# Hercules GmbH > Engineering and project management for tire and rubber extrusion lines: extruders, multiplex heads, upstream and downstream. 25 years of experience, independent of equipment manufacturers, 3D survey accurate to 0.05 mm. Hercules GmbH (Ronnenberg near Hanover, Germany) is an independent engineering and project-management company for tire and rubber extrusion lines. Managing director and contact person: Raymond Jöhnk. Hercules plans and leads rebuilds, retrofits and modernisations of existing extrusion lines of any manufacturer: extruders (pin-barrel / cold-feed), multiplex extrusion heads (duplex, triplex, quadruplex) and cassette changers, and the complete upstream and downstream chain (feeding, shrinkage conveyors, cooling line, cutting, winding, booking). It brings 25 years of experience in tire plants and performs its own on-site 3D scanning with up to 0.05 mm accuracy. Projects worldwide in German, English and Spanish. ## Services ### 01 · Extruders: Output and compound temperature under control. Whether a new product, higher throughput or a drive at the end of its service life: we assess the extruder as a whole and design the intervention to match the compound and the head. - Size and replace drives: motor, gearbox, coupling - Optimize screw geometry and pin configuration - Match output to the product, not simply increase it - Adjust barrel length and temperature control zones - Wear measurement on screw, barrel and pins - Modernize temperature control units and controls Typical case: New compound, the compound temperature is too high. Adjust pin rows and screw geometry, retune the temperature control zones. A stable process window for the new compound, without a new extruder. ### 02 · Extrusion heads: More components, faster changes. The head determines profile, layer structure and changeover time. We plan extensions, new inserts and change systems for multiplex, roller-head and wide extrusion heads. - Extend multiplex heads, for example from triplex to quadruplex - Add a chimney: side-arm extruder at extrusion height or on the upper head part - Design and balance flow channels and preformers - Head inserts for new widths and component layouts - Speed up cassette and die changes - Rework locking, hydraulics and head temperature control Typical case: A new tire type needs a conductive chimney. Side-arm extruder at extrusion height, adapted flow channel insert. The product runs on the existing line. ### 03 · Upstream & downstream: The line around the extruder. An extruder is only as good as the line around it. We look at the process chain from strip feeding to the book cart or winder. - Feeding: Strip feeding, strip festoon, metal detection, cold feed instead of hot feed. - Take-away and shrinkage: Take-away conveyor, shrinkage roller conveyor, strip tension and dancer control. - Measurement and control: Profile, width, weight per meter, control loops for take-away and screw speed. - Cooling: Spray, immersion and drum cooling, multi-tier, including water systems. - Cutting and handling: Skiver, cross cutter, booking and wind-up with liner. - Quality: Marking, reject handling, traceability and rework. Typical case: The line needs to run faster, but the profile reaches the skiver too warm. Extend the cooling line, rework the spray pattern and water circuit. Higher line speed with stable length. ### 3D survey · Digital twin Many lines have been running for decades, but their documentation has not. We scan components, heads and entire line sections on site and turn them into dimensionally accurate CAD models as the basis for design, clash detection and spare parts. - 3D scan from single part to line layout - CAD reconstruction, not just a point cloud - Clash detection for new components - Spare parts without original drawings ## Project process 1. Assessment: We record the condition, interfaces and data of your line, by 3D scan where needed. Result: Condition report, 3D data, bottleneck analysis 2. Concept: We evaluate options technically and economically. Result: Feasibility study, layout, budget range 3. Specification and award: We write the specification and compare bids on a vendor-neutral basis. Result: Specification, bid comparison, award recommendation 4. Execution: We coordinate suppliers, installation and schedules within the agreed shutdown window. Result: Schedule, installation supervision, acceptance reports 5. Ramp-up: We support commissioning until weight, profile and output are stable. Result: Ramp-up report, documentation, handover ## Why Hercules - Vendor-neutral: We recommend what fits your line, not what a catalog offers. - The entire line: Extruder, head, upstream and downstream in one assessment. - From the shop floor: 25 years in tire plants: production, development and rebuilds. - Predictable shutdowns: Measure and plan before the first intervention, rebuild within the agreed window. - Our own 3D data: Survey accurate to 0.05 mm, even where drawings are missing. - Three languages: German, English and Spanish, directly with plant, supplier and installation crew. ## FAQ Q: Does Hercules carry out the rebuild itself? A: We plan, engineer and lead. We handle assessment, design, measurement and optimization ourselves. The physical work is carried out by your staff and your suppliers. We provide supervision, coordinate the interfaces and make sure schedule and quality are met. Q: Does the make of our equipment matter? A: No. We are not tied to any make and work on existing equipment from every manufacturer, from the extruder and head to the peripherals. Where design documents are missing, the 3D survey provides the data basis. Q: How does the shutdown stay predictable? A: Before the first intervention, we record the existing equipment precisely and plan the rebuild in detail, including pre-assembly and spare parts. The work takes place within an agreed shutdown window. This keeps the downtime calculable. Q: Do you also work internationally? A: Yes. Tire plants are located worldwide, and we work where the line is. The project language is German, English or Spanish. Q: How does a project start? A: With a conversation about your equipment and your goal. If it makes sense, an on-site assessment follows. After that you know what is technically possible, how long it will take and what the cost range is. ## Contact - Company: Hercules GmbH - Contact person: Raymond Jöhnk, managing director (Geschäftsführer) - Email: raymond.joehnk@hercules-engineering.de - Phone / WhatsApp: +49 162 3223301 - Address: Nenndorfer Str. 85i, 30952 Ronnenberg, Germany - Languages: German, English, Spanish - Area served: worldwide ## Pages - [Website (German)](https://hercules-engineering.de/): Hauptseite auf Deutsch - [Website (English)](https://hercules-engineering.de/en/): main page in English - [Sitio web (Español)](https://hercules-engineering.de/es/): página principal en español - [Impressum](https://hercules-engineering.de/impressum.html): legal notice ## Kurzprofil (Deutsch) Engineering und Projektleitung für Reifen- und Gummi-Extrusionsanlagen: Extruder, Multiplex-Spritzköpfe, Up- und Downstream. 25 Jahre Erfahrung, herstellerunabhängig, 3D-Aufmaß bis 0,05 mm. Ansprechpartner: Raymond Jöhnk, Geschäftsführer. Ein Umbau an einer laufenden Reifenlinie berührt Mechanik, Verfahrenstechnik, Elektrik, Termine und mehrere Lieferanten gleichzeitig. Wir übernehmen die Projektleitung auf Ihrer Seite: Wir legen fest, was gebaut wird, wählen mit Ihnen die passenden Lieferanten aus und begleiten die Umsetzung, bis die Linie wieder stabil produziert.