Process parameter optimization for sustainable manufacturing of elastomeric components used in water treatment systems

Abstract

The demand for water treatment systems is increasing, urging industries to deliver quick and sustainable solutions. This study focuses on the sustainable manufacturing of elastomeric components used in water treatment systems and adopts an Integrated Product Development approach. Diaphragms, produced by compression molding of a thermoset elastomer (EPDM), were selected as case study components. The study aimed to optimize the process parameters by reducing the cycle time of the molding process while maintaining or improving product quality. Data collection involved preliminary rheology testing of the elastomer across various time and temperature conditions, followed by mechanical testing. During production trials, energy consumption and product quality were closely monitored under different cycle conditions. The produced diaphragms underwent functionality and quality assessments through a 150-day accelerated aging test to simulate their service life. The study concluded that the optimization process significantly enhanced production efficiency, increasing output by 172%, while halving the carbon footprint and energy consumption. This demonstrates the potential for sustainable manufacturing practices to effectively meet the rising demands of the water treatment industry