WORK FLOW MODEL

DEFINTION OF TYRE:
A Tyre is a most essential component of a vehicle. Depending on
the various factors several definitions may be attributed for the Tyre.
Geometrically --- A Tyre is a Torus.
Mechanically --- A Tyre is a flexible membrane pressure composite.
Structurally ----- A Tyre is a high performance composite.
Chemically------ A Tyre consist of materials composed of long chain
macro molecules.

A TECHNICAL DEFINTION:
A Tyre is a Toroidal- shaped inflatable envelope made of an
elastic material, natural or synthetic rubber or a blend reinforced with
textile cord ply fabric carcass.
Thus Tyre is a strong and elastic shell, which takes over
stresses, ensures adherence to road avoids side slip and protects the
tube.
In other words “It is a thick rubber ring, often filled with air to
carry the load, which is fitted around the edge of the wheel of a
vehicle, allowing the vehicle to stick to the road surface and improving
the smoothness of the journey by acting as a shock absorber”.

BASIC FUNCTIONS OF PNEAUMATIC TYRE:

The Tyre has a major contribution to motor vehicle performance like,
 1. Load carrying capacity.
2. Cushioning and enveloping.
3. Transmit driving and braking torque.
4. Provide lateral stability / dimensional stability.
5. Provide cushioning and flotation.
6. Resist to abrasion.
7. Provide steering force / response.
8. Low rolling resistance.
9. Minimum noise and road vibration.
10.Durable and safe.

So, a Tyre must provide high adherence, proper ride

characteristic, and stiffness, low rolling resistance and noise, high
reliability (fatigue and separation) and wear resistance (including
bruise, cutting cracking and tearing resistance).

CLASSIFICATION OF TYRES:
The Tyres can be classified accordingly to many criteria. But they
are mainly classified base on their construction into three classes as:
1. Standard Diagonal Ply Tyre (Bias Tyre)
2. Belted Bias Tyre
3. Radial Ply Tyre
BIAS TYRES:

A bias Tyre has a carcass which is made of fabric cords

crossed over each other at an angle of 35 to 40 degree to the
center line. The number of such crossed layers is called plies,
which functions as the load carrying member, related inflation
pressure and can range from two plies for scooter Tyre to as
much as 40 plies or more in an earth mover Tyre. The fabric
cords generally use are rayon, nylon and polyester. A bias
construction is continuous in its carcass structure from bead to
bead.

RADIAL TYRES:

A radial Tyre consists of a Radial carcass and a stabilizing Belt

underneath the Tread. Radial carcass consist of reinforcement layers of
steel cords running from one bead to other at 90 degree to the tread
center line and is designed to hold the air pressure. The stabilizing belt
consist of reinforcement cords of high modulus steel cords running
circumferentially around the carcass at an angle of 18- 22 degree to
the tread center line beneath the tread and is driving/ breaking /
cornering torques. It is built such that the major short comings of the
bias construction are eliminated.

ADVANTAGES OF RADIAL TYRES OVER BIAS TYRES:

1. Increase in mileage.
2. Overall fuel efficiency up to 5% to 7% for car Tyres and 10% to
truck Tyres.
3. Excellent Traction and breaking on both dry and wet roads.
4. Safe high speed cornering.
 5. Excellent riding comfort especially at high speed.
6. Improved endurance life and Retread ability.
7. Radial Tyres runs quieter.
8. Excellent impact breaks resistance.

TYPICAL TYRE SECTION:

COMPONENTS OF A TYRE:
DEFINTION AND FUCTIONS OF THE COMPONENTS OF
A TYRE:

