Dual Production Plants • 45,000+ Sq.Ft. Infrastructure • ISO 9001:2015 Tier-1 Facility

World-Class Manufacturing Infrastructure &
Dual Production Hubs

Operating two specialized manufacturing plants in Gurugram, India — combining automated German DESMA vacuum injection molding, 55L computerized dispersion kneaders, liquid nitrogen cryogenic deflashing, and sub-micron optical camera vision sorting.

45,000+ Sq.Ft. Dual Campus 35+ Hydraulic & DESMA Presses < -120°C Cryogenic Deflashing 400 Parts/Min Optical Sorting
Explore Dual Plants Machinery Specifications

Plant Intelligence Dashboard

Live Infrastructure Metrics
150+ T Monthly Compounding Output
35+ Units Hydraulic Presses (up to 400T)
100% In-House Tooling & Mold CAD
±0.005 mm Sub-Micron Optical Metrology
Manufacturing Facilities

Manufacturing Expertise —
Precision at Every Stage

Our manufacturing facilities are equipped to produce high-quality rubber and plastic components for automotive and industrial applications, as per customer drawings, specifications and international standards.

In-House Manufacturing

Manufacturing of custom rubber and plastic components as per customer requirements.

Consistent Quality

Process control and inspection at every stage to ensure consistent quality.

Skilled Manpower

Experienced team of mold operators, compounding chemists, and QA technicians.

Flexible Production

From rapid prototype pilot molds to high-volume million-piece OEM production.

Bhushan Rubber Industries precision molding press facility
Zero Flash Molding Vacuum DESMA Presses
100% Lot Traceability Compound Barcoded Batches
Dual Production Corridors

Strategic Manufacturing Facilities in Gurugram

Positioned in North India’s premier automotive manufacturing corridor, our dual plants ensure zero downtime, scalable redundant capacity, and immediate supply chain integration with Tier-1 OEMs.

Bhushan Rubber Industries Unit 1 Heavy Molding Facility Basai Road
Plant Unit 1 • Registered HQ
25,000+ Sq.Ft. Production Floor

Heavy Molding, Compounding & NVH Bonding

Plot No. 6, Govind Puri, Basai Road, Gurugram – 122001, Haryana, India

Plant Capabilities & Machinery:
  • 35+ Hydraulic Compression & Transfer Presses (up to 400T)
  • Internal 55L Computerized Dispersion Kneaders & Two-Roll Mills
  • Automated Phosphating & Chemlok® Rubber-to-Metal Bonding
  • In-House Tooling & Mold Maintenance Workshop
Get Directions (Maps) Call Plant 1 Gate
Bhushan Rubber Industries Unit 2 Cleanroom & Metrology Facility
Plant Unit 2 • Automation & Metrology
20,000+ Sq.Ft. Cleanroom QA

Cleanroom Deflashing, Sorting & Metrology

Plot No. 42, Sector 8 / Sector 37 Industrial Area, Gurugram – 122050, Haryana, India

Plant Capabilities & Machinery:
  • German DESMA Sealmaster Vacuum Rubber Injection Presses
  • Automated Liquid Nitrogen Cryogenic Deflashing Chambers (< -120°C)
  • 4-Camera Telecentric Optical Glass-Dial Sorting (400 parts/min)
  • Moving Die Rheometer (MDR) & Tensile Metrology Testing Lab
Get Directions (Maps) Call Plant 2 Gate
Advanced Machinery Fleet

Core Equipment Specifications & Capacities

Explore our complete fleet of high-precision molding presses, computerized internal mixers, sub-zero cryogenic deflashers, and telecentric optical sorting lines.

Vacuum Injection

German DESMA Vacuum Injection Presses

State-of-the-art horizontal and vertical FIFO injection presses engineered for zero-flash automotive connector seals and O-rings.

Clamping Force150T – 300T
Platen Size600 × 600 mm
Vacuum Chamber< 10 mbar absolute
Temp Uniformity±1.5°C across mold
Compression & Transfer

Heavy-Duty Hydraulic Compression Presses

Multi-daylight hydraulic presses with computerized PLC heating controls for large diaphragms, NVH mounts, and bridge bearings.

Tonnage Range100T – 500T
Max Platen1,200 × 1,200 mm
DaylightsMulti-deck hydraulic
Pressure ControlProportional servo valve
Internal Compounding

55-Liter Computerized Dispersion Kneaders

Heavy-duty cooling jacketed rotor chambers delivering homogeneous polymer-filler dispersion without thermal scorching.

Batch Capacity55 Liters / 75 kg
Rotor TypeIntermeshing tangential
Temperature ControlChilled water & steam
Batch TraceabilityAutomated barcoding
Open Mixing

Two-Roll Mixing Mills with Stock Blenders

Precision chilled cast iron rollers with motorized nip adjustment and continuous blender arms for curative incorporation.

Roller Diameter16 × 42 inches
Friction Ratio1 : 1.25
CoolingPeripherally drilled rolls
SafetyEmergency reverse braking
Sub-Zero Finishing

Liquid Nitrogen Cryogenic Deflashing Chambers

Automated tumbler chambers using liquid nitrogen to freeze flash to glass transition temperature (-120°C) with polycarbonate media blast.

