As regulations increase and require environmental data at the project level, our customers need verified product information to complete their calculations. To provide our customers with the right documentation, we at V.A.V. Group turned to Reforest Finland Oy for help.

Sustainability requirements are going through changes

According to Atte Borgenström, CEO of sustainability consultancy Reforest, the change in mindset over the past few years has been dramatic.

“We’ve worked with sustainability reporting and carbon footprint calculations for years – carbon footprint reporting has been the core of our work for a long time. But regulation is tightening fast, and requirements keep growing. As a result, companies now need much broader solutions than before.”

Reforest, founded in 2020 and located in Tampere, Finland, supports companies with sustainability reporting, carbon footprint calculations, EPDs, and other environmental assessments. While interest started off slowly, in recent years the demand has accelerated rapidly.

“The number of inquiries has increased massively. Around 2021, sustainability was still often seen as something close to charity. Today, decision-makers understand that it’s an essential part of doing business.”

A combination of EU regulation and market pressure drives this shift. Larger companies increasingly require verified environmental data from their suppliers, which means smaller and mid-sized manufacturers must also be able to provide credible, standardized information.

What the EPD covers

An EPD is based on a life cycle assessment (LCA) of a product. It usually applies to construction products, where environmental performance plays a key role in project-level calculations.

“An EPD shows the environmental impacts of a product across its entire life cycle – from manufacturing and use to end of life. That includes CO₂ emissions and other greenhouse gases, but also impacts on water and ecosystems,” Borgenström explains.

The result is a detailed document containing a large amount of quantified data. While this may seem complex at first glance, its value becomes clear at the project level.

“A building consists of many different components. By combining EPDs, you can calculate the total carbon footprint and environmental impact of the entire building.”

Because EPDs follow harmonized standards and are third-party verified, the data is consistent and comparable, something that unverified calculations cannot guarantee.

Why this matters to us

One of the key strengths of EPDs is that they are always produced according to the same rules. All assumptions must be justified, and nothing essential can be left out.

Once the calculations are complete, the EPD is reviewed by an accredited verifier, who checks the methodology, data sources, and results before approving publication. Verified EPDs are public documents and can be found in databases such as EPD Hub.

A verified EPD is valid for 5 years, provided the product’s composition does not undergo significant changes. If production methods, materials, or energy sources change during that time, updating the EPD can help reflect improved environmental performance.

This is the first EPD calculation for V.A.V. Group and, as such, a starting point for continuous evaluation and improvement of materials, production, and recycling processes to achieve even better results in the future.     

What if a product has no EPD?

If a product does not have its own EPD, generic emission factors are typically used in building or project calculations. While this allows projects to move forward, the results are often less accurate and frequently less favorable than product-specific data.

“For manufacturers operating in Finland and other regions with energy-efficient production and low-carbon electricity, this can be a missed opportunity,” Borgenström notes.

EPDs make it possible to demonstrate real differences between products, especially when compared to alternatives manufactured under very different environmental conditions.

Ask our team for more details!

Reforest carried out the EPD calculations for V.A.V. Group’s products, supporting the process from life cycle assessment to third-party verification. For broad product portfolios, EPDs can often be created for product groups within defined variation ranges, making them a practical and scalable solution even when individual product variants are numerous.

You can now find EPD verifications for our silicone profiles and our TPE sealing profiles on EPD-Hub or by following the links below!

As sustainability expectations continue to evolve, EPDs offer a stable foundation grounded in data, verified by third parties, and increasingly essential for doing business in construction and industry. We at V.A.V. Group will continue to do our part in providing up-to-date documentation on our materials and products.

Artikkeli V.A.V. Group Shares EPD Verifications julkaistiin ensimmäisen kerran V.A.V. Group.

Why Standards Matter in Sealing Solutions

In regulated industries, it is not enough for a seal to simply perform well in practice. Authorities, manufacturers, and operators require documented compliance with recognized standards. This ensures that the materials, design, and testing methods meet a common benchmark for quality and safety. For customers, working with a supplier that understands these requirements provides peace of mind and reduces risks during inspections, audits, and certifications.

Railway Applications and Relevant Standards

Railway environments subject seals to constant vibration, fluctuating temperatures, and exposure to cleaning chemicals. Profiles must maintain performance over long service lives while supporting passenger safety and comfort.

The most important framework is the EN 45545 series, which specifies fire safety requirements for railway applications. For sealing profiles, this means using materials with proven fire resistance and low smoke and toxicity in case of fire. Compliance with EN 45545 is mandatory for rail vehicles operating in the European Union.

In addition to fire safety, standards such as EN 61373 (shock and vibration testing) influence the design and testing of profiles. Seals must withstand mechanical stresses without losing elasticity or sealing capability. Noise and vibration reduction are also part of railway comfort requirements, so seals are often expected to contribute to a quieter and more stable travel environment.

Marine Applications and Relevant Standards

The marine industry presents its own set of challenges. Saltwater, UV exposure, humidity, and fluctuating temperatures accelerate material wear. Safety is also paramount, especially on passenger vessels or offshore platforms.

Standards such as the IMO Fire Test Procedures Code (FTP Code) define fire safety criteria for marine equipment. Sealing profiles used in doors, windows, and bulkheads must pass flame spread and smoke emission tests. Many ship classification societies, including DNV and Lloyd’s Register, require documented compliance before approving materials for use.

Environmental resistance is another key factor. Marine seals often need certification for resistance to ozone, UV light, and salt spray. By meeting these standards, profiles ensure long-term durability in one of the harshest operational environments.

ISO Standards for Materials and Testing

Alongside sector-specific requirements, a range of ISO standards guide material testing and performance evaluation. For example:

• ISO 37 covers the determination of tensile stress and strain in rubber materials, a key measure of elasticity.
  
• ISO 815 defines how to test compression set, which shows how well a seal retains its shape after being compressed.
  
• ISO 48 describes hardness testing, ensuring that materials meet design specifications.
  

These tests provide reliable data on how seals will perform under real-world conditions. When manufacturers follow ISO testing methods, customers can trust that the results are accurate and comparable across different suppliers.

The Role of Compliance in Design and Procurement

Compliance is not only about passing tests at the end of production. It starts with material selection, continues through extrusion design, and extends to the final installation in the field. By considering standards early in the design phase, companies can avoid costly redesigns and delays. For procurement teams, documented compliance simplifies supplier selection and reduces the risk of non-conformity in later inspections.

Conclusion: Standards as a Foundation for Reliability

In the railway and marine industries, sealing profiles must do more than simply provide a tight fit. They need to perform consistently under harsh conditions and prove compliance with strict EU and ISO standards. Fire safety, mechanical resistance, and environmental durability are all part of the requirements.

Choosing a sealing partner who understands and applies these standards ensures that every profile contributes to the overall safety and efficiency of the system. At V.A.V. Group, we help our customers navigate the complexity of compliance by providing seals that meet industry regulations without compromising on performance. If you need sealing solutions that combine reliability with proven certification, our team is ready to support your next project.

Artikkeli EU and ISO Standards for Sealing Profiles in Railway and Marine Applications julkaistiin ensimmäisen kerran V.A.V. Group.

