Production stages

The advanced formulae of composite materials are composed of the highest quality components which are always checked in terms of conformity with quality certificates and mixed in accordance with specific technological parameters so that the uniformity of friction mixture was ensured in one hundred percent.

Precise, fully automated cutting out of load-bearing plates. The computer system ensures the highest quality and representation of dimensions in accordance with the parameters of OE products.

The operation aims at mechanical cleaning of load-bearing plates off various types of contamination and to extend the surface of the connection with the friction material.Each production batch is controlled with the use of a profilometer and also based on the complex laboratory tests and controlled in the whole process with the use of SPC methods.

Load-bearing plates of brake pads arecovered with the highest quality glue in order to strengthen the joint with the friction material. Both, the thickness of the glue layer as well as the surface coverage are always strictly controlled.

The process involves formation of friction material joined with the load-bearing plate under the influence of high temperature and pressure. Each block is pressed in accordance with the ‘Pressing technological sheet’. The sheets were prepared based on long-term experience and research in order to ensure uniform quality of all pressed pads.

Tempering of pads aims at obtaining the optimum mechanical resistance by the thermosetting friction material. The process ensures uniform cross linking of the adhesive so that it was possible to obtain the same material properties within the whole block cross-section.

Mechanical operation involving levelling of the surface of pads friction pad using a modern grinding machine for planes. Fully automated line constantly controls all the process parameters. The objective is to obtain a product of uniform thickness. In the selected pads chamfers are also ground and grooves are cut in accordance with the manufacturer’s specification.

The process involves burning the organic components from the top material layer in order to reduce the time of the brake block adjusting. In order to create high burning temperature, modern infrared illuminators are applied which guarantee the maintenance of stable temperature of operation and supply of heat energy only to the surface of the friction material. The burnt brake block ensures high efficiency of braking directly after its assembly.

Brake pads of TOMEX company are varnished using a modern powder painting method in ‘Tribo’ system. Due to it, our products characterize with one hundred percent paint coverage while assurance of its constant thickness within the range of 40-80 micrometres means that the requirements of both, OE and OES markets are observed; it also influences on the proper block performance in the brake clamp.

Moreover, the applied paint ensures high thermal and chemical resistance of the product what guarantees the efficiency of its performance during the whole operational period (protection from aggressive environment, corrosion). During the process, the thickness of the powder paint is controlled what guarantees its even distribution on the whole surface.

Whenever it is required by the brake system construction, on TOMEX brake pads, noise dampening anti-screech plates (SHIM), these are metal sheets covered bilaterally with special rubber layer are located. The assembly process takes place in hot conditions under pressure and in appropriate time what guarantees maximum adherence of the anti-screech pad during the whole operational period of the pads.

Each production batch is examined and then admitted to sale by the Quality Control Department. Products prepared in such a way are then supplied to the packing hall and warehouse and further on to the distributors all over the world.