Solving Tearing Issues in PU Films: GUMI’s Success Story
Client introduction
Israel’s GUMI is a leading producer, importer and distribution of rubber and plastic products for industrial use. Established in 1976, they offer a wide range of customized solutions for variuos industries, including heavy industry, food processing, chemicals, and more.
The challenge
GUMI previously acquired polyurethane (PU) films with a hardness range of 30A-40A, which unfortunately encountered significant tearing issues during the unpacking process. This problem was particularly evident as the films were being removed from their packaging, where the edges of the product were found to be excessively brittle. This brittleness caused the edges to break easily upon handling, resulting in a notable 12% decrease in the yield rate, which directly impacted production efficiency and increased material waste.
The initial technical approach that was employed to address this issue proved inadequate, as it failed to achieve a crucial balance between the necessary flexibility of the films and the stability required during processing. This imbalance further exacerbated the tearing problem, highlighting the need for a more effective solution to enhance the durability and performance of the PU films.
Our solution
We first focused on understanding the core problem by conducting cross-border sample testing and reviewing via video conference. Our technical team identified two major issues:
- Excessive migration of plasticizers results in a weakened material structure.
- Incomplete vulcanization leads to inadequate strength of the internal molecular chains.
Having understood the root issues, we approached solving the problem from three angles:
- Reconstructing the formula (challenging industry norms)
- Reduce plasticizer content by 18% and implement a composite plasticizer system.
- Introduce nano-scale reinforcing fillers to enhance interface bonding.
- Optimizing performance parameters
- After collaborative testing with the customer’s lab, we adjusted the hardness standard to 50A-55A.
- Develop a transition layer design to ensure compatibility with downstream injection molding processes.
- Upgrading the process
- Extend vulcanization time to 1.3 times the industry standard.
- Add an infrared online monitoring system to ensure uniform vulcanization.
Results
Our solution led to a substantial improvement in quality for our client, achieving a complete eradication of embrittlement issues and a 47% boost in tear strength.
