harsh environments, making it suitable for applications in marine environments, medical and food-grade systems, and chemical processing. [2] 

3. UV, Ozone, and Weather Resistance

Unlike natural rubber, silicone rubber is inherently resistant to UV radiation, ozone, and weathering. These properties make it ideal for outdoor applications and exposure to harsh environments. For example, Jehbco has developed silicone door hatch seals for ships in the marine industry. These seals protect door hatches from the damaging effects of saltwater, UV rays, and weather conditions, ensuring long-lasting performance even in the harsh marine environment. Such applications highlight silicone’s superiority in resisting environmental degradation. [3] 

4. Flexibility and Elasticity

Silicone rubber maintains its flexibility and elasticity across its temperature range. It can stretch, compress, and bend without losing its structural integrity, making it ideal for seals, gaskets, and tubing that need to accommodate movement or pressure changes. Furthermore, silicone’s flexibility makes it ideal for forming tight seals as it readily deforms to fill the empty spaces of its mating parts. [4] 

5. Non-Toxic and Biocompatible

Silicone rubber is non-toxic, hypoallergenic, and biocompatible, making it a trusted material in medical and food-grade applications. For example, it is used in medical implants, catheters, and food processing seals. Medical-grade silicone is used in products that come into direct contact with the human body, such as catheters, implants, and prosthetics. 

For example, Jehbco has developed high-quality tubing for filtered water systems. Our silicone tubing ensures hygienic fluid transfer in water filtration systems, providing chemical resistance and preventing contamination. Additionally, Jehbco has contributed to the healthcare industry by manufacturing silicone tubing used in vaccine development processes, where sterility and biocompatibility are paramount. These applications demonstrate the versatility and safety of silicone in industries that demand the highest levels of performance and hygiene. [5] 

6. Electrical Insulation

Silicone rubber is an excellent electrical insulator, providing reliable protection for wires and electronic components in high-voltage, high-temperature, and wet environments. Jehbco has produced silicone cable sleeves for high-voltage electrical cabling that are flexible yet durable, protecting the inner cables from harsh environments.  

7. Customizability

Silicone rubber can be formulated into different grades, colours, and hardness levels, and can be extruded into virtually any shape and size, allowing for custom solutions tailored to specific applications. 

Advantages of Silicone Rubber Over Natural Rubber 

While natural rubber has been a staple in manufacturing for decades, it has limitations that silicone rubber overcomes. Silicone rubber has vastly superior properties, making it the preferred material for demanding applications. The key advantages of silicone rubber over natural rubber include: 

  • Temperature Range: Silicone rubber can withstand extreme temperatures, typically ranging from -60°C to 230°C, and up to 300°C for specialized grades. This makes them ideal for applications exposed to high heat or freezing cold, such as industrial ovens, engine components, and outdoor seals. This is vastly superior to natural rubber which is limited to just -20°C to 70°C and cannot withstand extreme temperatures as silicone rubber can. Natural rubber becomes brittle at low temperatures and degrades in high-heat environments while silicone remains perfectly stable in such environments. 
  • Weather Resistance: Natural rubber is prone to degradation when exposed to UV rays, ozone, and weathering, whereas silicone rubber is highly resistant to these factors. 
  • Chemical Resistance: Silicone rubber remains stable when exposed to oils, solvents, and corrosive chemicals, making it more durable in harsh environments. However, natural rubber swells and deteriorates in similar conditions. This makes silicone rubber indispensable in chemical plants and automotive fuel systems. 
  • Shelf-life: Silicone rubber has an extremely long lifespan of 20 years or even longer with proper storage, thanks to its resistance to environmental and chemical degradation. Natural rubber, on the other hand, is prone to oxidation and degradation over time. [1] 
  • Biocompatibility: Natural rubber contains latex proteins, which can cause allergic reactions in some individuals. Silicone rubber, being non-toxic and hypoallergenic, is widely used in medical and food-grade applications. [5] 

Table 1. Advantages of Silicone Rubber Over Natural Rubber 

Property 

Silicone Rubber 

Natural Rubber 

Temperature Range 

-60°C to 230°C (up to 300°C for some grades) 

-20°C to 70°C 

Weather Resistance 

Highly resistant to UV, ozone, and weathering 

Degrades under UV and ozone exposure 

Chemical Resistance 

Resistant to oils, solvents, acids, and bases 

Vulnerable to oils and solvents 

Longevity and Durability 

Long-lasting, durable in harsh conditions 

Degrades faster under environmental stress 

Biocompatibility 

Hypoallergenic, non-toxic, biocompatible 

May cause allergic reactions (latex) 

Customizability 

Wide range of formulations and applications 

Limited adaptability to extreme conditions 

Microbial Resistance 

Resistant to bacteria and fungi 

Prone to microbial growth 

 

Applications of Silicone Extrusions in Various Industries 

Thanks to its excellent material properties, silicone extrusions have found applications in countless industries, offering custom solutions for seals, gaskets, tubing, and more. Indeed, Jehbco Silicones have been producing silicone extrusions for over 50 years to both Australian and international customers, and our products can be found everywhere from flame retardant door seals on trains, ships and planes, to filtered water systems in your home to architectural gap seals such as Quickjoint, just to name a few. 

Below are some more applications of our silicone extrusions: 

  1. Healthcare and Medical

The biocompatibility and sterility of silicone rubber make it essential in the medical field. 

  • Medical Tubing: Silicone extrusions are used for fluid transfer in catheters, peristaltic pumps, and respiratory devices due to their flexibility and non-toxicity.  
  • Seals and Gaskets: Silicone seals ensure a sterile and reliable environment in medical devices and laboratory equipment. 
  • Prosthetics and Implants: Medical-grade silicone extrusions are used for implants and prosthetics because of their hypoallergenic nature and durability. 
  1. Automotive, Aerospace and Transportation

Silicone extrusions play a critical role in enhancing vehicle performance and durability. 