Why Seal Reliability Matters

When a seal loses its function, the consequences can be serious. Leaks may damage equipment, reduce energy efficiency, or even compromise safety in critical applications such as transportation, marine environments, or heavy machinery. The costs of emergency repairs and unscheduled downtime are usually much higher than investing in high-quality seals and proper maintenance from the start.

Common Causes of Seal Failure

Most sealing profiles fail for predictable reasons. By recognizing these issues early, it is possible to prevent them from shortening a product’s service life.

1. Incorrect material selection. Each environment places unique demands on seals. Exposure to extreme temperatures, aggressive chemicals, or continuous mechanical stress can cause premature failure if the material is not suited for the application.
   
2. Improper installation. Even the best seal will fail if installed incorrectly. Twisting, stretching, or damaging the profile during installation can create weak points that later lead to leaks.
   
3. Wear and tear. Over time, seals are exposed to friction, compression, and vibration. Without regular inspection and replacement, natural wear can progress unnoticed until performance is lost.
   
4. Environmental exposure. UV light, ozone, moisture, and salt can degrade some materials. Outdoor applications in particular require seals with high weather resistance.

Signs That a Seal May Be Failing

Maintenance teams can often spot early warning signs before a complete failure occurs. Stiffening, cracking, visible surface damage, or reduced elasticity are common indicators. Another signal is the need for repeated tightening of equipment or components, which often points to a seal losing its ability to maintain compression. Regular checks help detect these problems before they lead to larger breakdowns.

How to Extend the Service Life of Seals

While no seal lasts forever, careful planning and maintenance can make a significant difference. Companies can increase reliability and reduce lifecycle costs by focusing on a few essential practices:

• Choose the right material. Rubber, silicone, and TPE each perform best under different conditions. Considering temperature range, chemical exposure, and mechanical stress is critical to achieving a long-lasting result.
  
• Maintain regularly. Scheduled inspections, cleaning, and timely replacement prevent small issues from becoming costly failures. A proactive approach reduces downtime and keeps equipment running smoothly.

The Role of Design in Seal Durability

Material choice is only part of the equation. The design of the extrusion profile also affects how well a seal performs over time. Proper compression, tolerance, and shape all influence how effectively a profile maintains contact and prevents leakage. Working with an experienced manufacturer helps ensure that seals are tailored to both the mechanical and environmental requirements of the application.

Balancing Cost and Reliability

It can be tempting to save on material or installation costs, but cutting corners often leads to higher expenses later. A low-cost seal that fails prematurely may result in repeated replacements, lost production, and expensive repairs. In many industries, the total cost of ownership is much lower when seals are designed and maintained with long-term performance in mind.

Conclusion: Prevent Failure Before It Happens

Seal failure is rarely a sudden event. In most cases, it is the result of predictable issues such as poor material selection, incorrect installation, or neglect in maintenance. By understanding these causes and addressing them proactively, companies can extend the lifespan of their sealing solutions and avoid costly downtime.

The right material, the right design, and the right maintenance routine form the foundation for reliable sealing. At V.A.V. Group, we work with our customers to provide solutions that last, from material selection to custom design and long-term support. If you want to improve the reliability of your equipment and prevent seal failure, our experts are ready to help.

Artikkeli Understanding Seal Failure: Common Causes and How to Extend the Life of Your Sealing Solution julkaistiin ensimmäisen kerran V.A.V. Group.

Three materials stand out in industrial sealing: rubber, silicone, and thermoplastic elastomers (TPE). Each has its own strengths and limitations. By understanding the differences, it becomes easier to select a sealing solution that ensures reliability and long service life in your environment.

Why Material Choice Matters in Sealing Solutions

Seals are small components with a big impact. The wrong material choice can lead to leaks, vibration issues, or premature wear. These failures increase maintenance costs and may cause downtime in critical industries such as construction, marine, railway, and heavy machinery.

Selecting the right sealing profile from the start reduces lifecycle costs and improves overall system reliability.

Rubber Seals: Durable and Cost-Effective

Rubber has long been a standard choice for seals because it combines durability with affordability. Rubber profiles are elastic, abrasion-resistant, and able to handle mechanical stress. They are widely used in construction, automotive parts, and general industrial machinery, where cost control matters.

The main limitation is sensitivity to weathering. Standard rubber can degrade when exposed to UV light, ozone, or extreme conditions. Its temperature tolerance is also more limited compared to silicone. For applications where performance under harsh environments is not required, rubber remains a practical and economical choice.

Silicone Seals: Resistant to Heat and Weather

Silicone provides reliable performance where rubber falls short. Its wide temperature range, from about –60 °C up to +200 °C, makes it suitable for demanding conditions. Silicone also resists UV radiation and ozone, which ensures flexibility even after years of outdoor exposure.

These properties explain why silicone profiles are widely used in the rail industry, marine environments, healthcare equipment, and food processing machinery. The trade-off is cost. Silicone is more expensive than rubber, and in some cases, it does not match rubber’s mechanical strength. Still, for long-term reliability in harsh or fluctuating environments, silicone is often the best option.

TPE Profiles: A Versatile Middle Ground

Thermoplastic elastomers, or TPE, combine rubber-like elasticity with the processing advantages of thermoplastics. This gives them a versatile role in sealing applications. TPE profiles are recyclable and provide a balance between performance and cost, making them attractive to many industries.

They are commonly used in transportation, building profiles, and consumer products. TPE is easy to customize and can be adapted to different designs, but it cannot match silicone’s resistance to extreme heat or chemicals. Companies that value both performance and sustainability often find TPE to be a strong alternative.

Key Factors in Choosing a Sealing Material

The right choice depends on the environment and requirements of each project. When comparing materials, decision-makers often consider temperature tolerance, chemical resistance, and the expected mechanical stress on the seal. Regulatory standards such as ISO, EN, or FDA requirements also guide the selection process. Increasingly, sustainability plays a role as companies look for recyclable materials and lower environmental impact.

Rubber vs Silicone vs TPE: Quick Comparison

Conclusion: Selecting the Right Material

There is no single “best” sealing material. The optimal choice depends on the environment, budget, and performance needs. Rubber offers durability and cost efficiency in everyday industrial use. Silicone excels under extreme temperatures and outdoor exposure, making it the material of choice for demanding conditions. TPE strikes a balance, offering flexibility and sustainability benefits that meet modern industry requirements.

By weighing performance, cost, and environmental considerations, companies can select the sealing material that provides both reliability and value.

At V.A.V. Group, we help our customers design and manufacture custom sealing solutions that perform in even the toughest applications. Contact our experts to discuss the best material for your project.

Artikkeli Rubber vs Silicone vs TPE – Which Material Should You Choose for Industrial Sealing? julkaistiin ensimmäisen kerran V.A.V. Group.

Step one: Mixing the silicone compound

First we receive the blueprints of the requested profile from our client. We calculate the amount of raw materials depending on the length, wall thickness, and shape of the silicone profile. The material is stored as silicone bricks, which are cut and weighed to the requested total length of the profile. Hard and soft silicone compounds are mixed together with the dyeing agent to match the end product. This is done by feeding the silicone through a steel mill over and over again, until the “dough” is homogenous from texture and colour.