Operating TempDown to -130°C (LN2)
Basket Volume120 Liters
Cycle Time3 – 6 minutes/batch
Surface FinishBurr-free, zero flash
Automated Metrology

Telecentric 4-Camera Glass-Dial Sorters

High-speed glass rotating dial optical sorting machine inspecting inner diameter, outer diameter, flash, and voids at 400 parts/min.

Inspection SpeedUp to 400 parts/min
Cameras4 CCD telecentric lenses
Resolution±0.005 mm (±5 microns)
EjectionPneumatic air jet sorting
Compound Rheology

Computerized Moving Die Rheometer (MDR)

Measures cure characteristics (ts2 scorch, tc90 cure, min/max torque) for every single production batch under ASTM D5289.

StandardASTM D5289 / ISO 6502
Test TempUp to 200°C (±0.3°C)
Oscillation±0.5° @ 1.67 Hz
OutputReal-time digital cure curve
Mechanical Testing

Universal Testing Machine (UTM Tensile)

Microprocessor-controlled dual-column tensile tester measuring ultimate tensile strength, 100% modulus, and elongation at break.

StandardASTM D412 / DIN 53504
Capacity10 kN (1,000 kgf)
ExtensometerOptical video tracking
Data LoggingAuto-generated stress-strain
Rubber-to-Metal

Multi-Stage Phosphating & Chemlok® Bonding

Continuous ultrasonic degreasing, zinc phosphating, and automated adhesive spray booths for high-strength NVH bonding.

Adhesive SystemChemlok® / Megum®
Pretreatment7-tank zinc phosphating
Bond Strength100% rubber tear failure
ApplicationEngine mounts, dampers
Bhushan Rubber Industries QA Metrology Caliper Inspection
Sub-Micron Calibration Optical Profile Projectors
PPAP Level 3 Certified FAIR Metrology Reports
Quality Assurance & Testing

Quality You Can Measure.
Confidence You Can Trust.

From incoming materials to finished components, our quality-focused approach and testing facilities ensure consistent manufacturing as per customer drawings, specifications and international standards.

Dimensional Inspection

Checking dimensions as per approved drawings, tolerances, and CAD specifications.

Hardness Testing

Verifying Shore A and IRHD durometer hardness across multi-point lot samples.

Material Performance

Testing tensile strength, elongation, rheology, and fluid swell immersion.

Final Inspection

Automated optical camera vision checks and defect verification before dispatch.

Shop-Floor Operational Excellence

6-Stage Zero-Defect Production Flow

End-to-end traceability from raw polymer batch intake to automated optical vision sorting and sealed export packaging.

01
Material Intake

Certified Polymer Ingestion

Virgin elastomers (DuPont Viton™, ExxonMobil, Lanxess) barcode-logged with precision chemical curatives and carbon black weighing.

02
Compounding

Dispersion Kneader Mixing

Internal 55L cooling-jacketed kneaders achieve uniform polymer-filler crosslinking dispersion without premature scorch.

03
Precision Molding

Vacuum Injection & Pressing

Hardened CNC tool molds loaded on German DESMA vacuum injection and heavy hydraulic compression presses for flash-free vulcanization.

04
Deflashing

Cryogenic Nitrogen Finishing

Liquid nitrogen tumbling freezes flash to glass transition temperature (-120°C), cleanly removing parting line excess with polycarbonate media.

05
100% Quality Assurance

Optical Camera Vision Sorting

Glass-dial 4-camera telecentric optical sorting units inspecting 400 parts/min for inner diameter, outer diameter, flash, and surface voids.

06
Release & Logistics

Lab Metrology & PPAP Release

Final lot testing (MDR rheology, Shore A durometer, UTM tensile) and sealed desiccated packaging with Material Test Certificates (MTC 3.1).

Quality Testing Laboratory

Zero-Defect Metrology & ASTM Testing Suite

Every production compound lot is tested in-house to verify cure kinetics, tensile strength, compression set, and fluid aging under PPAP Level 3 guidelines.

Moving Die Rheometer (MDR)

Measures scorch time (ts2), minimum viscosity (ML), and optimum cure time (tc90) for every compound batch.

ASTM D5289 / ISO 6502

Tensile & Elongation Tester

Computerized universal testing machine recording tensile strength, modulus at 100%, and elongation at break.

ASTM D412 / DIN 53504

Compression Set Fixtures

Precision hot-air convection fixtures testing elastomeric memory and recovery after 22h and 70h exposure.

ASTM D395 Method B

Ozone Resistance Chamber

Controlled ozone exposure testing chamber (up to 200 pphm @ 40°C) verifying zero surface micro-cracking.

ASTM D1149 / ISO 1431

Optical Telecentric Measuring

High-resolution profile projector measuring outer diameters, cross-sections, and flash down to ±0.005 mm.

Sub-Micron Calibration

Fluid Immersion & Swell Test

Autoclaves and oil bath test stations measuring volume swell, hardness shift, and weight change across engine oils.

ASTM D471 / SAE J200

Planning an OEM Supplier Quality Audit?

We welcome technical audit teams from automotive, industrial, and defense OEMs. Contact our plant directors to schedule an on-site factory walk-through or request a virtual digital audit.

Schedule Factory Audit WhatsApp Coordinator