  • Weatherstripping and Door Seals: Silicone seals prevent water and air leaks while reducing road noise. 
  • Engine Components: High-temperature silicone tubing and gaskets are used in engine compartments to handle heat and chemical exposure. 
  • Vibration Dampening: Silicone extrusions absorb vibrations, improving vehicle comfort and reducing noise. 
Figure 2. Sydney Metro Trains, one of the many applications of Jehbco's silicone extrusions.

Figure 2. Sydney Metro Trains, one of the many applications of Jehbco’s silicone extrusions.

  1. Construction and Architecture

Silicone extrusions are widely used in construction due to their durability and weather resistance. 

  • Window and Curtain Wall Seals: Silicone gaskets provide airtight and watertight seals, ensuring energy efficiency and protection against the elements. 
  • Expansion Joints: Flexible silicone extrusions accommodate thermal expansion and contraction in buildings, bridges, and roads. 
  • Roofing and Façade Systems: Silicone seals and gaskets enhance the longevity of building exteriors by resisting UV radiation and weathering. 
Figure 3. Applications of Quickjoint by Jehbsil, a custom engineered solid silicone solution for architectural gap seals.

Figure 3. Applications of Quickjoint by Jehbsil, a custom engineered solid silicone solution for architectural gap seals.

  1. Electronics and Electrical Engineering

Silicone extrusions protect sensitive components in challenging environments. 

  • Cable Insulation: Silicone tubing provides electrical insulation and protects wires from moisture, heat, and chemical exposure. 
  • Seals for Electronic Enclosures: Silicone gaskets ensure a watertight and dustproof seal for devices used in harsh conditions. 
  • LED Lighting: Silicone extrusions shield LEDs from environmental factors, improving performance and durability. 
  1. Food and Beverage

The non-toxic and food-grade properties of silicone rubber make it ideal for food processing and packaging. 

  • Food-Grade Tubing: Silicone tubing is used for transferring liquids and food products in hygienic conditions. It is easy to clean, resistant to contamination, and compliant with food safety standards. 
  • Oven and Freezer Seals: Silicone extrusions are used in ovens, refrigerators, and freezers due to their ability to withstand extreme temperatures. 
  1. Industrial Applications

Silicone extrusions enhance performance and efficiency in industrial settings. 

  • Heat-Resistant Seals: Silicone gaskets are used in industrial ovens, kilns, and autoclaves where they maintain performance under extreme heat. 
  • Chemical Transfer Systems: Silicone tubing is ideal for transporting chemicals in manufacturing processes due to its resistance to corrosion and degradation. 
  • Conveyor Belts and Rollers: Silicone extrusions are used in machinery components that require high friction and temperature resistance. 
  1. Renewable Energy

Silicone extrusions contribute to the durability and efficiency of renewable energy systems. 

  • Solar Panel Seals: Silicone gaskets and extrusions provide weatherproof seals for solar panels, protecting them from moisture and dirt. 
  • Wind Turbine Components: Silicone extrusions are used for sealing and vibration dampening in wind turbines. 

Conclusion 

Silicone rubber is a game-changing material with properties that outshine natural rubber in many aspects, including temperature resistance, chemical inertness, and durability. Its ability to be extruded into custom profiles makes it a versatile solution for a wide range of industries, from healthcare to construction and electronics. 

Jehbco Silicones has exemplified the versatility of silicone with its innovative solutions, such as tubing for filtered water systems and components for vaccine production in the medical field. These applications highlight the importance of silicone in solving real-world challenges and improving efficiency and safety across industries. 

For companies seeking high-quality silicone extrusions, working with Jehbco Silicones can unlock new possibilities and ensure precision-engineered solutions tailored to specific needs. Silicone rubber is truly the material of the future, offering versatility, durability, and performance that stands the test of time. 

 

References 

  1. SpecialChem. Silicone Rubber Properties and Applications.https://omnexus.specialchem.com/selection-guide/silicone-rubber-elastomer
  2. AZoM Materials Science. Properties of Silicone Rubber. https://www.azom.com/properties.aspx?ArticleID=920 
  3. Dow Corning. Silicone Rubber Handbook. Retrieved from https://www.dow.com/en-us.html 
  4. Vanguard Products. Silicone Properties and Benefits. Retrieved from https://www.vanguardproducts.com/silicone-properties 
  5. Medical Design BriefsSilicone in Medical Applications. Retrieved from https://www.medicaldesignbriefs.com/ 

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Heat Resistant Food Grade Silicone for Oven Seals and High Temperature Gasketing

Heat Resistant Food Grade Silicone for Oven Seals and High Temperature Gasketing

Oven seals are a critical component of commercial ovens which ensures that heat is contained within the designated heating space, and prevents the uncontrolled release of volatiles and heated products into the surrounding workspace. Common to laboratory, industrial and commercial ovens is a need to reach high temperatures, often above 200 °C. Thus, it is critical that the sealing material selected can withstand such high temperatures for extended periods of time to avoid sealing failure.  

Of the available elastomeric materials suitable to form seals, silicone rubber is widely regarded for its exceptional heat resistance and low flammability. Typically, silicone rubber can withstand working temperatures up to 250 °C, and does not exhibit autoignition until temperatures above 450 °C. This working temperature range can also be increased up to 300 °C, with select use of heat resistant additives. In addition to these properties, silicone is widely regarded as an excellent sealing material due to its low compression set and ability to be manufactured in a variety of different hardnesses, typically between 20-90 ShA. These mechanical properties allow silicone to be used in low sealing pressure applications and retain its sealing ability over extended periods of time.  

Another substantial benefit of using silicone rubber as oven sealing materials is its FDA food safe compliance under FDA 21 CFR 177.2600. Food-grade silicone does not contain harmful volatile organic compounds, and is widely used as a clean, byproduct free alternative to organic and other synthetic rubber compounds, which makes it a popular choice among food processing industries. 

At Jehbco oven seals can be manufactured in simple premade designs or in custom manufactured profiles to perfectly fit the dimensions and seal groove designs of newer prototypes. Jehbco also uniquely specializes in food-grade heat resistant additives that allow seals to be used in up to 300 °C environments while maintaining its food grade compliance. Please contact us through the Jehbco website for more information on oven seals and our high temperature resistant silicone extrusions.  