Silicone rubber is a very versatile material and it can be produced in all RAL colours. It can also contain additional agents and chemicals to enhance its properties, such as fire-retardant chemicals. Even without any additives, silicone rubber is highly resistant to high temperatures, pressure, chemicals, and oils. This is why it is often used in various operating environments.

Step two: Extrusion

Once the silicone rubber has been prepared for extrusion, the custom tool that forces the silicone into a recognisable shape of the requested profile is installed. The extruder feeds the softened silicone rubber mass through the tool or die, shaping the silicone into the desired profile. This results in a seal or profile that matches the client’s requests. Before producing large quantities of the profile, we have ensured that the blueprints and the end

Step three: Furnace

The extruder then feeds the profile into the furnace. The heat of the furnace vulcanises the profile, stabilising it. Our traditional furnace uses coils that surround the conveyor belt on which the profile travels through the furnace. Our revolutionary vertical furnace drives the profile upwards through the air with no contact with a conveyor belt. The infrared heaters are a lot faster to heat up than the traditional heater’s coils, which means a smaller carbon footprint for the end product. A further advantage of the vertical furnace is that since the profile is not in contact with a conveyor belt, we are able to manufacture more complex designs of seals and profiles with it.

To read more about our vertical extrusion line, click here.

Step four: Cooling and curing

From the furnace, the profile is transferred into a pool of water mixed with talcum, where it cools down efficiently. The talcum ensures that the surface of the profile does not become sticky, making it easier to handle and install. After this phase, the silicone profile is in its final shape and has reached the desired consistency.

Step five: Drying and quality control

Finally, the profile will be dried after its water bath with compressed air. Before packing the product into boxes or reels and shipping them to our clients, we run the final quality control. We cut a 100 cm piece of the profile, weighing it, and comparing the results with the original references.

Our quality control process also utilises several other optical and mechanical measuring tools to ensure that the client will get exactly what they need. Not only will this result in happy clients, but it is also beneficial for us as the manufacturer, because we are able to pinpoint any possible faults or hiccups in any part of the manufacturing process if the measurements were off even by a margin.

Further processing and profile assembly

Since V.A.V. Group specialises in custom seals and profiles, some further assembly or processing is often (but not always) the last step of the silicon extrusion process. Laser engravings and mounting tapes are the most common additional features. We have vast experience in joining the profiles into frames of all shapes, making pneumatic profiles, and attaching all sorts of valves and metal connectors to our custom-made seals and profiles, so that the client will receive a product that is 100% ready for installation.

To read more about our wide range of processing and assembly services, click here.

Conclusion

The silicone extrusion process is relatively simple, and there are only a handful of steps in our highly automated process. The difference between superior and inferior products is in the human touch. We put great effort into prototyping, process management, and quality control, which reduces wastage and reclamations. From the initial weighing of the silicone blocks to a finalised product (excluding further processing or assembly services), producing 120 kg of silicone profile takes merely an hour.

The traditional and vertical furnaces complement each other, and neither would be sufficient on its own. The more complex or delicate structures demand a vertical extrusion line to achieve the perfect result, but the efficiency of our trusted furnace cannot be underestimated during the most hectic times at our factory. The horizontal extrusion line is ideal for producing large quantities of a certain profile in one go since it is very precise once calibrated. Then again, the vertical furnace’s infrared heaters respond rapidly, and producing smaller batches in one shift is more efficient.

There is one more factor that underlines the need for both extrusion lines at our growing production facility: The colour of the profile. The lighter colours react differently to the infrared heaters of the vertical furnace, which means the darker colours heat up faster than the lighter ones. The traditional furnace’s coils work like an oven, so the profile reaches the optimal temperature despite its colour.

Thanks to the two different types of extrusion lines, we have broadened our range of available products significantly. If this woke interest in our services, we advise you to read more about our services or simply contact us to hear about possible solutions for your individual needs!

Artikkeli Silicone Extrusion Process julkaistiin ensimmäisen kerran V.A.V. Group.

WHAT ARE FIREPROOF SEALS AND PROFILES?

Fireproof seals and profiles are specially designed components. They are used to seal gaps and openings in walls, floors, and ceilings to prevent the spread of fire and smoke. These seals and profiles are made from materials that are capable of withstanding high temperatures without breaking down, degrading, or catching fire.

Fireproof seals are typically made from fire-retardant or intumescent materials. They are designed to expand rapidly when exposed to high temperatures. In general, fireproof seals and profiles create a barrier that prevents flames and smoke from spreading or slows the spread of fire. Fireproof profiles are similar to seals but are typically used in larger gaps or around the edges of doors and windows.

HOW DO FIREPROOF SEALS AND PROFILES WORK?

Fireproof seals and profiles work by creating a physical barrier that prevents or slows down the spread of fire and smoke. There are different solutions to do that, for example, fire-proof silicone, ablative sealants, or intumescent seals and fire-retardant profiles.

Fire X profiles are made of self-extinguishing silicone that withstand temperatures up to 300°C. Not only does the Fire X withstand extremely high temperatures for long periods of time, but it is also fire-retardant and non-flammable in itself.

In comparison to intumescent seals and profiles that expand when exposed to high temperatures, Fire X profiles, for example, are airtight in all temperatures. This prevents the spread of smoke, carbon monoxide, and other dangerous gases to other rooms or compartments before the temperature rises to a certain level. Since carbon monoxide can reach dangerous levels without an actual fire, Fire X seals are significantly safer than seals and profiles that only prevent the spreading of fires. 

Furthermore, if the compartments are sealed air-tight with Fire X profiles, they will significantly slow the spread of fire or even suffocate the flames in certain conditions. In normal conditions, the Fire X profiles act as normal silicone profiles. By comparison, intumescent seals have little to no sealing capability without high temperatures.

WHY ARE FIREPROOF SEALS AND PROFILES IMPORTANT?

Fireproof seals and profiles are incredibly important for several reasons. First and foremost, they can help to save lives in the event of a fire. By containing flames and smoke in the area where the fire originated, these seals and profiles provide occupants or passengers with more time to evacuate the building or vehicle safely. Additionally, fireproof seals and profiles can help to prevent extensive damage to the building, vehicle, or the possessions and cargo inside, as they can help to contain the fire in a smaller area.

Up to code

Fireproof seals and profiles are also essential for meeting building codes and regulations. In most jurisdictions, building codes require the use of fireproof seals and profiles in specific applications. These include e.g., doors, windows, and other openings. Specific areas within buildings or compartments often have different fire classification requirements. Those can be met with different seals and profiles. By using these components, building owners and operators can ensure that their buildings are in compliance with local regulations and are as safe as possible for occupants. In public transportation, the criteria are similar to those, but with certain additions or alterations. First and foremost, they can help to save lives in the event of a fire.

Buying valuable time in emergencies

Fireproof seals and profiles are essential components of any building that is designed to withstand the damaging effects of fire. By sealing gaps and openings in walls, floors, and ceilings, these components can help to prevent the spread of fire and smoke. This gives occupants or passengers valuable time to evacuate the building or vehicle safely. If you are involved in the design, construction, or maintenance of a building, it is essential that you understand the importance of fireproof seals and profiles and ensure that they are used appropriately in your building. In the maritime, railway, military, or transportation industry, the importance of fireproof seals and profiles can be even more important. The environment is very different, and first responders may have difficulties in reaching the site fast enough.