1. BEAD: Part of the Tyre which is so shaped, so as to fit the rim

and hold the Tyre on to it. It has core made of several of
inextensible steel wire, with the ends of plies wrapped the core
for anchorage.
2. SIDE WALL: The part of Tyre between bead and tread which
flexes in service.
3. SIDE WALL RUBBER: The rubber layer on the side wall of the
Tyre and over the carcass, which may include protective rims
and fittings lines to assist in centering of Tyre on to rim. This
protects Tyre from scuffing and damages.
4. TREAD: It is the part of Tyre which comes in contact with road
and through which driving, breaking and cornering forces are
transmitted. It is made of special rubber compound to give good
wearing properties and in conjunction with the tread patterns to
transmit these forces.
5. CORD: Textile or Non-textile strands (treads) used in various
components of the Tyre like carcass, plies, belts, breakers etc.
6. PLY: A layer of rubber coated fabric cords.
7. CARCASS: The rubber bonded cord structure of a Tyre integral
with the bead, which provides the requisite strength to carry
load.
8. BREAKER (Diagonal): Immediate rubberized fabric layers /
Plies between the carcass and the tread which help in bonding as
well as protect the casing from road shock.
CLASSIFICATION OF TREAD PATTERNS

TREAD PATTERNS:

Different Tyres have different tread patterns. Tread may define

the field of application of Tyre. A Tyre tread has pattern to take water
from the ground engaging tread surface on a wet road so its tread can
engage the road surface and to provide edges to give grip on road
conditions such as mud, ice and snow. Road surfaces vary greatly and
there are many differing vehicle Tyres and conditions of use different
patterns are used.
The tread pattern generates noise as its edges contact the road.
The tread pattern also affects other properties of Tyres, its reaction to
breaking and cornering forces. As a results there are many different
patterns,

The basic types of highway truck Tyre designs are:

1. RIB TYPE TREADS:

Tyre with Rib Tyre tread are “all position” Tyres.
They can be used on all wheel positions at legal highway
speeds. These Tyres are always recommended for steering
wheel use on long haul, high speeds service. The
circumferential groove design provides maximum steering
capability and good skid resistance.
 2. LUG TYRE TREADS:
Lug type Tyres are designed for drive wheel service.
The provides greater traction in high torque application.

3. SEMI LUG TREADS:

Semi lug tread types are designed for drive wheel
service and are suitable for many “Off The Road”
operations. These tread design provide maximum
resistance to wear and greater traction in high torque
service. These designs are also suitable for steering wheel
applications.

TYRES MANUFACTURED IN VIKRANT TYRE PLANT:

In the Vikrant Tyre Plant, Unit-1, Nylon Tyres are manufactures
for various automobiles such as passenger cars, agricultural
application vehicles, animal driven vehicles, trucks and other Off-The-
Road vehicles.

TYRE MANUFACTURING PROCESS:

Tyre manufacturing is a consolidated process of many steps,
which themselves are on their own, are complex processes. The
different stages of the Tyre manufacturing process are enclosed. The
steps involved are further dealt in brief separately in the following
paragraphs.
 1. Mixing
2. Calendaring
3. Extrusion
4. Bead Preparation
5. Tyre Building Process
6. Curing (Vulcanization)
7. Post Cure Inflation
8. Trimming
9. Final Inspection

Mixing:

Banbury

The description of the features of Banbury is explained below.

 i. Body: Chamber sides are made out of heavy cast iron
fabrication end frames are the main supports that carry the
chamber sides and in which rotors bearings are based. Both the
rotors are drilled at the center for water cooling system and
coated with hard chromium plating to resist the wear.
ii. Doors: The doors comprises of an air cylinder carried on side
rails of the bottom part of the body of the mixer. The doors apex
is mounted on top of the cylinder and slides pneumatically to
open and close the bottom of the chamber.
iii. Dust rings or Dust seals: Helps preventing of materials
leakage from the chamber due to the high internals pressure
exerted while mixing.
iv. Feed hopper: This is the entrance, through which all the
ingredients are fed into the mixer.
v. Ram: Is also called as float. This works pneumatically moves up
and downs through a vertical cylinder above the feed hopper. As
the ram pressure increases the time of the mixing decreases.
vi. Drive system: The internal mixers are powered by a heavy duty
motors and reduction gear units.