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Creating Bespoke Silicone Solutions with Custom Dies: The Science Behind Extrusion Die Design

Creating Bespoke Silicone Solutions with Custom Dies: The Science Behind Extrusion Die Design

Custom extrusion dies play a critical role in the silicone extrusion manufacturing process, transforming raw silicone material into precise shapes required for countless industrial applications. Jehbco Silicones, a leader in high-quality silicone extrusion, supplies critical components to a range of industries, including food, medical, defence, aerospace, construction, and more. With a vast library of over 2700 unique extrusion dies, Jehbco enables unparalleled flexibility and precision in delivering custom extrusion profiles. From initial design to the final product, Jehbco’s extrusion process reflects a commitment to precision engineering and an understanding of the unique behaviours of silicone during extrusion. 

The Challenges of Silicone Extrusion 

Silicone rubber is a popular material choice because of its flexibility, elasticity, and malleability. However, these same qualities make silicone extrusions significantly more challenging to execute with dimensional accuracy than other commonly extruded materials such as metals. While metals are generally stable during extrusion and retain consistent dimensions after exiting the die, silicone’s elastic and deformable nature means that controlling its exact dimensions is far more complex. 

1. Elasticity and Deformation 
Unlike metals, silicone rubber is highly elastic and prone to expanding, compressing, and deforming both during and after extrusion. As a viscoelastic material, silicone rubber changes shape as it exits the die, making it difficult to achieve precise dimensions in the final extrusion. This elasticity causes immediate post-extrusion swelling, known as die swell or the Barus effect, where the silicone recovers its shape and expands slightly once the shear stress of extrusion is removed. Jehbco’s engineers work meticulously to account for these factors by adjusting die geometry and closely monitoring extrusion parameters. 

Figure 1. Die swell, a manifestation of viscoelasticity in polymer extrusions, as depicted here on exiting an extrusion die. The extruded material “remembers” its former shape and attempts to return to it after leaving the die orifice.

Figure 1. Die swell, a manifestation of viscoelasticity in polymer extrusions, as depicted here on exiting an extrusion die. The extruded material “remembers” its former shape and attempts to return to it after leaving the die orifice.

2. Thermal Expansion and Contraction 
During the curing process, the silicone is subject to high temperatures. As silicone rubber has a high thermal expansion coefficient, it changes size more significantly with temperature variations compared to other commonly extruded materials (see Table 1). These thermal expansions and contractions create additional challenges in achieving consistent dimensions. Jehbco’s engineers carefully account for these properties when designing extrusion dies, calculating dimensions that accommodate potential thermal shifts during both extrusion and curing processes. By considering these factors, Jehbco can create extrusion dies that maintain dimensional consistency, even under changing temperature conditions. 

Table 1. Coefficients of Thermal Expansion (CTE) of Commonly Extruded Materials 

Material 

Expansion Coefficient 
(10^-6/C) 

Alumimium 

21.0 – 24.0 

Brass 

18.0 – 19.0 

Copper 

16.0 – 16.7 

Nickel 

13.0 

Polyethylene (PE) 

100-200 

Polypropylene (PP) 

100-180 

Polystyrene (PS) 

30 to 210 

Silicone Rubber 

200 to 400 

Titanium 

8.5-9.0 

3. Post-Extrusion Curing 
Another challenge lies in the curing process. Silicone extrusions undergo vulcanisation curing to solidify and stabilize their final shape. During the curing process, the cross-linking of rubber molecules can cause the silicone to unpredictably shrink or expand, complicating the task of dimensional accuracy. Jehbco’s team manages this through iterative die adjustments, fine-tuning the process to accommodate these changes and produce profiles that meet our customer’s precise specifications. 

Understanding Die Swell in Silicone Extrusions 

Die swell is a phenomenon in extrusion where the material expands upon exiting the die, a behaviour influenced by silicone’s viscoelastic properties. As a viscoelastic material, silicone exhibits both elastic and viscous characteristics, which result in an elastic recovery effect after it leaves the die. The extent of die swell depends on several factors, each of which Jehbco’s engineers carefully consider when designing and refining custom extrusion dies. 

  1. Die Design 
    The geometry of the die plays a crucial role in determining the amount of swell. Dies with a longer land, the straight portion at the die exit, allow the silicone to relax more before leaving the die, reducing the degree of swell. In contrast, shorter lands may result in more significant expansion. Jehbco’s engineers consider each die’s length, taper, and overall shape to achieve optimal results for each extrusion. 
  2. Silicone Rubber Hardness and Viscoelasticity 
    Silicone’s elasticity contributes to its tendency to swell, especially under high deformation. During extrusion, the high shear rates within the die force the silicone into a compressed state. As the silicone exits, its elastic properties prompt it to expand, creating the swell. Silicone rubber with a higher Shore A hardness rating will extrude with much less die swell than that of low hardness, producing extrusion profiles much closer to original die profile.  
  3. Extrusion Speed 
    Higher extrusion speeds tend to increase the degree of swell due to greater molecular alignment and shear rates. Jehbco carefully calibrates extrusion speed according to the specific die and material properties, balancing efficiency with dimensional precision to ensure the final product meets specified tolerances. 
  4. Temperature 
    The temperature of the silicone and the die affects both viscosity and elasticity. Higher temperatures reduce viscosity, allowing the silicone to flow more easily, but can also enhance its elastic recovery and thus influence the degree of swell. Jehbco’s engineers monitor and control temperature conditions to optimize extrusion consistency, balancing temperature settings to achieve desired properties in the final product. 
  5. Processing Conditions 
    Beyond the die itself, other factors like extrusion pressure and cooling rates post-extrusion can impact the final product’s dimensions. Managing these variables carefully, Jehbco ensures that products remain within required tolerances by adjusting extrusion pressure and cooling rates to control the extent of swell and prevent dimensional deviations. 

The Iterative Process of Fabricating Custom Dies 

Creating a custom extrusion die is a complex process involving iterative adjustments, each bringing the extrusion profile closer to the desired specifications. Initial tests with a new die may reveal major discrepancies in dimensions, requiring significant modifications to compensate for the extreme die swell in the extrudate. Jehbco’s iterative process, informed by decades of experience, ensures that each custom die meets the precise requirements of the application.  