DID YOU KNOW?

Where are fireproof seals used? Many of our fireproof seals go into rolling stock or maritime transportation, but these seals are used for plenty of other applications as well; here are just a few examples of them!

FIRE X – A FIREPROOF SILICONE PROFILE BY V.A.V. GROUP

What is Fire X?
V.A.V. Group developed Fire X profiles for fire-rated applications such as fire doors, trains, urban transport, and maritime transport. They are used in conditions that require a high thermal resistance (< +270 °C) and where the seal must slow the spread of fire in extreme conditions. The primary material used in Fire X is silicone or TPV, with fire-retardant agents added to it.

Fire X is a silicone profile enhanced with fire-retardant and halogen-free materials. In short, the seals and profiles (along with other materials used in trains and their interiors) cannot ignite easily, burn aggressively at any point, or emit toxic fumes when predisposed to extreme heat. Fire X profiles are treated so that they will not burn but rather smolder and char even at the highest temperatures, maintaining their ability to prevent fires from spreading. This is a crucial feature for any profiles used in doors, windows, and latches on rolling stock.

Halogen-free profiles enhance the safety of railway passengers, as they will not be exposed to toxic gases but also the safety of firefighters. Halogen gases are also highly corrosive, which may cause further damage to other components of the vehicle (or building).

We produce Fire X profiles entirely at our manufacturing site in Ii, northern Finland. We use our own recipe and carefully selected raw materials. This way we can ensure that our Fire X profiles meet the highest standards for fire-retardant profiles.

FIRE X DEVELOPMENT AND TESTING

The main raw material that is used for Fire X is silicone. TPV, while not as heat resistant, is also an option for some components. A basic silicone profile will burn through fairly quickly, as many basic materials do. For silicone Fire X, chemicals are added to the raw silicone material that gives it heat and fire retardant properties. When Fire X catches fire, only the surface will burn momentarily. Due to its fire-retardant constitution, any flames die out quickly. Fire X has been developed to fit European standards in railway applications and is regularly tested to ensure its quality.

Trial by fire

Our testing for Fire X is outsourced and measures various aspects in a controlled environment. The tests are used to time how long the material takes to burn, how much smoke is generated, and what kind of toxicity levels are found in the smoke. Smoke and gas tests have strict directions and conditions. The test chamber and specimen are prepared to code, and the data is meticulously collected and analyzed. The goal of these tests is to ensure that in the case of a fire, the material will slow down the spread and produce a minimal amount of smoke into the environment. 

Sometimes the materials are tested in collaboration with the client. This lets us see how the material behaves in its intended use or environment. This can mean, for example, testing the whole component, such as a train door. 

The fire-retardant Fire X profile ensures the safety of the crew and passengers and has the following fire safety certificates:

• IMO FTPC Part 2 & 5
• UL 94 V Classification V0
• EN 45545-2

EN 45545-2:2020
V.A.V. Group’s self-extinguishing Fire X silicone has passed the most demanding railway transportation safety tests. It is now classified as HL3 level profiles according to the EN 45545-2:2020 standard. The Fire X material has passed the tests before, but now we have reached the highest level of fire safety. The renewed Fire X product is known as Fire X 2023.

Manufacturers of materials, components, and systems used in railway vehicles must ensure that their products comply with the relevant fire safety requirements. These requirements are specified in EN 45545-2:2020. The standard is part of the broader effort to harmonize safety standards for railway systems across Europe. It helps ensure consistent fire safety standards for railway vehicles in European countries.

It’s important to note that the EN 45545 series is part of a larger framework of European standards related to railway safety. It works in conjunction with other standards that cover different aspects of railway systems and components. Compliance with EN 45545-2:2020 is essential for manufacturers and operators. It ensures the fire safety of railway vehicles and protects passengers and personnel in the event of a fire.

CURRENT APPLICATIONS  FOR FIRE X

Because the railway industry demands such high standards for fire safety, the Fire X can be easily used in other environments with less strict requirements. The halogen-free Fire X does not burst into flames at any temperature, nor does it emit toxic fumes. It is a safe choice for small enclosures as well as large rooms or buildings. For example, the building and automotive industries have their own standards, but Fire X meets them in most cases. Of course, there are other alternatives. Our silicone or TPV profiles can also be treated to enhance their natural heat-resistant properties even further. For example, server rooms are often equipped with automatic fire extinguishers that protect the rest of the building in case of fire in the server room itself. Sealing the doors with Fire X can enhance fire safety even further.

We produce Fire X profiles entirely at our manufacturing site in Ii, northern Finland. Using our carefully developed recipe, we can ensure our clients that Fire X meets the highest standards for fire-retardant profiles.ern Finland. Using our own recipe and carefully selected raw materials, we can ensure our clients that our Fire X profiles meet the highest standards for fire-retardant profiles.

Artikkeli Testing and functions of fireproof profiles julkaistiin ensimmäisen kerran V.A.V. Group.

MATERIALS USED IN PROFILE MANUFACTURING

Seal profile materials are designed and selected according to their intended use and operating conditions. V.A.V. Group makes its own raw material mix for seal profiles, which allows us to have complete control over the various properties of the profile, whether it is hardness, color, or other special features.
The primary materials used for profiles are silicone rubber, TPV (thermoplastic vulcanizate), and TPE (thermoplastic elastomer). These materials all have their functional properties, with some overlap in potential use cases. Silicone rubber has the broadest operating temperature range, and TPE and TPV profiles have excellent chemical resistance, which makes both well-suited for multi-component seals. Fire X is our self-extinguishing silicone profile that fits European standards for rolling stock, the maritime industry, and other sectors. It can also be used for doors and windows in other transport industries.

SILICONE RUBBER

What is silicone rubber?

Silicone rubber is a versatile, synthetic elastomer made from a polymer composed of silicon, oxygen, carbon, and hydrogen. It is widely used in various industries, including automotive, medical, and consumer goods, due to its stability over a wide temperature range and resistance to environmental factors. Its applications range from seals and gaskets to medical devices and kitchenware.

Silicone rubber is an excellent material for demanding conditions. We can adapt its properties to fit various operating environments; the properties of silicone rubber include resistance to steam, pressure, moisture, chemicals and oils, UV, and ozone. Silicone rubber has a superior operating temperature range, making it a perfect choice for almost any industry.

Properties of silicone rubber 

• Operating temperature of -80 °C – +250 °C
• Extruded hardness Shore A 10-80
• Tensile strength 200-1500 PSI
• Basic, metallic, and RAL chart -colors

Silicone rubber is commonly used for insulation in many industries and is an excellent electrical insulator. We also manufacture non-stretch silicone profiles, foam silicone, and self-adhesive seals, all of which have their own special advantages. Silicone rubber has an incredible range of applications.

Applications for silicone rubber

• Window and door seals
• Silicone tubing (including food-grade silicone)
• Pressure profiles
• Appliance seals
• Rings and gaskets
• HVAC tubing

Even though silicone as a raw material is not exactly recyclable, it has significant advantages, like its long service life, that still make it an ecological choice, especially when you get it from us. We at V.A.V. Group have the advantage of creating small to medium-sized batches, perfectly meeting the needs of manufacturers without risking leftover products going to waste.