COMPOUNDING:
Is a process of mixing all the necessary ingredients with
elastomer, when compounding the ingredients are added step by step.
General compounding consists of following ingredients.
1. Base Polymer: The basic components of all rubber compounds
may be in the form of rubber alone or blends. The elastomer is
selected according to the physical properties. Normally Natural
rubber, Synthetic rubber (SBR, IIR, Reclaim rubber, Neoprene
etc...)
2. Reclaim rubber: For the purpose of cost reduction the reclaim
rubber is also used.
3. Reinforcing agent: Carbon black is the most widely used. It
increases the tensile strength, hardness and modulus of
elasticity. It has resistance to abrasion.
4. Processing oils: They are the dark green colored viscous
liquids, which are used as processing aids; commonly used oils
are pine tar, cast or oil, Napthanic oil, Paraffin oils, Aromatic oils.
5. Activators: ZnO and Stearic Acid are used as activators. They
 mainly help in the curing. ZnO gives high tensile strength and
Stearic acid increases the vulcanizing rate.
6. Anti-degredants: These ingredients oppose the degradation by
ozone and atmospheric oxygen during service condition.
7. Cross-linking Agent: Sulphur is mainly used as the cross
linking agent to carry out the vulcanizing process.
8. Accelerators: Accelerators are used to accelerate the curing
agents, thus increasing the curing rate and decreasing the curing
time,
The compounding process mainly consists of the following three
processes:
1. Mastication: Mastication process is used for the natural rubber
because it has high viscosity. So mastication is done to
decreases the viscosity by using peptizer along with heat and
pressure to breakdown the molecules. The decrease in the
viscosity makes the compounding process easier.
Pentachlorothiophenol is commonly used as peptizer.
2. Master Batch: Master is the processes of mixing elastomers
with specified ingredients expect curing agents and accelerators.
A major element in the master batch is the carbon black and
other ingredients are also added in stage wise oils are added
many times as the processing aids. The following ingredients are
used in the master batch are;

(i).Masticated rubber or synthetic rubber

(ii). Activator,
(iii). Fillers,
(iv). Processing aids,
(v). Antioxidants and antiozonents.
Master batch is prepared in the Ban bury with the temperature of
140 +/- 10 C, about 4 to 6 minutes.
3. Final batch: Is the process where the vulcanizing agents such
as Sulfur are added to the compound and is mixed.

FABRIC DIPPING
Fabric processing takes place in the Zell plant, during which the
processing adhesive is applied on the fabric and the woven fabric is
treated under electrically controlled conditions of time, temperature
and tension. Each fiber and fabric is contracted for different ends uses.
Dip Solution Preparation:
The solution is made in two stages under controlled temperature
conditions,
1. Master Batch: Contains the Resorcinol and Formaldehyde in
water with caustic soda as catalyst for the reaction. The Ph is
maintained by the caustic soda. The reaction is allowed between
3 to 6hr at 20-25C. This reaction is exothermic reaction.
Resorcinol Formaldehyde is the product of this reaction.
2. Final Batch: Contains the master in the rubber latex and water
for better adhesion. Vinyl Pyridine latex gives better adhesion
properties.

The process contains of the fabrics getting dipped in a containing

the dipping solution. After the dipping the excess dipped solution is
removed that uniform coating of the solution is obtained.
Record the observations and identity the fabric after the dipping
process. Adjust the width control devices justifiable. During the
process if any abnormal visual defects like water patches, oil/greases
contamination is observed, then identity neatly on the platform.

FABRIC CALENDERING:
Calendar is a machine, which consists of 3 or more rollers held in
a frame work. We can obtain rubber sheets of required width and
strength. It is used for fractioning and skim coating of the fabrics.
Calendar rolls have extra hardness and are made up of chilled cast
iron.
In a calendaring machine the following things are important:
 Continuous lubrication system to roll bearings.
 Drilled rolls to maintain temperature.
 Precession gears to ensure smoothness of operation.
The parameter's that have to be taken care in the calendaring process
are;
 The roller speed.
 The roller temperature.
 The friction ratio.
 The accuracy in the roller setting.
The following are the processing machinery used in the 4 Roll Calendar
for the coating of textile fabric.