With each iteration, Jehbco’s skilled engineers adjust factors like the die’s profile, land length, internal bridge configuration, and other design aspects to achieve the final profile. This iterative refinement process ensures the resulting extrusion meets exacting standards, delivering profiles that perform as expected in real-world applications. Furthermore, recent revolutionary advancements of the custom die fabrication process at Jehbco have allowed us to push the limit of what is possible and achieve even tighter tolerances than ever before.  

Figure 2. Iterations of a custom square profile extrusion (25.4mm x 25.4mm). Excessive die swell present in the initial extrusion (pictured left) was reduced with each iteration.

Figure 2. Iterations of a custom square profile extrusion (25.4mm x 25.4mm). Excessive die swell present in the initial extrusion (pictured left) was reduced with each iteration.

Precision Cutting with the Excetek V400G Wire EDM Machine 

Jehbco employs the advanced Excetek V400G wire EDM (Electrical Discharge Machining) machine to cut extrusion dies with exceptional precision, achieving tolerances as tight as ±5µm. This capability is essential in silicone extrusion, where even the smallest variations in die dimensions can result in deviations from specified tolerances in the final product. By leveraging wire EDM technology, Jehbco ensures that each die meets stringent design specifications, guaranteeing repeatability and accuracy across production runs. 

The V400G wire EDM machine allows Jehbco to quickly adapt to custom profiles, providing high-quality, consistent dies for even the most intricate shapes. Its precision helps mitigate potential issues related to die swell, a phenomenon common in silicone extrusion, by creating dies that account for silicone’s unique material properties and extrusion behaviour.  

Expanding Possibilities with Jehbco’s Custom Extrusion Solutions 

Jehbco’s extensive library of extrusion dies—comprising over 2700 unique designs—serves as a testament to the company’s expertise and flexibility in custom silicone extrusions. These dies enable Jehbco to accommodate an array of application requirements across industries, from healthcare to automotive and beyond. Whether designing seals for high-temperature environments or gaskets with complex internal channels, Jehbco leverages its knowledge of die swell, extrusion dynamics, and precision machining to deliver quality silicone profiles. 

Using the Excetek V400G wire EDM machine, Jehbco provides clients with unparalleled accuracy and flexibility in custom extrusion dies, opening doors to applications where precision and consistency are paramount. By balancing material properties, temperature, extrusion speed, and other factors, Jehbco controls die swell and ensures high-quality, reliable products with each extrusion.

Figure 3. Jehbco’s vast library of over 2700 custom extrusion dies.

Figure 3. Jehbco’s vast library of over 2700 custom extrusion dies.

Partnering with Jehbco for Precision Custom Extrusions 

With the right extrusion die, silicone’s unique properties can be harnessed to deliver highly durable, flexible, and custom-tailored components. Jehbco’s dedication to precision engineering and its understanding of silicone behaviour make it a trusted partner for businesses in the food, medical, defence, aerospace, construction, and other industries seeking custom extrusions. Through rigorous quality control, iterative refinement, and the use of cutting-edge technology, Jehbco Silicones stands at the forefront of silicone extrusion, committed to meeting each customer’s specific needs with precision and expertise. 

Whether for a small-scale custom order or large production runs, Jehbco’s custom extrusion dies enable the creation of silicone profiles that fulfill stringent requirements and perform reliably in demanding applications. For more information or enquiries, please email sales@jehbco.com.au for a quick response from our sales team. 

References 

  1. M.P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 4th Edition, Wiley, 2010, pg. 271
  2. https://www.engineeringtoolbox.com/linear-expansion-coefficients-d_95.html
  1. https://www.professionalplastics.com/professionalplastics/ThermalPropertiesofPlasticMaterials.pdf
  2. https://www.dryseals.com/app/uploads/2016/09/Basic-Info-Wacker.pdf
  3. https://www.engineeringtoolbox.com/linear-expansion-coefficients-d_95.html
  4. https://link.springer.com/chapter/10.1007/978-94-011-4421-6_22

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Jehbco’s promise to quality is a dynamic, ongoing journey. By implementing a comprehensive QMS, incorporating advanced testing, and fostering a culture of continuous improvement, Jehbco provides customers with silicone products they can trust.

Jehbco – A trusted name for high-quality, dependable products

Jehbco’s promise to quality is a dynamic, ongoing journey. By implementing a comprehensive QMS, incorporating advanced testing, and fostering a culture of continuous improvement, Jehbco provides customers with silicone products they can trust. This commitment to quality assures that Jehbco remains at the forefront of innovation and reliability in the silicone manufacturing industry. 

With an unwavering commitment to excellence, Jehbco has implemented a robust Quality Management System (QMS) certified to ISO 9001 standard. This globally recognized certification underscores the company’s dedication to maintaining a stringent and effective quality system, ensuring that every product meets the highest industry benchmark. Jehbco also has AS4020 and FDA approved products to be used in FMG sector as well as in pharmaceutical sectors. Few of our silicone materials are flame retardant materials which are commonly used in transport applications. 

The manufacturing process at Jehbco is predefined at every step, with detailed written procedures and Standard Operating Procedures (SOPs) in place to ensure that all employees adhere to established guidelines. Various checklists and inspections conducted during each production run further emphasize the quality of the products manufactured. All employees are adequately trained to ensure they are proficient in the tasks they perform. If any potential risks to product quality are identified, additional training sessions are conducted. Furthermore, procedures and checklists are reviewed and updated by the Quality department in collaboration with the Production team 

Continuous Improvement is a core principle at Jehbco. By conducting regular audits, gathering customer feedback, and holding company meetings, Jehbco identifies opportunities for improvement, which are documented in our Process Improvement book. Team members from relevant departments will be assigned to investigate these opportunities and address potential root causes to drive improvement.  

