HiSiaddi is an innovative foreign trade service provider driven by both technology transformation and foreign trade business. It has established a "1+2+3+4=1" service system and can supply TBBS products from multiple well-known original manufacturers.
As a tech-driven foreign trader with independent R&D capabilities, HiSiaddi has repeatedly collaborated with manufacturers on technology conversion and accurately captured market demands to propose TBBS formulation optimization plans and application improvement suggestions. The following is a case of HiSiaddi’s TBBS formulation optimization consulting service.
Contact HiSiaddi customer service for more formulation optimization consulting services.
Purchaser: RubberVech Srl, Milan, Italy A designated Tier 2 supporting manufacturer for Iveco and Fiat commercial vehicles, specializing in EPDM air suspension bellows for buses, NBR hydraulic oil seals for heavy-duty trucks and light-colored chassis damping rubber. Its products comply with IATF16949, EU REACH, in-vehicle VOC control standards and Italian DM food contact specifications.
Previously, HiSiaddi delivered two customized TBBS grades for the customer: high-purity refined powdered TBBS and EPDM carrier pre-dispersed TBBS-80 pellets, with an annual framework procurement volume of 260 tons. The first delivery of 95 tons was directly put into production across four internal mixing lines using the original mature vulcanization formula matched with Lanxess TBBS.
Benchmark original formula: 100 phr EPDM, 52 phr carbon black, 9.5 phr naphthenic oil, 4.2 phr zinc oxide, 1.1 phr stearic acid, 1.4 phr Lanxess TBBS, 0.35 phr CBS, 1.6 phr sulfur.
After 1:1 equal-weight replacement with domestically customized TBBS for one week of production, three consecutive mass production failures emerged: yellowing on light-colored damping rubber, internal bubbling voids inside mixed air bellows, unstable vulcanization rate with inconsistent scorch time within the same batch of rubber compounds, excessive finished product VOC, and two consecutive failed incoming inspections by Iveco. Production lines experienced intermittent shutdowns, resulting in weekly raw material and finished product scrap losses exceeding 10,600 Euros.
The customer’s R&D team independently adjusted TBBS, accelerators and oil dosage 18 times, trapped in a deadlock: increasing accelerators caused bubbling and blooming, while reducing dosage led to incomplete vulcanization and degraded mechanical properties. The TBBS manufacturer could only provide factory COA guaranteeing product physical and chemical compliance, lacking rubber formulation and end-product processing technology to troubleshoot on-machine abnormalities. The customer formally entrusted HiSiaddi’s rubber and plastic technical team to conduct targeted remote research and resolution.
HiSiaddi employs rubber formulation engineers and additive synthesis specialists with hands-on experience in TBBS synthesis and EPDM/NBR modification. Distinct from traditional spot goods traders, it can distinguish raw material quality defects from formula compatibility conflicts through parallel raw material testing, formula decomposition and production line process simulation, and systematically deliver rectification solutions.
After HiSiaddi sampled and conducted parallel SGS testing on original Lanxess TBBS and domestically customized TBBS, all domestic customized TBBS met contracted technical specifications. Failures stemmed from formulation compatibility imbalance caused by physical property differences:
1. Refined TBBS exhibits higher polarity than imported products, leading to excess lubricating oil in the original formula. Customized TBBS undergoes anhydrous recrystallization refining with far lower free amines and small-molecule impurities than standard grades, resulting in elevated molecular polarity. The original naphthenic oil and processing wax were designed for low-polarity Lanxess products, creating surplus oil beyond the rubber’s dissolution saturation. Small molecules migrate during high-temperature processing, triggering yellowing of light-colored rubber and internal bubbling of air bellows under heat;
2. Altered vulcanization synergy efficiency unbalanced accelerator ratios. The domestically produced TBBS has a vulcanization initiation temperature 3~4°C lower than the imported version. The original TBBS:CBS ratio matched the vulcanization curve of Lanxess products; equal replacement raised overall vulcanization activity, causing premature local vulcanization and void formation. Adjusting a single accelerator failed to balance scorch time and vulcanization efficiency;
3. The Mooney viscosity of the EPDM carrier in pre-dispersed TBBS-80 differs slightly from the customer’s base raw rubber, resulting in marginal incompatibility between pellets and base rubber. Under conventional feeding sequences, uneven additive dispersion causes local accelerator enrichment, exacerbating vulcanization fluctuations.
