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Calgasket / Alliance Hose & Extrusions

Company Overview
California Gasket and Rubber Corporation (CGR) was established in 1942
and is comprised of two manufacturing divisions housed in a 50,000 square foot manufacturing facility.

 

CGR is a “job shop” in that it has no proprietary products of its own.  Parts are made to order per customer furnished blueprints and specifications or are reverse engineered from samples.  Jobs are quoted on a competitive bid basis.  There are approximately 25 employees producing total annual sales approaching 4 million dollars.  Major industries served include Defense, commercial aircraft, aerospace, agriculture, automotive, automotive aftermarket, OEM, electronics, irrigation, heavy equipment and more.
 
Competition is stiff and comes from both domestic and foreign sources. One Rubber Industry Directory lists 152 pages of rubber products manufacturers in the United States.  Competition in the Gasket and Metal Stamping side is even tougher due to the fact that the capital equipment requirement for those processes is far less than for molded rubber.


                                                                                                   

 

STAMPING DIVISION:

Gasket Department – Die cut non-metallic gaskets and washers manufactured from rubber, plastic, cork, compressed sheeting, felt, paper, foam/sponge, and many other materials.
 
Metal Stamping Department – Custom metal washers, metal stamping and forming, solid and laminated shims manufactured from all types of metals and metal alloys.
 
Rolled or sheet materials are cut to a pre-determined size utilizing shears.  The prepared material is delivered to a punch press.  A die is secured to the punch press and the material is fed into the die or press bed.  The press is cycled and the die stamps/forms a part from the material. In some cases, the parts are deburred in a vibratory tumbler.  Metal parts, when required, are sent to outside vendors for heat treating and/or plating.






MOLDED RUBBER DIVISION:

Custom molded rubber products, rubber to metal bonding, custom o-rings, seals, compression molding, transfer molding, injection molding, custom formulating and mixing of all types of natural and synthetic rubber.
 
A chemist or compounder writes a proprietary formula to meet the required performance specifications.  That formula is then held as a trade secret.  The formula is then mixed by an outside vendor, or in house, and is tested in an in-house laboratory to confirm that it meets the specifications.  The approved batch is then formed to a pre-determined size/shape and delivered by various methods, into a mold installed in a heated hydraulic press.  The mold is clamped and held for a specific time at a specific temperature to achieve proper vulcanization.  The press and mold are opened and the hot, cured part is removed and another cycle is started.
 
Sometimes a part must be post-cured in an air circulating oven to allow the rubber to achieve its final physical properties.  Excess rubber that has flowed out of the mold cavity is called flash and must usually be removed before a part can be considered finished.  This flash is removed by several methods including die cutting, scissor cutting, hand buffing, and cryogenic deflashing.  When cryogenic deflashing, the parts are placed on a stainless steel mesh belt in a sealed, computer controlled machine, and liquid nitrogen is forced into the chamber until the part is frozen and the flash has become brittle.  The belt is turned causing the parts to tumble and plastic shot is discharged causing the flash to break off and fall into a separator.  The frozen parts are then removed from the machine whereupon they are washed and dried and made ready for shipment.
 
CGR is fortunate to have a stable work force of highly skilled workers who have been employed there for many years.  There is a great deal of craftsmanship that goes into the products.  Over the years, workers have developed job-specific skills and techniques that are invaluable.  Most of the newer production machines are computer controlled, but even a sophisticated machine is just so much metal and wires in the hands of someone who does not know, or care how to use it.
 
Quality is assured through the use of a plan defined in a Quality Manual and procedures described in a Procedures Manual.  The plan and procedures are prepared in accordance with international specifications AS9100/ISO 9001-2015.  The company has had its plan audited and approved by a recognized independent registrar and has been issued a certificate so certifying this fact.  The company also practices Continuous Improvement and uses Statistical Inspection Plans and Statistical Process Control to that end.
 
CGR has a wholly owned subsidiary company, Alliance Hose & Extrusions, Inc., which was created in 1999 and operates and manufactures out of the same building in Orange, CA.  AH&E produces extruded profiles, extruded vacuum tubing, braided heater hose, mandrel built and wrapped heater hose, transition hoses, turbocharger hoses and elbows, all made from silicone rubber for sale internationally.  While most of its products are marketed under its own AHE Brand, the company also does a significant volume of business producing private label products for many recognized national brand names.
CGR and AHE jointly own a Mexican Corporation, Alliance Hose de Mexico, which is located in Guadalajara and serves as a warehouse and distribution center for the AHE products designated for the Mexican Market. AHE de Mexico currently has a fully trained staff of 12 employees to support the marketing efforts in South America.  It currently has 26 authorized distributors, across Mexico, most of which have multiple store locations. A pilot program is currently underway to begin manufacturing products intended for the Mexican Market, at AHE de Mexico.

 

 
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