Thermoplastic Rubber

Thermoplastic Rubber & Highly Filled Elastomer Compounds

Thermoplastic rubbers (TPR, TPE, TPV) combine elastic behavior with thermoplastic processability, but their compounding presents specific technical challenges, especially when high levels of mineral fillers are required.

Typical requirements in thermoplastic rubber processing include:

• intensive dispersion of mineral fillers

• stable processing of high-viscosity melts

• precise temperature control to avoid degradation or scorch

• uniform distribution of additives and elastomeric phases

In highly filled formulations, conventional counter-rotating extrusion systems often reach their mechanical and mixing limits and are unable to properly load and homogenize the melt.

ICMA solution

ICMA designs high-torque co-rotating twin-screw extruders specifically suited for thermoplastic rubber compounding and highly filled elastomer systems.

Thanks to their mechanical robustness and modular screw architecture, ICMA extruders allow:

• effective melt loading with mineral fillers

• intensive dispersive and distributive mixing

• stable processing of highly viscous and elastic materials

• controlled energy input into the melt

Unlike counter-rotating technologies, co-rotating twin-screw extruders can:

• accept high filler loadings directly into the melt

• maintain homogeneous dispersion even at elevated torque levels

• ensure continuous and stable operation under heavy mechanical stress

Advanced thermal management

Thermoplastic rubbers often have narrow thermal processing windows.
ICMA extrusion lines integrate advanced temperature control systems that provide:

• precise thermal profiling along the barrel

• reduced risk of premature crosslinking or degradation

• improved compound stability and repeatability

Typical applications

• Thermoplastic rubber compounds (TPR, TPE, TPV)

• Mineral-filled elastomer blends

• Soft-touch and technical rubber compounds

• Automotive and industrial elastomer applications

• Rubber-like compounds requiring high filler content

Why ICMA

ICMA combines:

• high-torque extrusion capability

• superior melt loading capacity

• advanced thermal control

• deep experience in elastomer compounding

Each thermoplastic rubber line is engineered according to:

• filler type and loading level

• elastomeric phase characteristics

• target mechanical and functional properties

The result is a reliable, industrial-grade compounding solution for thermoplastic rubbers that cannot be efficiently processed with counter-rotating extrusion technologies.

Consult our technical team to better assess your needs! 

Processes and formulations for this industry can be developed and validated on ICMA Lab & Pilot extrusion systems before being transferred to full-scale production lines.