At Jehbco, customer product issues are treated with the utmost priority, reflecting the company’s commitment to customer satisfaction—a core value of the organization. Every customer product issue is acknowledged and responded to within two days of receiving the email. For any reported product issue, a thorough investigation is conducted, and the customer is provided with a detailed Customer Product Issue Form and a Non-Conformance Report. These documents outline the findings, remedial actions taken, and proposed solutions. The effectiveness of corrective and preventive actions is rigorously verified through documented proof, ensuring long-term resolution and continuous improvement. 

Jehbco’s maintenance and cleaning routines reflect the company’s strong commitment to providing quality products to its customers. The high number of repeat customers purchasing from Jehbco is a testament to our dedication and the satisfaction we deliver. Additionally, many new customers come to us through recommendations from existing clients, reinforcing our reputation as trusted manufacturers of high-quality silicone products. 

Jehbco’s maintenance and cleaning routines reflect the company’s strong commitment to providing quality products to its customers. The high number of repeat customers purchasing from Jehbco is a testament to our dedication and the satisfaction we deliver. Additionally, many new customers come to us through recommendations from existing clients, reinforcing our reputation as trusted manufacturers of high-quality silicone products. 

We take great care in our packaging processes to prevent contamination during transportation. Jehbco consistently adheres to promised delivery timelines and ensures customers are promptly informed of any unforeseen changes. Furthermore, we partner with recognized cargo providers to guarantee secure delivery and prevent any product damage during transit. 

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Jehbco: From little things, big things grow

Jehbco: From little things, big things grow

Local Beaches company Jehbco Manufacturing Pty Ltd – whose products are used worldwide in almost every industry imaginable – is celebrating its 50th year.

Originating in an unassuming factory in Brookvale, you’ll find little pieces of this third-generation family-run company in planes, trains and automobiles, boats, buildings, restaurants, hospitals and research facilities all around the world.

Founded on the northern beaches in 1974 by partners Jim, Eric, Hank and Burt (their initials forming the company name), Jehbco is a world-leading manufacturer of quality silicone extrusions that are fire, UV, oil, heat and weather resistant, for industries such as mining, pharmaceutical, construction, defence and transport.

Since 1974 the business has grown from a small rented space with one extruder and mill at 52 Winbourne Road to a fully equipped factory at 24 William Street.

The company’s first 10 years were demanding – three of the founding partners were bought out by Hank Tuynman, and he and his wife Janice became business partners.

“It was emotionally and financially challenging in those first few years as we had three small children under five when the idea was first mooted,” explained Janice.

“But through sheer hard work, expertise and entrepreneurial skills, Hank strengthened the original concept to build the business up to what it is today, reinforced by our son Karl,” she said.

Three generations of the Tuynman family are currently involved in the business – Janice who become sole owner when Hank passed away in 2015, their son Karl (who started in accounts in 2000 before moving into production and now Operations Manager); and grandchildren Jacob, who has progressed from the factory to Sales Manager, and Kailey who is the HR, Marketing and Admin Assistant.

Hank and Janice’s other sons, Keith, David and Samuel have also worked at Jehbco over the years and half of its 20 current employees have been with the company for two decades or more.

figure 2

 

CORE VALUES

While there have been major shifts in the manufacturing sector, being a small business has allowed Jehbco to be dynamic and agile, reacting to changes within industries quickly.

“Our core product range has not changed a lot over the past 50 years,” said Karl Tuynman.

“We have always specialised in the production of HTV silicone extrusions and gaskets, staying true to my father’s philosophy that we never produce other rubber products in-house to avoid any chance of cross contamination, something our high-end food and medical grade customers appreciate to meet the high specifications they require,” he said.

Specialist milling silicone rubber

Specialist milling silicone rubber

As demands for certain products changed over time, the company narrowed its focus and strengthened its reputation in its niche market, including silicone sheet and mouldings.

“At the same time, we have developed specialised material formulas for the rail, construction, lighting and drinking water industries that have enabled us to create stable and long-term mutually beneficial partnerships with our customer base,” Karl said.

Jehbco’s vision is “To empower global industries with next-gen silicone extrusions”.

“We export about 15 per cent of our product to countries like the US, China, Singapore, and New Zealand. Our brand is very well known throughout the Asia Pacific Region, selling to companies like Boeing, Fonterra, Zip (Culligan) and ANSTO” Karl said.

“Our products provide innovative solutions including in construction, where we provide Quickjoint – a precured façade extrusion which can be installed at any time and temperature with no skill, unlike its wet silicone alternative.”

“Also, we have developed high-end flame-retardant silicones for the transport industry and in particular for rail.”

“Our high-grade silicone tubing allows companies within

Australia to access this product in any size and grade.”

“We keep abundant supplies of the raw material for our customers as it is unavailable in Australia and has long lead times.”

THE FUTURE

Kailey and Anju

Kailey and Anju

The Australian manufacturing sector has faced its share of challenges over the years with small businesses constantly facing various headwinds.

“We are the last of a dying breed, so it is essential we do whatever it takes to play our part in keeping manufacturing alive in this country,” Karl said

“We are proud to be all-Australian and find this helps with support for many local businesses who are keen to invest in this great nation.

“Many of our very good customers are helping Jehbco continually improve through their ever-increasing demands on upgrading our processes and product quality.

“We are growing with them and will continue to do so, with no foreseeable alternative product on the horizon.

“Every aspect of the business is working together with a common goal to make this the best company it can be, with each key position now filled with motivated and driven employees who have many years of expertise between them.

“I am very optimistic for the future and can see Jehbco being a market force for many years to come, continuing my father’s legacy that he set in motion for us half a century ago,” Karl said.

 

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Optimising Silicone Extrusion Cutting with Gillard Cutting Machines

Optimising Silicone Extrusion Cutting with Gillard Cutting Machines 

Jehbco Silicones, a leading manufacturer in the silicone extrusion industry, has always prioritised precision and efficiency in its production processes. In pursuit of these goals, the company has integrated three cutting-edge Servo-Torq® Standard rotary cutting systems from Gillard Cutting Technology into its operations. The ST-MT/50C models in use at Jehbco are engineered to handle the rigorous demands of cutting silicone extrusions, such as tubing, with unparalleled accuracy and speed. 