1. Let off roll: The aged fabric rolls from the Zell plant are loaded
to the let off stand.
2. Splicer: Splicer is used to splice the leading end of the first of
the fabric and the second roll of the fabric. Splicer having a hot
plate which is electrically heated and which used to join the 2
ends of the fabric.
3. Tension variable roll I: This rolls pulls the fabric from the let
off rolls in tension.
4. Let off Accumulator: The main purpose of the accumulator is
when the let off and tension roll I stopped or the supply of fabric
stops in the let off unit. The accumulator stores about 80 mts of
fabric. The upper part is fixed and the lower part moves down to
store the fabric in this unit the fabric is supplied from the let off
rolls, thus enabling a continuous supply of fabric for the processing.
5. Tension variable roll II: It pulls the fabric the accumulator, so
that fabric remains under tension and fabric is passed on the
next unit.
6. Hot can: The hot cans are used to remove the moisture content
from the fabric. It consists of 21 rollers arranged in a zigzag
manner of temperature around 110 C.
7. Dancing roll I: It is used to maintain the uniform tension in the
fabric. It consists of 3 rollers, in which 2 are kept below the
fabric and one is above the fabric and driven by the chain gear
system.
8. Photo sensitive centering device I: The centering device
centers the fabric while in operation.
9. 4 Calendar: The Z-configuration 4-roll calender is used for
coating of the textile fabric. The main advantage of the 4-roll
calender is double side coating simultaneously. The upper
surfaces of the rolls are ground and high glass polished. The
temperature is maintained constants by using steam.
10.Cold cans: It has 6 rolls in zigzag manner. Cold water
circulation is provided for the cooling of rollers. The function is to
cool the fabric, and no external force is provided.
11.Tension variable roll III: It pulls the fabric from the cold can
 rolls, so that fabric remains under tension and fabric is passes on
the next unit.
12.Tension variable roll IV: It pulls from the wind up
accumulator, adjusts the tension and passes the fabric to the
center device.
13.Wind up rolls: The set up has two winds up strands where the
coated fabric is winded in a liner to avoid sticking of the fabric to
one other.

EXTRUSION OF TREAD:
Extrusion is carried out through the extruder machine, which
forces the rubber through a nozzle or a die to give a profile strip of the
material. Screw extruder is used in the plant here. In the screw
extruder, a helical screw turning in a cylinder forces the compound
through the die. It is operated by the electric motor through the
reduction gear. The extruder consists of feed hopper through which
the rubber compound is fed into the extruder.

The following are the machineries used in the extruder section are;
Cracker mill, Homogenizing mill, Feeding mill, Single screw
extruder, 3-roll-calender, cooling conveyor and Cutting circular blade.
Steps in the Extrusion process;
(I). Compounding Milling:
• Open water circulation to the mill during the milling operation
and close the water when not in use.
• Take respective compound for milling as per requirement.
• Load the compound required to the cracker mill/ warm up mill
and mix well to get smooth surfaces by giving cut and rolls.
• Pass the compound to the feed mill.
• Set the feed strip dimension according to specifications.
• Pass the compound strips to the extruder hopper or over head
conveyor.

(II). Extrusion:
• Pick up the required die the pre-former from the hot chamber,
which is required for the extrusion as per shift schedule.
 • Change the die and the pre-former. Apply the soap solution.
• Slide the die and the pre-former in the slot and clamp it.
• Start extruder and guide the compound strip to the extruder
hopper.
• Set the RPM and ensure feed of the compound as specified.
• Apply under tread cushion centrally as per specifications.
• Apply under tread polythene to truck and OTR treads.
• Allow tread to continue on inclined and cooling conveyor.
• Set the specified length and weight as per specification.
• Pass the extruded treads from the cooling to booking conveyor
through dancer rollers.
• Put auto switch in auto position and start cutting.
• Ensure the length and weight of treads extruded in each size
randomly while booking.
• Book accepted treads in clean and neat leaf trucks and store the
treads in such a way that polythene/ under tread surface is
facing upward.