FOAM SILICONE

What makes foam silicone different from our other profiles is its “spongy” closed cell silicone structure, which works almost like a foam mattress; it’s thick and sturdy and holds its shape well, making it especially great for example, insulating corners, where it provides support and keeps out the cold air and outside noise. Our foam silicone comes quite often as a co-extruded structure with two different grades of hardness: the soft, flexible, round, and insulating part and the harder “spine” that settles into the groove and makes installation easy while keeping the seal from stretching. We can also provide threaded foam silicone, which absolutely prevents the silicone from stretching.

The spongy structure of foam silicone makes it an excellent noise insulator, perfect for loud urban environments.

The properties of foam silicone aren’t too different from our other profiles, but there are some areas where it excels. Noise penetrates better than air and will slip through even the smallest of cracks, but foam silicone has exceptional noise-canceling properties. For example, proofing your front door or balcony doors with foam silicone can notably muffle outside noise, something that people living in big city apartments are all too familiar with. We recommend installing the foam silicone on the warmer doorcase side instead of the leaf for best results.

Foam silicone is still criminally unrecognized, even when it has the potential to be a real game-changer for insulation, as well as for noise-canceling in big cities and homes near highways.

FLUOROSILICONE

What is the difference between silicone and fluorosilicone? 

Silicone and fluorosilicone are elastomers made from oxygen, carbon, and hydrogen but differ in their polymer chains and properties. Silicone has a silicone polymer chain, while fluorosilicone includes fluorine atoms, changing some of its chemical and physical properties.

In summary, silicone is flexible and elongates well, while fluorosilicone is more heat and chemical-resistant, stronger, and more durable. The right material should be chosen based on these properties.

PLATINUM SILICONE

Platinum silicone or platinum-cured silicone uses, as you could guess from the name, a platinum-based catalyst to cure. The process results in a material that is free from any by-products like peroxides, which makes it safe for medical- or food-grade products. Platinum silicone has high thermal temperature, chemical resistance, and elasticity.

Due to its high purity and non-toxicity, platinum silicone can be used in medical devices, kitchenware, and baby products. It is also clearer than other silicone types and maintains this clarity without yellowing over time.

CHLORINE-FREE SILICONE

Chlorine – or halogen-free silicone profiles are produced by adding organic, chlorine-free peroxides to the silicone during its vulcanization instead of the traditional peroxide that has been used for decades in the silicone vulcanization process. Chlorine-free silicone can be used in all profile applications, from door and window gaskets to ventilation systems and many more.  

The benefits of chlorine-free properties are important, for example, in shipbuilding and rolling stock sectors, where silicone profiles work as a fire-safe insulator. One of the advantages of chlorine-free silicone is that should it be exposed to flames and burn; it will not produce harmful chlorine compounds or hydrochloric acid.

FIRE X SILICONE

Fire X profiles are made of self-extinguishing silicone that withstand temperatures up to 300°C. Not only does the Fire X withstand extremely high temperatures for long periods of time, but it is also fire-retardant and non-flammable in itself. 

In comparison to intumescent seals and profiles that expand when exposed to high temperatures, Fire X profiles are airtight in all temperatures. This prevents the spread of smoke, carbon monoxide, and other dangerous gases to other rooms or compartments before the temperature rises to a certain level. Since carbon monoxide can reach dangerous levels without an actual fire, Fire X seals are significantly safer than seals and profiles that only prevent the spreading of fires. Furthermore, if the compartments are sealed air-tight with Fire X profiles, they will significantly slow the spread of fire or even suffocate the flames in certain conditions. 

In normal conditions, the Fire X profiles act as normal silicone profiles, unlike intumescent seals that have little to no sealing capability without high temperatures.

Fire X is a silicone profile enhanced with fire-retardant and halogen-free materials. In short, the seals and profiles (along with other materials used in trains and their interiors) cannot ignite easily, burn aggressively at any point, or emit toxic fumes when predisposed to extreme heat. Fire X profiles are treated so that they will not burn but rather smolder and char even at the highest temperatures, maintaining their ability to prevent fires from spreading. This is a crucial feature for any profiles used in doors, windows, and latches on rolling stock.

Halogen-free profiles enhance the safety of railway passengers as well as firefighters sent to the scene, as they will not be exposed to toxic gases. Halogen gases are also highly corrosive, which may cause further damage to other components of the vehicle (or building).

The fire retardant Fire X profile ensures the safety of the crew and passengers and has the following fire safety certificates:

• IMO FTPC Part 2 & 5
• UL 94 V Classification V0
• EN 45545-2

Fire X and TPV can replace the commonly used EPDM, which can also be treated to withstand extreme temperatures. The advantages of Fire X, compared to EPDM, are a greater variety of hardnesses and colors, along with more manageable and often more reliable joints in angles or round shapes.

Main properties of different silicone compounds

Conventional silicone rubber

Silicone rubber is a very versatile synthetic elastomer. It is widely used in various industries, including automotive, medical, and consumer goods, due to its stability over a wide temperature range and resistance to environmental factors. Its applications range from seals and gaskets to medical devices and kitchenware.

• Heat resistance: Breaks down above 149°C
• Excellent flexibility and elongation
• Generally food-safe

Foam silicone

• Foam silicone has a its “spongy” closed cell silicone structure
• Great for insulating corners, windows and doors, where it provides support and keeps out the cold air and outside noise.
• Foam silicone is often co-extruded with harder surface protecting the softer inner material as well as often acting as a spine for installation purposes.

Fluorosilicone

• Heat resistance: Withstands up to 204°C
• Higher chemical resistance
• Lower flexibility and elongation but higher tensile strength and tear resistance. Longer lifespan, more stable, and less prone to swelling and shrinking compared to silicone

Platinum Silicone

• Heat resistance: Withstands up to 230°C
• Safe for medical- or food-grade products.
• High chemical resistance, and elasticity.
• Usually clearer than other silicone types and maintains this clarity without yellowing over time.

Chlorine-Free Silicone

• Chlorine-Free Silicone will not produce harmful chlorine compounds or hydrochloric acid when exposed to extreme temperatures (fire).

Fire X Silicone

• Self-extinguishing, non-flammable
• Operating temperature of up to 300°C
• IMO FTPC Part 2 & 5
• UL 94 V Classification V0
• EN 45545-2

TPE – THERMOPLASTIC ELASTOMER

What is TPE?

TPE is a class of materials that combines the properties of thermoplastics (like polyethylene and polypropylene) with elastomers (like rubber). TPEs are typically composed of a mixture of hard and soft segments, with the soft segments providing elasticity and the hard segments providing structural integrity.

TPE seals and profiles offer flexibility, resilience, and excellent sealing capabilities. They are softer and more elastic than PVC, making them suitable for applications requiring a tight seal and flexibility. The latest material developments have brought more rigid TPE materials to the market, thus closing the gap in this sector.

While a material like PVC typically has a higher melting point and is more suitable for high-temperature applications, TPE excels in low-temperature flexibility, ensuring effective sealing even in cold climates. TPE can also be treated to withstand very high temperatures, up to the point of being fireproof.

