Precision Manufacturing Processes & Plant Capabilities
Operating modern compression, injection, and transfer moulding presses alongside cryogenic deflashing and in-house CAD/CAM tooling at our 45,000 sq.ft Chennai MEPZ-SEZ plant.
Rubber Compression & Transfer Moulding
Up to 500 TonsCompression moulding is the primary process for producing high-durability elastomeric seals, heavy anti-vibration mountings, bridge bearing pads, and large-diameter O-rings. Pre-weighed compound blanks are placed directly into pre-heated multi-cavity hardened steel moulds, where hydraulic clamping pressure and high temperature induce vulcanization.
Transfer moulding utilizes an upper pot and plunger system to force liquefied pre-heated elastomer through runner gates into closed cavities. This process is exceptionally suited for multi-cavity delicate parts and complex rubber-to-metal bonded inserts with tight positional tolerances.
Key Highlights & Declarations:
- Over 20 hydraulic transfer and vacuum compression moulding machines ranging from 50 to 500 Tons.
- Capacity to mould parts from a fraction of a gram up to 25 kg.
- Multi-zone digital temperature control ensuring uniform cure cross-linking.
- Vacuum-assisted de-airing chambers eliminating micro-voids and blistering.
Precision Rubber & Plastic Injection Moulding
High-Volume AutomationFor medium to high-volume industrial and automotive orders, Horiaki utilizes microprocessor-controlled injection moulding machines. Solid compound or thermoplastic granules are plasticized inside a reciprocating screw barrel and injected at high velocity into temperature-controlled mould cavities.
This automated process guarantees minimal cycle times, exceptional dimensional repeatability, and near-zero parting line flash, making it the preferred method for mass-production O-rings, automotive grommets, and electrical connector seals.
Key Highlights & Declarations:
- Closed-loop CNC injection machines with shot capacities up to 1.5 liters.
- Multi-cavity high-precision hot runner and cold runner tooling.
- Cycle time reduction of up to 40% compared to traditional compression moulding.
- Automated part demoulding and robotic transfer cells.
Liquid Silicone Rubber (LSR) & Cleanroom Processing
Class 10,000 CleanroomLiquid Silicone Rubber (LSR) processing utilizes two-component (A & B) platinum-cured liquid silicone pumped through dynamic mixing meters directly into closed, heated moulds. Processed in our ISO Class 7/8 cleanroom environment, LSR components deliver ultimate biological inertness, clarity, and temperature stability (-60°C to +250°C).
Key Highlights & Declarations:
- USP Class VI and US FDA 21 CFR 177.2600 sanitary compliance.
- Flashless tooling design with automated robotic part extraction.
- Used for medical diagnostic diaphragms, baby feeding components, and EV battery thermal gaskets.
Cryogenic Deflashing & Surface Finishing
Zero Flash StandardTo achieve pristine, burr-free edges without mechanically damaging sealing surfaces, Horiaki uses automated liquid nitrogen cryogenic deflashing machines. Molded parts are chilled to glass transition temperature, where the ultra-thin flash becomes brittle and is safely eliminated by high-speed polycarbonate media blasting.
Key Highlights & Declarations:
- Pristine edge finishing complying with ISO 3601-1 and DIN 3771 standards.
- Preserves critical sealing lip profiles and dimensional tolerances.
- 100% optical inspection on high-resolution Video Measuring Machines (VMM).
Need Official Compliance Certificates for Your Audit?
Connect directly with our regulatory compliance team in Chennai. We provide IMDS MDS entries, SCIP dossier numbers, CMRT reports, and formal declarations for OEM supply chain verification.