BIAS CUTTING:
Bias cutter is a machine, which is used to cut the rubber-coated
fabric at the required width and angle, so as to suit it for the
production of various types of Tyres. Bias angle is the angle of cords in
Tyre w.r.t center line. The width is adjustable from (135-1300mm).
The cutting angle changes from 32-90 degree. The cut fabrics are
spliced in a roll of either 80 or 60 degree cuts. The fabric is shifted on
a driving roll.

As the conveyor pulls the fabric, the coated fabric comes out
from the let off roll. The fabric moves with the help of the photo-cell,
which instructs the motor to run by means of limit switches. The width
is adjusted before putting it into operation. The motor placed on the
carriage drives the cutting disc tools, which cuts the fabric. The cutter
runs on the cutting rail, which is diagonally adjustable to the
longitudinal axis of the conveyor.
BEAD PREPARATION:
One of the major components in the Tyre is the bead. The bead,
which anchor's the Tyre safety to the rim and it, functions as the
supporting components to carry the load. The bead is the combination
of multi treads copper coated high tensile steel wires. They have the
function of providing rigidity to the Tyre and to retain the inflated Tyre
on the rim under all condition of loading.

The bead consists of number of strands of copper coated steel

wires embedded in a semi-hard rubber compound secured in the
turned up loops. All carcass plies are symmetrically wound around the
bead wires. The purpose of using copper coated steel wires is to help
in the better adhesion between steel and compound and also protect
the wire from corrosion during the service of the Tyre. The diameter of
the steel wire is of 0.0905 +/-0.075 the Tyre. The bead wire are made
up of high carbon steel which has in extensibility as on of the main
property.

For the construction of the bead following stages are carried out.
1. Bead building unit.
2. Fillering machine.
3. Flipping machine.
4. Wrapping.

TYRE BUILDING UNIT:

(Eg.) Truck\RT-Building (Pocket Type).

1. Apply drum cement and collapse.
2. Insert the inner bead; center the beads on rings, (With hold too
loose/too tight beads).
3. Insert the pocket and centralize by finger feeling.
4. Expand the drum and confirm centralization.
5. Turn down the ply ends and apply naphtha.
6. Apply both the beads after applying naphtha’s.
 7. Turn up plies without wrinkles and air trap.
8. Stitch the turn up with hand stitcher.
9. Apply naphtha and fix the chafer as specified.
10. Stitch with turn up stitcher by hand.
11. Apply naphtha and fix the tread centrally by hand uniform
pulling. (Without short/long treads).
12. Apply naphtha on tread ends and stitch by hand stitcher.
13. Remove air trap and wrinkles on tread.
14. Stitch by hand stitcher.
15. Apply bottom spinner.
16. Collapse the drum and remove the Tyre.

TYRE CURING:
The Tyre curing is a process of cross-linking of the rubber
compound through the heat and pressure. In the curing process the
Tyre is cross-linked in a series of chemical reaction. The press contains
the mold that determines tread design and final Tyre dimensions.
Before the curing process, some of the preliminary process must be
carried out. They are;
1. Splice Jamming and Painting.
All green Tyres are to be splice jammed. The splice jamming
is done only to the tread joining area. After splice jamming
operation Tyres are taken for the Tyre painting area.