  Properties of TPE

• Excellent flexibility and elasticity
• Wide range of hardness options, from very soft to rigid
• Wide range of color options
• Moderate to excellent resistance to UV radiation and weathering, depending on the specific formulation
• Good chemical resistance can vary based on the TPE type
• Extremely versatile when it comes to thickness, shape, and size
• Hardness 40 Shore A – 45 Shore D
• Operating temperature of -40 – +120°C

TPE’s flexibility and elasticity make it ideal for applications where a secure and pliable seal is necessary. TPE seals are used in industries like automotive, where they are employed in weather-stripping and fenestration applications, providing an effective seal for doors and windows. The softness of TPE makes it suitable for areas where impact resistance and noise reduction are essential. 

    Applications for TPE

• Soft-touch grips and handles
• Overmolded parts and handles on tools and consumer products
• Automotive interior components, e.g. dashboard trim and cup holders
• Appliance seals
• Medical devices and equipment
• Cable and wire insulation

TPE materials are also known for their recyclability and environmental friendliness. TPE is often considered a more environmentally friendly option than materials like PVC and EPDM, as it can be reprocessed. While a material like PVC is generally more cost-effective than TPE, TPE’s superior performance and environmental considerations may justify its higher initial cost in specific applications. Thanks to its recyclability, TPE can become more cost-effective than PVC when considering disposal costs.

Due to its recyclability, TPE can be more cost-effective than other alternatives, like PVC.

TPV – THERMOPLASTIC VULCANIZATES

Thermoplastic vulcanizates (TPV) are part of the thermoplastic elastomer (TPE) family of polymers but are closest in elastomeric properties to EPDM thermoset rubber, combining the characteristics of vulcanized rubber with the processing properties of thermoplastics. Like TPE, TPV is recyclable and has good UV, ozone, and chemical resistance, and in some cases, even greater resistance than EPDM. 

What is the difference between TPE and TPV?

TPE is a mixture of rubber and plastic that can stretch under stress but snaps back into shape afterwards.TPV includes a blend of EPDM rubber and polypropylene which, when vulcanized, makes it highly resistant to heat and compression.

Our selection includes combinations of foam and hard TPV. Our TPV material has been tested accordingly for EN45545-2 R22/23 HL2.

Applications for TPV are much the same as those for TPE.

♻ BIO-TPE

Our selection also includes Bio-TPE, in which 65 % of fossil materials have been replaced with bio-based oils, making it an ecological alternative for TPE. Like TPE, Bio-TPE is a fully recyclable material with the same features as TPE. 

Like regular TPE, Bio-TPE is a fully recyclable, non-toxic material, and it has the same excellent chemical resistances and hardness of 50-90 ShA in a full RAL color scale.

PVC, EPDM, OR TPE?

In this section, we have shared some basic information about PVC and EPDM. These materials have been commonly used in profile manufacturing for a long time, but they are currently being replaced by more environmentally friendly alternatives.

Note: V.A.V. Group does not produce PVC or EPDM profiles. In most cases, they can be easily replaced by custom-treated TPE, TPV, or silicone materials.

PVC – POLYVINYL CHLORIDE

PVC is a synthetic plastic polymer known for its durability and versatility. It exhibits excellent resistance to chemicals, weathering, and UV radiation. PVC seals and profiles are rigid and provide stability, making them ideal for applications where structural integrity is crucial. Additionally, PVC is cost-effective, making it a popular and affordable choice in the construction industry.

Speaking of construction, PVC is commonly used in applications where structural stability is critical, such as window frames, door frames, and pipe fittings. Its rigid nature ensures long-term durability and resistance to wear and tear. PVC profiles are widely utilized in construction due to their affordability and ability to withstand harsh environmental conditions.

PVC typically has a higher melting point than TPE, making it more suitable for applications where high temperatures may be a concern. Conversely, TPE excels in low-temperature flexibility, ensuring effective sealing even in cold climates. However, TPE can be treated to withstand very high temperatures, up to the point of being fireproof, at which point it can effectively replace PVC.

EPDM

EPDM (Ethylene Propylene Diene Monomer) and TPE (Thermoplastic Elastomer) are both materials commonly used in various industries for their flexibility and durability, but they have distinct differences in terms of composition, properties, and applications.

EPDM is a synthetic rubber made from the polymerization of ethylene, propylene, and a small amount of diene monomers. It has a saturated polymer backbone, which gives it excellent resistance to environmental factors like UV radiation, ozone, and weathering.

The composition itself does not play a significant role in the actual use of the profile, but it does in the manufacturing process. EPDM profiles are a lot harder to join together than TPE or TPV profiles, which means they cannot be “welded” together like our TPE/TPV profiles. To create angles or round shapes from an EPDM profile, the joint requires a joining block or an adhesive, which may become a weak link later on. TPE and TPV profile ends are simply heated, and the two ends are then pushed together to form a very reliable connection that requires no additional adhesives or other materials.

Even though it may lack some of EPDM’s features, TPE is more customizable than EPDM. TPV can be considered a highly functional hybrid between these two materials. In most cases, TPE can replace EPDM, which we have seen in the industry in the past years. One reason for this is that EPDM is typically processed using methods like extrusion, injection molding, and compression molding. It cannot be re-melted and reprocessed after curing. TPEs, however, are thermoplastic, which means they can be melted and reprocessed multiple times. They are well-suited for injection molding, blow molding, and extrusion processes.

This brings us to the biggest difference between EPDM and TPE, the recyclability. EPDM cannot be recycled, so it can only be disposed of as energy waste after its lifecycle has come to an end. It is also the main reason why several companies are looking for more environmentally-friendly alternatives, such as TPE or TPV. EPDM is often cheaper to produce, but because of its disposable nature, the total cost may actually become higher after waste management costs, whereas TPE and TPV can be melted and granulated after use.

ARE YOU LOOKING FOR A PVC OR EPDM REPLACEMENT?

The choice between PVC, EPDM, silicone, and TPE seals and profiles ultimately depends on the application’s specific requirements. Silicone has amazing temperature-resisting properties, PVC offers durability and structural stability, and EPDM offers weather resistance and insulation properties at a lower cost, while TPE provides flexibility, resilience, and environmental benefits. However, our modern solutions for TPE use have increased structural strength to the point where TPE can widely replace PVC and EDPM in most circumstances. 

Understanding the performance characteristics and considering factors such as temperature resistance, environmental impact, and budget constraints will guide the selection process, ensuring the optimal choice for each unique application in the construction and manufacturing industries.

IS TPE BETTER THAN SILICONE?

Between TPE and silicone, there is no clear winner as to which one is “better” since they both excel in their own fields of use. Here is a clear side-by-side comparison of their properties:

As seen in the table, it’s a pretty even match between the two until the optional and special properties, that can be added to silicone profiles in our downstream operations. TPE’s advantage over silicone is that it can be produced in higher hardnesses than silicone and is fully recyclable, whereas silicone has to be disposed of by incineration at the end of its lifecycle*. Silicone easily beats other materials with its wide range of operating temperatures.

* Some recycling centers for silicone exist in Europe. They are few and far between, and the transportation of used silicone profiles from Finland to these centers would ultimately undo any environmental benefits of the recycling itself.