1.
Black EPDM air bellows original formula: 1.4 phr TBBS-80 pellets, 0.35 phr CBS, 9.5 phr naphthenic oil Optimization: Reduce pre-dispersed TBBS-80 to 1.22 phr, raise CBS to 0.44 phr; cut naphthenic oil from 9.5 phr to 7.8 phr to eliminate excess softening oil; fine-tune sulfur to 1.52 phr to balance phosphorus-nitrogen synergistic vulcanization rate and eliminate internal bubbling.
2.
3.
Light-colored damping rubber formula (high-purity powdered TBBS) Reduce high-purity TBBS from 1.38 phr to 1.25 phr, partially remove paraffin lubricants, add 0.3 phr epoxy compatibilizer to improve compatibility between TBBS, white carbon black and light-colored fillers and inhibit discoloration caused by additive migration; fine-tune stearic acid to 0.95 phr to reduce discoloration induced by acidic additives.
4.
1. Segmented temperature reduction for internal mixing: Original one-stage 156°C, two-stage 148°C, extrusion die head 152°C adjusted to one-stage 147°C, two-stage 141°C, die head 144°C to minimize trace decomposition and volatilization of TBBS under high temperature;
2. Reduce internal mixer rotor speed from 390 r/min to 335 r/min to lower shear frictional heat and avoid scorching from instantaneous local high temperature;
3. Raise internal mixer vacuum negative pressure from -0.07 MPa to -0.088 MPa to rapidly extract trace volatile gases generated during mixing and eliminate air bellows bubbles;
4. Revise feeding sequence: Feed raw rubber and reinforcing fillers first and mix for 4 minutes; add oil, zinc oxide and stearic acid mid-process; feed TBBS accelerator last at low temperature to prevent premature thermal decomposition of accelerators.
Store customized TBBS under constant temperature ≤26°C and ambient humidity ＜58%. Use powdered products within 7 days after opening, and seal residual raw materials with nitrogen to isolate moisture. HiSiaddi compiled Chinese-Italian bilingual TBBS Custom Grade Processing Guidelines labeling recommended dosage and temperature ranges for each batch, delivered alongside shipments.
1. Lab sample testing: Optimized formula samples underwent 72-hour high-temperature accelerated aging with no yellowing on light-colored rubber, stable vulcanization curves and zero bubbling; oxygen index and tensile strength all met standards;
2. 72-hour mass production pilot on single line: Continuous full-load production on one line with optimized processes drastically reduced defective rates, raising yield from 75.2% to 99.5%. Re-inspection by Iveco’s third party fully passed. Remaining production lines switched formulas in two batches, enabling full production of 95 tons of in-stock raw materials and on-time delivery of backlogged vehicle supporting orders;
3. Stable execution of annual 260-ton orders: Monthly batch shipments of 110 tons high-purity powdered TBBS and 150 tons pre-dispersed pellets, with supporting process reference documents attached to each batch;
4. Delivery of incremental cooperation: The new energy bus damping rubber project launched the following year, with HiSiaddi collaborating with the factory to develop low-temperature modified TBBS, adding an annual procurement order of 85 tons.
Domestic customized refined TBBS outperforms general grades in crystallization process and impurity control yet exhibits inherent physical property differences from European original imported products. Additive manufacturers only control factory physical and chemical indicators without downstream rubber formulation R&D capabilities. European mid-to-high-end auto parts enterprises have formulas finalized around imported additives, and direct equal replacement easily triggers compatibility failures. Overseas R&D personnel lack familiarity with synthesis characteristics of domestic additives, incurring enormous time and material costs during independent debugging.
Backed by dual technical reserves in additive synthesis and rubber formulation, HiSiaddi accurately identifies core contradictions stemming from qualified raw materials yet incompatible compounding, delivering implementable solutions covering formulation ratios, processing techniques and warehouse usage to rapidly resolve customer production shutdown crises.
When European and American commercial vehicle Tier suppliers purchase accelerators, besides product quality and pricing, formulation optimization, on-site process technical support and full-cycle after-sales technical service are critical to locking long-term large-volume orders. Technical empowerment constitutes the core advantage for domestic additives to penetrate high-end European supply chains.
Contact HiSiaddi customer service for more formulation optimization consulting services.
+86-13120989737 
info@hisiaddi.com 
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