2. Green Tyre Awling.

Awling is done to the green Tyre to reduce the Tyre defects
by providing escape for the air trapped in between bladder and Tyre
while shaping and the air that is trapped stitching operation while
building.
CURING CYCLE:
There are different methods of curing used depends upon the type of
the Tyre. They are;
1. Dome Steam, Bladder Steam: Usually used in production
of small Tyres like passenger car Tyre, bicycle Tyres, and
agricultural Tyres.
2. Dome Steam, Hot Water in Bladder: This is the most
common method in production of big Tyres. Often circulation of
cooling water is used at the end of curing phase to cool the
Tyres before release.
3. Nitrogen Curing: Steam or hot water in the bladder is
replaced by nitrogen. With nitrogen curing, the curing time can
be shortened and problems caused by water or steam can be
eliminated. This method decreases energy consumption in curing
compared to hot water or steam curing,
Green Tyre Curing Process:
A curing cycle starts just after the mold closing and last up to.
Apply naphtha mold opening. In between these there are many steps,
each having their own functions. These steps and its duration change
depending upon the type of Tyre. The major steps involved are the
following;
1. Dome heating: Circulating steam does dome heating. This is to
heat the mold thus helps to flow the compound. For truck Tyres
steam is applied at 146 C.
2. High pressure steam (HPS): High pressure steam as applied
to heat the bladder since the bladder compound (butyl rubber) is
a poor conductor of heat. For truck Tyres HPS has a temperature
of 194 C and 13.4kgsn pressure.
3. Circulating hot water (CHW): Circulating hot water with high
pressure and temperature is applied to enhance the cross linking
process. It has a temperature of 168C and a pressure of 26kgs.
The high pressure (double pressure than HPS) will consolidate
the rubber compound into mold cavity.
4. Circulating cold water (CCW): This is applied to cool the
bladder and Tyre.
 5. Vacuum: Vacuum is applied to release the bladder from Tyre.

Types of Moulds used:

1. Two piece mould:
 Mold has two equal parts, open from middle.
 Mold is heated between heat platens.
 Sidewalls are attached to the actual mold
2. Segment mould:
 In this type of mold the tread pattern is divided into 8 segment
pieces. Sidewall plates are separate from the actual tread part.
Segment pieces are installed into container that is mounted into
press.
 Segment mold is also heated between platens, but in addition to
2-pieces mold also the container part is heated.
Curing Presses:
There are different types of curing, but the most popular is bladder
curing. The presses used are known as Bag-o-Matic press.
There are different types of presses mainly;
1. Hydraulic Curing press.
2. Mechanical Curing press.

Post Cure Inflation (PCI):

The PCI stage involves mounting the green Tyre on the flanges,
inflating it and cooling it according to a predetermined and preselected
procedure. The Nylon Tyres, which has thermal shrinkage property, or
post – inflated under stretched conditions, soon after the Tyres come
out of the mold after curing, by inflating with compressed air to avoid
deformation of Tyres and hence to stabilize their shape. This should be
done within three to five Min's of Tyres ejection from the mold and PCI
should be treated till the Tyre cools to 60 – 70 C.
PCI Process:
1. Refer the specification series displayed in the individual curing
processes.
2. Verify and ensure that the PCI air pressure and time are set as
per specified in the pressure gauze and timer provided.
3. PC Inflate all Nylon cure Tyres using PCI units as per
specifications.
4. Release the Tyre from the PCI unit after specified duration of PCI
treatment.
5. PCI treated Tyres/defective Tyres are to be sent to trimming and
inspection area.
6. For “Off The Road” OTR Tyres, soon after the Tyre is unloaded
from the press, insert no. of wooden peg sets for OTR Tyres at
the bead region at equal distances.

FINAL FINISHING:
The final finishing consists of the following stages;
 trimming: It’s the process of removing the excess material
that includes vents. The cured Tyre is kept on the trimming
machine and rotated by motor, while the trimming device is held
to the Tyre, thus removing the excess material that makes the
Tyre look good.
 Buffing: There are two types of buffing a). Rag Buffing and
b).Emery Buffing
 Inspection: All cured Tyres are inspected for visual defects.
The defective Tyres are held up separately for the modification
work. The production and the technical staff inspect the held up
Tyres and classify the Tyres according to the quality.
TYRES MANUFACTURED IN RADIALTYRE PLANT:
RAW MATERIAL PLANT/COMPOUND PLANT
CALENDAR FRABRIC

WIRE CALENDERING SQUEEGEE CALENDARING PROFILED INNER LINER EXTRUSION

BEAD WINDING

DUP
LEX EXTRUDER

SLITTIN
G

GUM SLITTING BEAD WRAPPING

& DIPPING

BEAKER PLY CUTTING BODY PLY CUTTING

FIRST STAGE TYRE BUILDING

SECOND STAGE TYRE BUILDING

GREEN TYRE PREPARATION

TYRE CURING

TRIMMING
NOT OK

VISUAL INSPECTION BUFF

OK
REPAIR

X-RAY INSPECTION
REINSPECT
 TY
YES
RE CLASSIFICATION
NOT OK

FGS
OK
SCRAP

ADVANTAGES OF RADIAL TYRES OVER BIAS TYRES:

1. Increases in mileage

2. Overall fuel efficiency up to 5% to 7% for car Tyres and 10% to truck Tyres

3. Excellent Traction and breaking on both dry and wet roads

4. Safe high speed cornering

5. Excellent riding comfort especially at high speed

6. Improved endurance life and Retread ability

7. Radial Tyres runs quieter

8. Excellent impact breaks resistance

 RAW MATERIALS

1. NATURAL RUBBER

2. SYNTHETIC RUBBER

3. CARBON BLACK

a. N 339

b. N220

c. N320

d. N326

4. INSOLUBLE SULPHUR

5. PARAFFIN WAX

6. SILICA

7. 6 PPD (Antiozonant)

8. PEPTIZER

9. PROCESSING OIL

10. BEAD WRAP

11. BEAD WIRE

12. STEEL WIRES FOR BODY PLY

MIXING

SPECIALITIES OF TRP MIXER

• The only mixer available in India for silica mixing

• Mixing based on heat history

• Variable roto speed (6-60rpm)

• Hydraulic ram (variable ram pressure during mixing)

• Tip hardened rotors for silica mixing

 • Equipped with fume extraction system to eliminate silica – silane reaction by
product

• High energy input into the compound leading to shorter mixing time

• Fully automated feeding and mixing sequence

• Equipped with twin screw sheeter

SILICA MIXING TECHNOLOGY

Silica is used because

• Low rolling resistance ,better efficiency

• Better wet grip

• Lower heat generation

• Better cut /chip resistance

• Improved dynamic properties

• Higher tear strength

• Improved adhesion to fabric and steel

BANBURY DETAILS

Intensive mixer

Mixer manufacturer: Krupp

Mixer make: GK 270

Mixer volume: 246ltr

Mixer motor type/KN: AC motor (variable)-1500

Ram dia: 22”

Radial Compounds

Compound Name Description

B 99 Body ply coating
B 176 Breaker skim compound
B 333 Nylon chafer compound
B 715 Tread under cushion
R 158 Flange cushion
B 610 Shoulder pad
PS 47 Sidewall compound
PT 208 Tread
T 6629 Tread
T 6730 LCV tread compound
22 G Tubeless inner liner
H 272 Tubeless inner liner compound
A 1032 Soft apex
A 1031 Hard apex
T 4063 Tread base
S 54 Bead wire coating
S 105 LCV Apex
T 542 Tread
JT 434 Sidewall LCV
K1 Inner liner LCV

STEEL WIRE CALENDERING PROCESS

Steel Tyre cord Body ply and Belts required for building All steel Truck
Radial Tyres are calendar at Hot Calender line.

Creel room is maintained as per the specified Humidity and

Temperature.

Steel Tyre cords after conditioning in the creel room are mounted on
the creel stand let off and drawn out.

Four roll Calender has “S” form axis of the rolls Nos. 1 and 4 is placed
45° over the vertical axis. Rolls are made from chilled alloyed cast iron
and are peripherally drilled.

Individual wires are spread in to the Comb roll through the Reed and
fed in to the Calender gap between roll nos. 2 and 3.

By feeding rubber compound from feeding mills through swinging

conveyors in to the gap between Roll No1 and 2 and between roll no 3
and 4 rubber films of the required thickness are drawn on the roll no 2
and 3.

The thickness of the rubber films are controlled through the scanning
heads of the thickness measurement device (Beta gauge control)

Rubberized steel cord is passed through the cooling cans and

accumulator and wound in to the liners at wind up unit.

The Calender roll temperatures are monitored with the help of TCU.

