Manufacturing custom rubber compounds and masterbatches in batches of 1 to 200 kg, including calendering, extrusion and vulcanization
WAGU Gummitechnik GmbH
WarsteinNew on Amplifa
About WAGU Gummitechnik
WAGU Gummitechnik GmbH in Warstein has been developing and producing custom rubber compounds and masterbatches for technical elastomer processing for over 50 years. Recipes for light and colored, black, fiber-filled and large-volume compounds are produced on four internal mixer lines, and fluoroelastomer (FKM) on a segregated, contamination-protected line; batch sizes range from 1 kg to 200 kg, and for FKM around 60 kg per batch. The service portfolio includes recipe and process development, toll compounding, straining (sieves 0.1–0.8 mm), extrusion, calendering, granulation, vulcanization of sheets with or without fabric insert, as well as blank production and further converting. All common elastomers such as NR, IR, BR, SBR, CR, FKM and FFKM as well as ebonite (hard rubber) are processed; the compounds are supplied, among other forms, as wig-wag sheets, endless feeding strips, granules (approx. 5 x 5 mm) and extruded or calendered sheets (product width up to 1,650 mm, thickness 0.3–15 mm). Around 5,000 recipes are in the repertoire, every batch is documented and delivered with a test certificate. Customers in 36 countries across Europe, Asia, North and South America and Africa come, among others, from the automotive, electrical, chemical and food industries, medical technology, the rail and shipping sector, and mechanical and plant engineering.
- Site
- Warstein
- Processes
- Compounding / rubber manufacturing (mixing of elastomer compounds), Toll compounding (compound to customer recipe), Recipe and process development, Straining (sieve filtration 0.1–0.8 mm, online), Calendering (calendered sheets, cut-to-length into individual plates), Roller-head extrusion (wide die head, bubble-free extruded sheets), Extrusion (profiles, blanks, sheets), Granulation (cubes approx. 5 x 5 mm)
- Materials
- Natural rubber, Polyisoprene rubber, Butadiene rubber, Styrene-butadiene rubber, Polychloroprene rubber, Fluoroelastomer, Perfluoroelastomer, Ebonite (hard rubber, with drinking water approval)
- Certificates
- DIN EN ISO 9001:2015, DIN EN ISO 50001:2018, Building authority approval (DIBt), ACS approval H 1005 KTW, WRAS Approval, FDA 21 CFR 177.2600, DVGW 270 (H 1005), Food safety, IATF requirements (implemented in a process-oriented manner), KTW / ACS H 1005, Food safety (Hygiene Institute of the Ruhr Area)
- Industries
- Automotive industry, Electromobility, Construction sector, Oil & Gas, Food industry, Mechanical and plant engineering
- 01
Recipe and process development
- 02
Raw material quality assurance and weighing
- 03
Mixing (toll compounding) on internal mixer lines
- 04
Straining (sieve filtration)
- 05
Extrusion / calendering / granulation
- 06
Vulcanization (with/without fabric insert)
- 07
Blank production / further converting
- 08
100% inspection and batch documentation
- 09
Delivery incl. import regulations and customs formalities
Materials and Processes
Natural rubber
Excellent mechanical properties with good elasticity, high strength and low abrasion for dynamic applications.
Polyisoprene rubber
NR-like rubber with good hysteresis properties for technical elastomer products.
Butadiene rubber
Very high elasticity and low abrasion for wear-intensive applications.
Styrene-butadiene rubber
Good processability and low abrasion for versatile technical compounds.
Polychloroprene rubber
Weather-resistant, flame-retardant and swell-resistant against certain oils, greases and solvents.
Fluoroelastomer
Produced on a segregated, contamination-protected mixer line in batches of approx. 60 kg with high purity.
Perfluoroelastomer
For applications with the highest chemical and temperature resistance, where other elastomers reach their limits.
Ebonite (hard rubber, with drinking water approval)
For linings and applications in the drinking water sector with the corresponding approval.