Superior Cutting Capabilities 

The primary advantage of the Servo-Torq® ST-MT/50C models lies in their ability to deliver high-speed cutting without compromising on precision. These machines are capable of making up to 2000 cuts per minute, a feat that significantly enhances production efficiency. Whether dealing with small or large batches, Jehbco can now ensure that cutting processes keep pace with the extrusion lines, eliminating bottlenecks and improving overall throughput. 

Moreover, the ST-MT/50C models are designed to handle a variety of extrusion sizes. With the capacity to cut extrusions with outer diameters (OD) of up to 50 mm, these machines offer versatility that is critical for Jehbco’s diverse range of products. The ability to manage both thin-walled tubing and solid cords with equal ease makes these machines indispensable in a high-mix production environment. 

Figure 1. Servo-Torq® Standard rotary cutter system (Model ST-MT/50C) with Accra-Feed™ UA75 caterpillar infeeder/puller.

Figure 1. Servo-Torq® Standard rotary cutter system (Model ST-MT/50C) with Accra-Feed™ UA75 caterpillar infeeder/puller.

Precision and Control 

Precision is another hallmark of the Servo-Torq® rotary cutting systems. The machines are equipped with a high-speed “flying knife” blade driven by a 5.5 kW brushless AC servo motor, which ensures clean, accurate cuts every time. The digital servo drive system, featuring Lenze i700 multi-axis control, offers precise torque and speed regulation, further enhancing cutting accuracy. This level of control is essential for maintaining the stringent quality standards that Jehbco’s clients expect. 

The inclusion of the Accra-Feed™ UA75 caterpillar infeeder/puller system further refines the cutting process. This component uses twin 2.3 Nm AC brushless servo motors to maintain consistent line speeds, which is crucial for ensuring that cut lengths remain uniform. The system’s ability to hold speed within ±0.1% of the maximum line speed is particularly beneficial when producing long, continuous runs of extrusions. 

Figure 2. One of three Gillard cutting machines in use at Jehbco Silicones.

Figure 2. One of three Gillard cutting machines in use at Jehbco Silicones.

User-Friendly Operation and Safety 

Despite their advanced capabilities, the Servo-Torq® ST-MT/50C machines are designed with user convenience in mind. The Siemens TP700 Comfort touch-screen control panel offers an intuitive interface, allowing operators to easily set cut lengths, batch quantities, and caterpillar belt speeds. This interface supports Jehbco’s goal of minimising downtime by enabling quick adjustments and real-time monitoring of the cutting process. 

Safety is another critical aspect of these machines. The Servo-Torq® ST-MT/50C models are equipped with full safety guarding and meet all relevant EN standards, ensuring a safe working environment for operators. The machines also come with an emergency stop button, cutter and caterpillar-on indicator lamps, and a power-on indicator lamp, providing clear and immediate feedback on the machine’s status. 

Conclusion 

The integration of the Servo-Torq® ST-MT/50C cutting machines at Jehbco Silicones represents a significant enhancement to their production capabilities. With the ability to perform up to 2000 cuts per minute and handle extrusions with ODs of up to 50 mm, these machines ensure that Jehbco can meet its customers’ demands for precision, quality, and efficiency. As a result, Jehbco is well-positioned to maintain its leadership in the silicone extrusion industry, delivering high-quality products that meet the most stringent standards. 

 

References 

  1. https://www.gillardcutting.com/applications/rubber-extrusion 
  2. https://www.gillardcutting.com/downloads/datasheets/Servo-Torq_LT__MT_Combi_DD_datasheet.pdf 

 

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AS4020 Compliance in Silicone Tubes

AS4020 Compliance in Silicone Tubes 

AS/NZS (Australia/New Zealand Standard) 4020 outlines tests for evaluating the suitability of products for use in contact with drinking water, focusing on their effect on the quality of the water. AS4020 tests are conducted on both hot and cold-water drinking applications. The testing focuses on wetted parts only. This test is usually done on pipes, tubes, taps and all other components that comes in contact with the drinking water. Jehbco offers tubes that are AS4020 complaint. Jehbco serves a diverse range of customers who use our silicone tubes for drinking water applications. Jehbco works with required customers to get the products certified to AS4020 test results are typically valid for five years, after which a retest is required to maintain compliance with the standard. 

AS 4020 test ensures that the silicone materials used in the drinking water applications do not adversely affect the water quality and are safe for human consumption. The test gives assurance to the customer that drinking water passing through our silicone tubes is non-toxic and free from contaminants. This test is typically conducted during the initial stages of a new order. The customer selects the required material, Jehbco manufactures the test pieces, and they are sent to NATA-accredited labs for testing. Once the product passes the test, the AS4020-compliant material is used for bulk production of the customer’s order. Jehbco ensures that the test piece is manufactured as per customers original requirement (color, catalyst, curing etc) to ensure all the products used in the manufacture of the tube is compliant to AS4020. 

A variety of tests are conducted in AS4020 certification to ensure the suitability of material used in drinking water applications. The main aspects being tested are Leachability tests, Microbiological safety, Physical and mechanical properties, taste and odor tests, PH and water quality impact as well as the regulatory compliance. The main tests conducted for the different aspects of the standard is given below. 

Taste: A trained panel tastes and evaluates the water extracts to identify whether the product releases compounds that have a detectable taste. 

Appearance: Water that has come into contact with a product is analyzed for any changes in color or turbidity. Appearance is also tested upon coming on contact with organic compounds. 

Growth of aquatic micro-organisms: Products are examined for their capacity to support bacterial growth by monitoring dissolved oxygen levels. This test usually takes 8 weeks to complete 

Cytotoxic activity: Water extracts are examined for cytotoxicity by utilizing mammalian cell lines cultured in the laboratory. Any negative impact on cell health is concluded as a cytotoxic effect. 

Mutagenic activity: An in vitro genetic toxicology test (AMES) designed to detect mutagenicity of chemicals by various mechanisms. The AMES tests help to assess whether products release mutagenic compounds. Water extracts are combined with specific bacteria, and any observed changes in the bacteria’s genetic makeup are concluded as the evidence of mutagenic activity. 

