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Technology
Monmouth Rubber and Plastics has an 11 point program for its
technology that it is proud to disclose:
- People
- Motivation
- People
- Innovation
- People
- Team Work
- People
- Total Commitment
- People
- Customer Satisfaction
- People
The secret of our technology is . . .
IT BEGINS AND ENDS WITH PEOPLE!
Monmouth, for over 30 years, has been a recognized leader in
innovative technology as it relates to cellular rubber and plastic
foam. A team of technologists that have hands-on shop floor experience,
laboratory expertise, and training and formal technical education,
has produced an impressive array of technology firsts. Some examples
are:
1965 - Monmouth designs, builds, and puts into commercial
operation a direct coating line of solvent based adhesives onto
cellular foam materials for the automotive industry.
1968 - Monmouth develops and perfects the Durafoam™ Multi-step
process for the curing and blowing of closed cell materials. Prior
to 1968, most materials were cured with the one step or jump-blow
process which resulted in densities no lower than 12 pounds per
cubic foot. By using a controlled multi-step-cure blow process,
Monmouth was able to crosslink and blow materials in densities
down to 2 pounds per cubic foot. Monmouth has made significant
improvements to this Durafoam™ Multi-step process over the years
as polymers, products and customer needs have changed.
1969 - Monmouth develops for B.F. Goodrich, Shelton CT,
a low density, Vinyl/Nitrile/Neoprene blend for industrial and
automotive markets. Monmouth's proprietary technology in hydrocarbon
polymer blending has been the keystone in its technology firsts.
The productline developed for B.F. Goodrich in 1969 is the forerunner
of the Vinyl/Nitrile/Neoprene blends produced today by Rubatex®
, Uniroyal Ensolite® Division and Halstead.
1971 - Monmouth develops the first commercial, low density,
Neoprene/SBR blend for the industrial and automotive markets.
Listed under ASTM-D-1056, SCE41 through SCE45, Monmouth produced
and sold commercial blends of its Durafoam™ C121A series in densities
as low as 3.5 pounds per cubic foot.
1974 - Monmouth commercializes the world's first 100% EPDM,
low density, closed cell sponge. Proprietary Durafoam™ technology
allowed Monmouth to produce the C191XLDS in densities as low as
to 2.0 pounds per cubic foot. One outstanding, commercially successful
application for this technology was as a sealing gasket for all
Chrysler tail lamps. Durafoam™ C191XLDS was used exclusively during
the 1980's in all Chrysler vehicles. A copy of the DuPont brochure
outlining this application is included.
1977 - Monmouth provides some of the initial EVA Polyethylene
crosslinked foam technology and developmental work for the Ensolite®
Division of Uniroyal. The product was ultimately marketed
by Uniroyal under the tradename "Ensofoam". This developmental
work included pilot plant production at our Long Branch facility
as well as product development.
1986 - Monmouth introduces its Bondaflex line of recycled
cellular and solid rubber and plastic materials. Monmouth's technology
centers around its proprietary process for controlled particle
size distribution of similar and dissimilar materials. Some examples
of market firsts from this technology are:
- A recycled bun of closed cell material four times larger in
size than any competitive material available - Specifically
400 pounds in weight as opposed to 100 pounds from its closest
competitor. The economies of fabricating a bun four times as
large are literally directly proportional.
- A sheet 54" wide making Bondaflex dimensionally compatible
with 54" wide transfer tape, fabric, and other materials that
fabricators choose to laminate to the Bondaflex material.
As of 1998, the Bondaflex process has resulted in Monmouth being
able to recycle in house 100% of all materials that it processes
and to offer to its customers a guarantee that it will accept back
in its Long Branch facility 100% of the materials that Monmouth
supplies. This guarantee includes skids, banding wire, stretch wrap
as well as the cellular and solid material that it makes and sells.
Monmouth guarantee is straight forward and simple. Monmouth will
take back anything, from anywhere, that is shipped from our plant,
and recycle it! There is no one else in the industry that Monmouth
knows of that offers such a guarantee.
1990 - 1995 - Monmouth Rubber & Plastics supplies to
Sentinel Products Corp. the basic Durafoam™ blend technology for
a comprehensive and complex family of crosslinked polyolefin foams
including polyethylene, EVA, EPDM, and the full family of metallocene
resins. With its proprietary blend technology, Monmouth was able
to achieve physicals and product performance significantly superior
to homogenous plastic foams. Some examples of commercially successful
products that resulted from this technology are:
- Crosslinked polyethylene packaging foam that is non-explosive.
- Crosslinked polyolefin foam in a density of 3.8 pounds per
cubic foot for the toy market commonly referred to as puzzle
foam. This product replaced a competitive 6 pound foam imported
from China.
- Crosslinked polyolefin tape grade foam in thin gauge applications
for both singe and double coated products.
- A full family of commercially successful metallocene blend
foams crosslinked in bun form for the polyolefin foam market.
1995 - Monmouth introduces the first vinyl nitrile shock
attenuating foam that can be thermoformed as easily as polyolefins
and vinyl dipped as easily as PVC nitrile non-thermoformable foams.
This technology has allowed OEM manufacturers significant design
improvements heretofore not attainable with PVC nitrile foams that
are dippable but not thermoformable. This product is one of Monmouth's
fastest growing product lines.
August 1996 - Monmouth commercializes its KGB 1 + 1=3 blend
technology (Kinetically Grafted Blends). KGB blend technology allows
dissimilar polymers (those that do not blend well mechanically)
to blend as a result of a chemical bond that develops through proprietary
KGB technology. The benefit to the customer is a blend product with
superior performance and value as opposed to more expensive, homogenous
polymers.
January 1998 - Monmouth introduces the largest pressed cured
bun in a neoprene blend available from anyone . . . anywhere. Proprietary
technology developed by Monmouth Rubber & Plastics has resulted
in a press cured bun having the quality features of a tight cell
structure and high physicals normally associated with a rubber closed
cell bun in the largest commercially available size. This accomplishment
is in keeping with our Phase 1 goal which is:
"To become and remain the highest quality, lowest cost producer
of cellular rubber and plastic buns in the world".
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