Location
Warstein
DEProduction and Sales
- Part weight / size
- Batches 1–200 kg; sheets up to 1,650 mm wide
- Lot size
- Smallest quantities from 1 kg to series batches
- Materials
- NR, IR, BR, SBR, CR, FKM, FFKM, ebonite
- Internal mixer line 1 (light/colored compounds, online strainer)
- Internal mixer line 2 (black compounds, online strainer)
- Internal mixer line 3 (large volumes, fiber-filled compounds)
- FKM mixer line 4 (contamination-protected)
- Combined Troester rollerhead calender line (year of construction 2020)
- Hybrid system for calender and roller-head sheets
- Internal mixer GK190E with two two-roll mills and batch-off
Delivery Forms and Parts
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Compounding / rubber manufacturing (mixing of elastomer compounds)Plastics | – | – | 1 kg – 200 kg | 1 kg – 200 kg | Natural rubber (NR), Polyisoprene rubber (IR), Butadiene rubber (BR), Styrene-butadiene rubber (SBR), Polychloroprene rubber (CR), Fluoroelastomer (FKM), FFKM, Ebonite (hard rubber) |
| Toll compounding (compound to customer recipe)Plastics | – | – | 1 kg – 200 kg | – | all common elastomers |
| Recipe and process developmentEngineering | – | – | – | – | all common elastomers |
| Straining (sieve filtration 0.1–0.8 mm, online)Plastics | – | – | – | – | all common elastomers |
| Calendering (calendered sheets, cut-to-length into individual plates)Plastics | Thickness from ±5 µm (measuring accuracy) | 1,650 mm | – | Series batch | all common elastomers |
| Roller-head extrusion (wide die head, bubble-free extruded sheets)Plastics | Measuring accuracy of thickness from ±5 µm | 1,650 mm | – | – | all common elastomers (Mooney 25–120 MU, density max. 2.5) |
| Extrusion (profiles, blanks, sheets)Plastics | – | – | – | – | all common elastomers |
| Granulation (cubes approx. 5 x 5 mm)Plastics | – | – | – | – | all common elastomers |
| Vulcanization of sheets (with/without fabric insert)Plastics | – | – | – | – | all common elastomers |
| Testing/material testing (100% inspection: hardness, density, Mooney viscosity, rheology, abrasion,Testing | – | – | – | – | rubber compounds / elastomers |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Combined rollerhead calender line (extruder with wide die head, 4-roll calender S-type, | Troester | 1 | Roll width 1,800 mm, roll diameter 600 mm; product width max. 1,650 mm, product thickness 0.3–15 | 2020 | Warstein |
| Internal mixer line 1 (light and colored compounds, online strainer) | – | 1 | – | – | Warstein |
| Internal mixer line 2 (black compounds, online strainer) | – | 1 | – | – | Warstein |
| Internal mixer line 3 (large volumes and fiber-filled compounds) | – | 1 | – | – | Warstein |
| FKM mixer line / internal mixer line 4 (fluoroelastomer, segregated, contamination-protected, | – | 1 | – | – | Warstein |
| Hybrid system for producing calender and roller-head sheets | – | 1 | – | 2021 | Warstein |
| GK190E with two two-roll mills and batch-off | GK190E | 1 | – | – | Warstein |
| Calender line (rollerhead calender line, see above) | Troester | 1 | – | 2020 | Warstein |
Additional services
Reference customers
Quality and Certifications
Every batch is 100% inspected, documented and provided with a test certificate – including hardness, density, Mooney viscosity and rheology, plus abrasion, tensile and media storage tests on request. Further analyses such as DSC, IR, TGA and UV/ozone resistance are carried out via partner laboratories.
| Evidence | Warstein |
|---|---|
| DIN EN ISO 9001:2015 | |
| DIN EN ISO 50001:2018 | |
| IATF requirements (implemented in a process-oriented manner) | |
| Building authority approval (DIBt) | |
| KTW / ACS H 1005 | |
| WRAS Approval | |
| FDA 21 CFR 177.2600 | |
| DVGW 270 (H 1005) | |
| Food safety (Hygiene Institute of the Ruhr Area) |
Company History
- 1998
Initial certification of the quality management system to DIN EN ISO 9001
- 2011
Production expansion; commissioning of the segregated FKM mixer line (2026: 10th anniversary)
- 2015
Initial certification of the energy management system to DIN EN ISO 50001
- 2018
Modernization of the weighing area, separation of filler weighing and commissioning of a fully automatic small-component weighing system
- 2019
Construction of a storage hall and modernization of the workshop; technological extension of the GK190E with two two-roll mills and batch-off
- 2020
Commissioning of the combined rollerhead calender line from Troester
- 2021
Expansion of production with a hybrid system for producing calender and roller-head sheets