Metals: Water extracts are tested for the presence of metals like aluminum, arsenic, antimony, barium, boron, cadmium, chromium, copper, iron, lead, manganese, mercury, molybdenum, nickel, selenium, and silver. The limits comply with the Australian Drinking Water Guidelines (ADWG). The extraction can be done using either an end-of-line test or an in-line test. 

High Temperature Tests: High temperature tests are conducted on parts that comes in to contact with high temperature. 

Some of the key benefits of AS 4020 compliances for silicone tubing include enhanced consumer confidence, improved market access, and reduced liability. At Jehbco, we offer a wide range of FDA-approved silicone products. One of our standout offerings is the 70 Duro platinum silicone, which is specifically designed for food and drink applications and complies with AS 4020. For silicone tubing, compliance with this standard not only enhances consumer trust but also opens doors to wider market opportunities. As industries continue to prioritize safety and quality, adhering to AS 4020 is extremely important to Jehbco.  

References 

  1. https://www.eurofins.com.au/biopharma-services/plumbing-products/asnzs-4020-for-watermark/#:~:text=AS%2FNZS%204020%20prescribes%20tests,application%20for%20WaterMark%E2%84%A2%20certification. 
  2. https://www.awqc.com.au/__data/assets/pdf_file/0010/579367/AWQC-Product-testing-to-ASNZS-4020-fact-sheet.pdf 
  3. https://www.scribd.com/document/436345643/As-4020-Testing-of-Products-for-Use-in-Contact-With-Drinking-Water 
  4. https://www.sandiego.gov/public-utilities/water-quality/water-quality-in-your-home-or-business 

 

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Fabricating Extrusion Dies and Tooling using Wire EDM Technology

For nearly 50 years, Jehbco Silicones has been at the forefront of silicone extrusion, amassing an impressive library of over 2,600 extrusion dies and a wealth of knowledge to ensure the delivery of perfect silicone products to their customers. One of the critical elements contributing to our sustained excellence and innovative edge is the use of advanced machining technologies for tool and extrusion die making at Jehbco, such as our Excetek V400G Wire Electrical Discharge Machine (Wire EDM). 

Figure 1. Excetek V400G Wire EDM Machine used for cutting extrusion dies and tooling at Jehbco.

What is Wire EDM? 

Wire EDM is a non-conventional machining process that uses a thin wire as an electrode to cut intricate shapes and fine details in hard materials. The Excetek V400G model employed by Jehbco Silicones stands out due to its precision, reliability, and ability to produce complex geometries with exceptional accuracy. The WEDM process works by generating a series of electrical discharges (sparks) between the wire and the workpiece. These sparks erode the material, creating the desired shape. The wire, typically made of brass or a similar conductive material, does not make physical contact with the workpiece, which allows for precise cutting without the wear and tear associated with traditional machining tools. This technology operates in a submerged environment, which helps to control the temperature and remove debris, further enhancing the precision of the cuts [1][2]. 

Figure 2. Diagram of wire EDM cutting process [3].

Advantages of Wire EDM Over Traditional Machining Methods 

Unparalleled Accuracy: Wire EDM machines, like the Excetek V400G, achieve a level of precision that is difficult to match with traditional machining methods. The accuracy of the Wire EDM process can reach tolerances within microns, making it ideal for producing intricate extrusion dies required in silicone product manufacturing. This precision ensures that the final product adheres to exact specifications, reducing waste and enhancing product quality​ [1][2]. 

Ability to Machine Intricate Geometries: Traditional machining methods often struggle with creating complex shapes and fine details, especially in hard materials. Wire EDM excels in this regard, as it can effortlessly cut intricate geometries, including sharp corners, thin walls, and delicate features. This capability is particularly beneficial for Jehbco Silicones, where the design of extrusion dies often demands intricate patterns to meet specific customer requirements​ [1][4]. 

Figure 3. Extrusion dies with intricate profiles cut using wire EDM.

Material Versatility: Wire EDM machines can cut a wide range of conductive materials, from common metals like steel and aluminium to exotic alloys and hardened tool steels. This versatility allows Jehbco to fabricate extrusion dies and tools from materials best suited to the specific demands of silicone extrusion [2][6]. 

Enhanced Surface Finish: The Wire EDM process produces a high-quality surface finish, often eliminating the need for additional finishing operations. This is crucial for extrusion dies, where a smooth surface ensures consistent flow through the extrusion die and reduces the likelihood of defects such as streaks in the final silicone product [2][6]. 

Automation and Efficiency: Modern Wire EDM machines like the Excetek V400G are equipped with advanced automation features, including CNC controls and automatic wire threading. These features enhance operational efficiency, reduce setup times, and allow for unattended machining. For Jehbco Silicones, this means faster production cycles and the ability to meet tight deadlines without compromising quality​ [2][5]. 

Jehbco’s Expertise and Experience 

With five decades of experience in silicone extrusion, and a library of over 2600 dies and extrusions at Jehbco, there is a wealth of knowledge and data to draw from. This experience and expertise, combined with the precision of our Excetek wire EDM machine, enables Jehbco to fabricate high quality extrusion dies with which to produce the perfect silicone products tailored specifically for our customers. The integration of Wire EDM technology has allowed Jehbco to push the boundaries of what is possible in silicone extrusion, offering innovative solutions and products that set industry standards. 

Overall, the adoption of the Excetek V400G Wire EDM machine at Jehbco Silicones underscores the company’s commitment to precision, innovation, and quality. By leveraging the advantages of Wire EDM, Jehbco continues to lead in the silicone extrusion industry, delivering products that consistently exceed customer expectations. The combination of advanced technology and extensive experience positions Jehbco as a trusted partner for those seeking high-quality silicone extrusion solutions. 