CUSTOM SOLUTIONS BY V.A.V. GROUP

In conclusion, the profile materials we provide all fit the needs and are widely used in construction, heavy industry, and transportation due to their easily customizable properties, high quality, and fast and flexible production times. 

While we might be best known for top-quality seals and profiles for transportation, construction, and heavy industry, and those three categories are indeed the largest sectors we do business with, they are not the only ones. Our ability to create custom extrusion tools lets us produce products for a wide variety of uses, from brewing tanks and composter seals to food-grade feeding tubes for calves.

Combined with flexibility and reliability, we can offer our customers a fast supply of products, with prototypes delivered in two weeks from when we receive the drawings or model of the product. Often, a customer’s R&D process requires several experimental prototypes before the final product design is found, but with our fast prototyping rounds, this part of the process becomes easy and efficient. We design and manufacture products from the start to fit the customer’s specific needs. The goal is to together create a prototype that follows the customer’s plans and that they can approve of without feeling like the resulting prototype is completely unrecognizable from their original idea.

We consider quality an element of reliability and are firmly committed to high-quality production. Our guiding principle is to find the best solution for each customer in order to ensure their success and competitiveness. With our flexible production lines, co-extrusion capabilities, speed in modifying products to customer specifications, and sometimes even co-designing the perfect solution to customers’ problems, we can say that innovativeness is the key driver in our company culture.

READ ABOUT OUR CUSTOMER CASES

Doors for generations – Hellbergs Dörrar

Hellbergs Dörrar is a Swedish steel door manufacturer that specialises in fire protection, soundproofing, and other high-security doors.

From craft breweries to calf feeders – Our more curious customer cases

We looked back on our more curious customer cases along the years with project manager Hannu and head engineer Tuomas.

Making sure the ship sets sail on time

Anyone who has ever been a part of a construction project knows how crucial it is to finish every stage on time to maintain the set schedule.

Artikkeli PROFILE & SEAL MATERIAL SELECTION GUIDE julkaistiin ensimmäisen kerran V.A.V. Group.

A smelly sample

Hannu recalls a case when a craft brewery contacted us a few years back, Pyynikin Brewing Company, that needed specific replacement gaskets for their brewing tanks. To be more specific, the manhole latch gasket for their bigger tanks that were so large someone could crawl inside them to wash them thoroughly. “As usual, we asked them if they could provide us with blueprints or a sample of the seal they needed. They sent us their old gasket and boy, that was a smelly one!”, Hannu laughs. Years of different hops, malts and yeasts had left their mark on the gasket that was already so worn out that the yeasty smell refused to wash away.

Having produced several applications from food-safe silicone, the choice of material was not a difficult task. The sample, although being smelly, made it easy for Hannu and Tuomas to make the custom tool for manufacturing the seals for brewing tanks. Since then, V.A.V. Group has delivered more brewing tank seals and gaskets on several occasions as Pyynikin Brewing Company has increased their production over the years. “I guess you could call us the craft beer experts at V.A.V. Group now”, Hannu adds with glint in his eye.

Speaking of smells, there is another sealing solution meant to protect a delicate process from the elements: composter seals. Composting has become rather popular in Finland, and most of Europe as well (we even have an official compost inspector) because it is a great way of disposing biodegradable waste and getting nutrients for growing plants and herbs in return. A good composter is solid, insulated, and has an airtight lid that allows the microorganisms to work in peace. As a result, hundreds and hundreds of composters on people’s yards have our seals that help them in being environmentally friendly and grow their own crops!

Silicone sleeves add protection

Not all our products are for sealing purposes. Being able to produce any custom shape from panels to tubes, the possibilities range from the tiniest nit-bit (but needed in massive quantities) to several metres long profiles. We are used to having seals protect us and our valuables from the elements, but sometimes it is even simpler than one could think.

A paint shop approached us some years ago, asking if we could produce a special silicone tube to protect the bolt threads when painting the bolt heads and other parts. Using masking tape is the first solution that comes to mind, but taping up bolt after bolt would take a lot of time, not to mention scraping it off from the threads afterwards. To be able to use the same tube for multiple bolt diameters, the solution was to make it in a specific shape: “We made this gingerbread-shaped tube that would fit the smaller bolts just like that, and thanks to its shape, could expand to fit over the larger bolts and screws just as easily”, Tuomas explains. Silicone was the optimal choice of material since paint doesn’t stick to it and can be wiped or easily chipped away if it dries. “The paint shop can just cut the tube to length and have a virtually endless stock of reusable thread protectors”, Tuomas continues.

In the world of agriculture

Our agricultural endeavours are not only limited to composters! Of course many of the machines, tanks and equipment may include our seals and profiles, but there is one special request from Finnlacto that both Hannu and Tuomas look back at with pleasure. “Feeding tubes for calves. We got to make milk feeding tubes for baby cows”, the two men say with a smile. As we know, baby bottle nozzles are made of silicone because it’s safe, hygienic and comfortable. Calves are not that different from human babies, and their needs are similar: a safe, comfortable and easy feeding tube ensures that the calf is willing to suckle milk from the feeding machine. “We are not cow experts, so we’re happy that Finnlacto provided us with enough information about the shapes and sizes, but also the strict material requirements. Food-grade silicone is required for livestock as well as humans, so we followed the instructions carefully. Technically, the same silicone mix is used in hospital environments, so it is indeed very safe for livestock and humans alike”, Tuomas explains.

Producing tubing of the most versatile shapes is nothing extraordinary for V.A.V. Group, even though it is rarely requested as such. “If a client is used to ordering replacement seals and profiles of highly hygienic and safe materials for medical use, for example, they may not realise they could order special tubing from us as well. We could easily produce dual tubing for milking robots as well, now that we are talking about agricultural needs”, Tuomas continues.

Sometimes it is all fun and games

We previously wrote an article about assembly and connections, where Sari Silvennoinen talked about a gaming solution that required a very specific damper system. The gaming solution was a mat with several pressure plates acting like keyboard buttons when the user stepped on them. The pressure plates needed a damper system that allowed the “keys” below the plates to be pressed easily, would let the plate move in all directions, but still keep it in place and prevent it from slipping out of the frame. “The challenge was that the profile had to be equally flexible in every direction but still act as a damper. We came up with this accordion-type profile that is both flexible and supportive, and because of the shape, it was rather tricky to join into a rectangular profile. But we did it, and it worked well!” Sari Silvennoinen recalls.

Hannu and Tuomas both remember the curious case and agree that it was an interesting task that involved some prototyping with different hardnesses.

But sometimes the prototypes never become a mass product, and that is part of the industry, the two men admit. “There are times when a customer orders a prototype to test their application, but after receiving the samples we may never hear from them again. Of course our sales team contacts them after some time, but the most common reply is that they had to go back to the drawing board because their original idea didn’t function as planned. Nevertheless, we store the custom tools made for the prototype in case the test version does go into production after all”, Hannu and Tuomas explain.

