Silverback HD Products uses a high compression positive molding process that relies on dry formulations. Unlike wet formulated flash moulding processes that often have excess resins in them and causes squealing or delamination, this process insures that all of the ingredients, including the resins, are dry and polymerize under high pressure and heat in order to produce a denser more
stable friction that has longer life.
These ingredients are mixed using calibrated mixing machines that measure each ingredient to exacting standards. These standards are not only a matter of precise mix, but also a precision timing of the mixing.
Once the dry formulation has been mixed, it is then delivered to a moulding station where the brake block is molded in a virtual “custom” fashion. One anchor and one cam is made in each press cycle.
Unlike flash moulding, where several hundred sets can be made at once and leave irregular consistency in the block and cause hypobaric delamination, Silverbackʼs positive moulding process allows a consistent pressurization that produces a high density, heat resistant product.
After compression, the brake block is oven cured in digitally calibrated curing ovens, then postcured, and finally removed for finishing.
The finishing process includes drilling, grinding, edge coding, riveting to new shoes, and finally packaging for shipment.

QUALITY CHECKS

Silverbackʼs friction formulators assure that they are meeting exacting standards for our friction ingredients. This includes chemical analysis verification and source verification.
Following the mixing, moulding and curing of the first set of friction on EVERY batch, the following tests are performed:
1. Specific Gravity: This test measures the density of the friction which will vary if the mix is inconsistent.
2. Transverse Rupture Strength (TSR): This will measure the relative brittleness of the friction.
3. Gogan Hardness: This tests the relative hardness of the friction, separate from brittleness.
4. SAE J661 Chase Test: This tests the relative heat resistance of the friction as a matter of Coefficient of Friction (COF).
The triangulation of this testing is consistent with a Six Sigma Design of Experiments (D.O.E.) for continuity of quality in lean manufacturing.
Following the riveting process, each pallet of shoes has a QC manager torque testing the rivets to insure that rivets are within our specifications. This QC check samples one of six shoes on each pallet.

ADDITIONAL QUALITY PROCEDURES:
• Our mixing hopper is calibrated on a weekly basis
• All presses are calibrated daily
• All curing ovens are calibrated daily
• All riveting machines are calibrated daily
• Drilling heads are replaced on regular intervals well below the recommended replacement cycle.