References 

  1. Wire EDM: Guide to EDM Wirecut Machine, Process & Uses – Fine Metalworking.
    https://finemetalworking.com/wire-edm 
  2. Wire EDM: Components, Types, Applications, and Advantages – IQS Directory.
    https://www.iqsdirectory.com/articles/edm/wire-edm.html 
  3. Wire EDM – Manufacturing Guide Sweden
    https://www.manufacturingguide.com/en/wire-edm 
  4. What’s Wire EDM Machining? Techniques, Benefits, and Uses – Rapid Direct.
    https://www.rapiddirect.com/blog/what-is-wire-edm/ 
  5. Wire EDM Explained: Everything You Need to Know – Union Fab.
    https://www.unionfab.com/blog/2023/10/wire-edm 
  6. All About Wire EDM Machining: Definition, Application, and Materials – Xometry.
    https://www.xometry.com/resources/machining/wire-edm-machining/ 

 

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Low Compression Set in Silicone Rubber and its Application in Seals

Silicone rubber is well known for its excellent elastomeric properties, exhibiting outstanding elongation at break values and rebound resilience. Due to these properties, silicone is an ideal material for producing a wide variety of seals and gaskets which readily form stable and durable mechanical seals upon applying pressure.  

A crucial parameter in the sealing performance of silicone is the compression set. In a sealing application, mechanical force is applied on the silicone seal to compress it between two surfaces. The elastomeric properties of the silicone causes it to bounce back to its original shape, and tightly forms a seal against the two surfaces that obstructs any flow of liquids and gasses. However, upon long-term compression, the silicone can lose a fraction of its shape memory, becoming permanently deformed and will no longer fully bounce back to its original shape. This permanent deformation after prolonged mechanical stress is applied and then released is known as the compression set. If a material has a high (poor) compression set, a large proportion of its original shape memory will be lost upon prolonged compression, which can cause sealing failure. Thus, compression set is a crucial property in sealing design as it indicates the ability of the seal to maintain its shape and sealing properties over extended periods of time. 

Compression set of silicone elastomers is typically measured using conventional standards such as ISO 815-1 B and ASTM D395 B. In these standards, standardised samples of silicone are placed between two metal plates which are then compressed, using gauge blocks to calibrate a fixed deformation distance, which is typically 75% of its original height. The entire apparatus is then placed in elevated temperatures to promote accelerated ageing, and compression set is provided at the testing values. For silicone rubber, a compression set testing period of 22 h at 175°C is often used. For related materials such as silicone sponge, separate testing samples and test durations are outlined in ASTM D1056.  

Solid silicone rubber exhibits excellent compression set values, typically between 10 – 30 % depending on the hardness and grade used, which is significantly lower than other elastomers such as EPDM or neoprene. In addition to an excellent low compression set, silicone is a chemically inert material, has outstanding heat resistance, and is safe for use in contact with food, and is thus the material of choice for sealing applications in high temperature environments, and food and medical grade industries. More information on silicone seals, mechanical properties and elastomeric behaviour is available on our articles page.  

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Post Curing of Silicone Tubing

Post Curing is the process of heating up the silicone tubing in an oven at a given temperature for certain amount of time.  The lowest and highest temperatures used in Jehbco for post curing is 160˚C and 200˚C. Post curing process helps to remove the volatiles from the manufactured products. 

As the name indicates, post curing is the secondary curing process in the silicone manufacturing. The Post curing helps to further cross link the polymer chains to enhance mechanical properties, thermal and chemical resistance. Post curing of silicone helps to improve the physical characteristics of the material. All silicone elastomers go through a peroxide silicone curing using peroxide-based chemicals or a platinum cure using a catalyst.  Even though the rubber is in a finished product format, it is still not a stable state. Few by products /volatiles from the chemical process is left with the silicone after the initial cure. These volatiles will be removed during the post curing process. Inadequate or poor post-cure may cause bubbling, delamination and unappealing sticky surface deposits. 

In a typical post curing process, the temperature is adjusted between 160˚C and 200˚C for a period of 2-6 hours. The time and temperature may be altered depending on the application. Post-curing ensures the product remains dimensionally stable. Post Curing also helps to reduce /eliminate the outgassing process. The main reduction in mechanical properties of the silicone occurs in the first couple of hours at a service temperature. Post-curing brings the silicone to a state where its degradation rate is minimized, ensuring long-lasting performance with consistent quality. 

Apart from all the advantages mentioned above, post curing also helps to enhance the thermal stability of silicone rubber. Allowing it to maintain its properties at higher temperatures without degrading. For silicone products that come into contact with high-temperature surfaces, undergoing the post-curing process is highly beneficial as it posts curing will produce a highly thermal resistant product.  

By completing the cross-linking process, post-curing improves the silicone’s resistance to chemicals and solvents. This is particularly important in environments where the material is exposed to aggressive substances, such as in pharmaceutical or food processing equipment. Current manufacturers recommendation from Jehbco’s supplier is to post cure at 200 degrees Celsius for 4 hours for pharmaceutical and food applications.

Oven temeprature records which shows the temeprature distribution in different locations of the oven

Jehbco is dedicated to meeting customer silicone requirements despite the costliness of post curing. The company employs oven curing or all post curing needs, a process involving placing manufactured goods in an oven under carefully controlled temperature and time conditions. Jehbco utilizes two new ovens from Steridium for this purpose, ensuring efficient post curing operations. One oven is exclusively used for platinum curing, while the other is dedicated to peroxide curing. This segregation guarantees that there is no cross contamination during the post curing stage at Jehbco.  The Airflow specification for Jehbco’s new ovens is 20,000 liters/minute. Thermocouples are positioned in nine locations on both sides of the oven to monitor and ensure even heat distribution throughout. The oven requires only 30 minutes to reach the desired temperature. Customers may request post curing of silicone from Jehbco if needed. Jehbco will monitor the temperature readings from the ovens to ensure the post curing process is executed effectively. Committed to delivering top-quality products, Jehbco prioritizes maintaining customer trust and satisfaction. The oven picture and the sample temperature records are added in the annex section of the article. 

References 

  1. https://rdabbott.com/wp-content/uploads/2017/08/Dow-Corning-Post-Curing-Silicone-Elastomers.pdf 
  2. https://shorehoses.com/news/importance-of-post-curing-of-silicone-products/ 
  3. https://www.adhesivesmag.com/articles/99586-post-cure-advantages-for-silicone-elastomers-and-adhesives 
  4. https://www.wacker.com/h/medias/7562-E-0323-final.pdf 
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