Making prototypes for new products or applications is something that comes up on a regular basis, and it’s always an interesting journey. “The customers understand that making a prototype is costly compared to mass production, because we have to 3D print the custom tool, mix the materials and run the production for a small sample, so obviously producing 10 metres of a custom profile takes as much time and effort as producing 1000 metres of the same profile”, Tuomas enlightens. “But if the prototype works as planned and we can continue with the original design, the costs are significantly lower in the mass production phase”, he continues. His advice is to contact the V.A.V. Group sales team and carefully plan all the details before proceeding with the prototype. “With our experience, we can give some valuable insight that may save the customer a lot of money in the long run.”

Innovative people find new use for leftovers

Working with seals and profiles makes you notice your surroundings in a different way. Anywhere you look, there are seals and profiles – visible or hidden inside a casing. “Oh you wouldn’t believe where you can find our profiles!” Hannu exclaims. Driving lights for cars, damper seals for air conditioners, industrial vacuum cleaner nozzles – just to name a few. In fact, even our trusty steed, the 3D printer used for printing every single custom tool, has its recoater blade replaced regularly with our own product. “We have delivered the same recoater blades to a few universities using similar 3D printers, and they say they’re even better than the original”, Tuomas laughs.

At the end of our discussion, Tuomas and Hannu tell about a coworker – let him or her be unnamed – who used leftover profiles to seal their garage door with a sturdier profile. “They were happy that the garage door is now better insulated and that the leftover pieces didn’t go to waste, but admitted they had to use a lot of elbow grease to fit the sturdier profile into the door profile slots”, the two giggle while looking at each other, knowing very well which coworker they’re talking about.

If you have any questions about whether we could find a solution for your specific needs, or happen to need some assistance with prototyping, do not hesitate to contact us!

Read our other customer cases!

Making sure the ship sets sail on time

Anyone who has ever been a part of a construction project knows how crucial it is to finish every stage on time to maintain the set schedule.

Hellbergs Dörrar – Doors for generations

Hellbergs Dörrar is a Swedish steel door manufacturer that specializes in fire protection, soundproofing, and other high-security doors

Support and Quality Profiles for Honkarakenne

Honkarakenne has years of experience in crafting beautiful, high-quality log houses, and they are a pioneer in healthy and ecological living.

Artikkeli From craft breweries to calf feeders – Our more curious customer cases julkaistiin ensimmäisen kerran V.A.V. Group.

What is the EN 45545 standard?

EN 45545-2:2020 is a European standard specifying fire behaviour requirements and testing methods for materials, components, and systems used in railway vehicles. This standard is part of a series of European standards (EN 45545) that were developed to improve the safety of railway vehicles concerning fire hazards. It is specifically concerned with the fire safety of railway rolling stock.

EN 45545-2:2020 covers the fire behaviour and fire resistance of materials and products used in railway vehicles. It provides requirements and testing procedures for assessing the reaction to fire of these materials, components, and systems. The standard applies to various materials used in the construction of railway vehicles, including seat covers, flooring materials, insulation, cables, and other interior and exterior elements.

EN 45545-2 categorizes railway vehicles into fire performance categories (HL1, HL2, and HL3) based on the vehicle’s intended use and passenger occupancy. Each category has specific requirements for fire behaviour. The standard outlines specific tests and methods for evaluating fire performance, including flame spread, smoke emission, and toxic gas production tests. These tests are used to determine whether a material or product meets the requirements for its intended use. EN 45545-2:2020 is the latest version of the standard and supersedes the previous version, EN 45545-2:2013. It reflects updates and improvements in fire safety standards for railway vehicles.

All new railway projects should be following the updated 2020 version of the EN 45545 standard, and meet all its requirements in all components.

Why is it important?

Manufacturers of materials, components, and systems used in railway vehicles must ensure that their products comply with the relevant fire safety requirements specified in EN 45545-2:2020. The standard is part of the broader effort to harmonize safety standards for railway systems across Europe. It helps ensure consistent fire safety standards for railway vehicles in European countries.

It’s important to note that the EN 45545 series is part of a larger framework of European standards related to railway safety, and it works in conjunction with other standards that cover different aspects of railway systems and components. Compliance with EN 45545-2:2020 is essential for manufacturers and operators to ensure the fire safety of railway vehicles and to protect passengers and personnel in the event of a fire.

How is it made?

Fire X is a silicone profile enhanced with fire-retardant and halogen-free materials. In short, the seals and profiles (along with other materials used in trains and their interiors) cannot ignite easily, burn aggressively at any point, or emit toxic fumes when predisposed to extreme heat. Fire X profiles are treated so that they will not burn but rather smoulder and char even at the highest temperatures, maintaining their ability to prevent fires from spreading. This is a crucial feature for any profiles used in doors, windows and latches on rolling stock.

Halogen-free profiles enhance the safety of railway passengers, as they will not be exposed to toxic gases, but also the safety of firefighters. Halogen gases are also highly corrosive, which may cause further damage to other components of the vehicle (or building).

We produce Fire X profiles entirely at our manufacturing site in Ii, northern Finland. Using our own recipe and carefully selected raw materials, we can ensure our clients that our Fire X profiles meet the highest standards for fire-retardant profiles.

Other use cases

Because the railway industry demands such high standards for fire safety, the Fire X can be easily used in other environments with less strict requirements. The halogen-free Fire X does not burst into flames at any temperature, nor does it emit toxic fumes, so it is a safe choice for small enclosures as well as large rooms or buildings. For example, the building and automotive industries have their own standards, but Fire X meets them in most cases. Of course, there are other alternatives, such as our silicone or TPV profiles, which can also be treated to enhance their natural heat-resistant properties even further. For example, server rooms are often equipped with automatic fire extinguishers that protect the rest of the building in case of fire in the server room itself, but sealing the doors with a simple solution could enhance fire safety even further.

Fire X and TPV can replace the commonly used EPDM, which can also be treated to withstand extreme temperatures. The advantages of Fire X, compared to EPDM, are a greater variety of hardnesses and colours, along with more manageable and often more reliable joints in angles or round shapes. In our previous article, you can read more about replacing EPDM with TPE/TPV.

Do you want to take fire safety to the next level?

The EN 45545-2:2020 is a specific standard for the railway and rolling stock industry, but our fire-resistant, fire-retardant, halogen-free, and self-extinguishing profiles can be adapted to suit your particular needs in other industries. If you want a modern, safe and versatile profile material, contact our sales so we can find the right solution for you!

Artikkeli Fire X silicone profiles receive highest HL3 hazard level of updated EN 45545-2:2020 standard julkaistiin ensimmäisen kerran V.A.V. Group.

Additional benefits from chlorine-free properties are gained for example, in shipbuilding and rolling stock industries, where silicone profiles work as a fire-safe insulator. One of the advantages of chlorine-free silicone is that should it be exposed to flames and burn, it will not produce harmful chlorine compounds or hydrochloric acid. This makes evacuation in the event of a fire more safe for passengers and crew.

We have the ability to add a chlorine-free property to all normal profiles on our production lines. We have organic peroxide in stock and are able to provide chlorine-free profiles to all of our customers. 

If you have any questions or think that your current profile would benefit from being chlorine and overall halogen-free, get in touch with our team!

Contact us

Artikkeli Chlorine-free silicone can be used in all profile applications julkaistiin ensimmäisen kerran V.A.V. Group.