STEEL BELT CUTTING PROCESS

Equipment: Fischer Belt Cutting Machine

Belts/Steel Chipper required for Building All steel Truck Radial Tyres
are cut and prepared at Belt cutter

The Calendared Rolls are mounted on the let off stand of the Belt
cutter and passed on the let off conveyor to the Cutting Blade nip

The letoff is mounted on a carriage, which can be set to the required

angle between 15° to 75°.

The machine settings are done with the help of PLC.The cutting Blades
are operated hydraulically.

The material to be cut is fed to the Blade nip with the help of advancer
consisting of electromagnet battery and cut to the specified width and
angle.

Cut material is transferred to the Splicing head through the conveyor

and the belts are spliced at the splicer head using zipper tool.

Gum Strips are applied at both the edges of cut belt and turned down
using turning down tool.
Belts are rolled in to Liners at Windup station and stored on Belt
storage trolley

BEAD WINDING PROCESS

Hexagonal Beads required for building All steel Truck Radial Tyres are
produced on the Bartell Single wire bead winding machine.

Bead wire spool is mounted on the let of stand of the winding machine
and passed through the wire pre heater to the Extruder.

Wire are rubberized with the specified compound at 21/2” extruder

and passed through the Festooner to the winder.

The wire is wound to the specified construction on the former with the
help of pay on wheel and lying unit.

The machine settings are done using PLC program.

Wound Beads are stored on trolleys with identification.

The extruder temperatures are controlled with the help of TCU

BODY PLY CUTTING PROCESS

Equipment: Body Ply Cutting Machine

Body ply material required for Building All steel Truck Radial Tyres are
cut and prepared at Ply cutter

The Calendar Body Ply Rolls are mounted on the let off stand of the Ply
cutter and passed on the let off conveyor to the Cutting Blade nip

The machine settings are done with the help of PLC.The cutting Blades
are operated hydraulically.
The material to be cut is fed to the Blade nip with the help of advancer
consisting of electromagnet battery and cut to the specified width at
90° angle.

Cut material is transferred to the Splicing table and spliced using

zipper tool.

Gum Strips are applied at both the edges of cut Body ply and turned
down using turning down tool.

Prepared Body ply material is wound in to Liners at Windup station and

stored on A frame storage trolley with identification.

II Stage Green Tyre Preparation:

Tyres are Painted on the Inner Liner with Water Based Inner Lube and
hung on the chuck loaders of the Tyre curing press.

TRUCK RADIAL TYRE CURING PROCESS

Equipment: 1. 63 1/2” SKODA BOM PRESS

2. KRUPP HYDRAULIC PRESS

Moulds: SEGMENTED TYPE (8 Segments assembled in the container)

Advantages:
• Perfectly Centered Moulding of Tyres
• Stress free moulding of Tyres as the Moulds approach the Green
Tyres during Press Closing.
• Better Uniformity of Tyres
• Improved Lateral and Radial Run outs of cured tyres
Curing Process:

Ensure the Moulds are free

from contamination before
loading

Place the Green Tyre centrally

on the Bladders with the help

of chuck loaders

Shape the Green Tyre with the

Shaping Steam as per
specification

Collapse the Chuck loaders

when the Tyre attains
specified Shaping

Segments will Open /Tyres are

Unloaded from the Press

Takeout the Chuck loaders and

Close the Press/Timer Starts

Press Opens after the

completion of the Cure
Cycle
 CHW with Specified Pressure
enters inside the Bladder

Dome Steam Enters at the

Specified Time/
In case of Hydraulic Press
Platens are continuously
heated in place of Dome
Steam

Vacuum starts at the specified

time through Ventury
effect

Drain Cycle starts at the

specified Time

Tyres sent to Trimming

followed by Visual and X
ray inspection

TRUCK RADIAL TYRE INSPECTION PROCESS

Cured Tyres after Trimming are inspected before W/H.Tyre inspection
consists of Visual and x-ray Inspection

1. Visual Inspection:

All the Cured Tyres are checked for any Visual defect as per the
standards and Okayed. Rejected tyres are Repaired/Scrapped
depending upon the severity and merit of the defect.

2.X-Ray Inspection

All the Cured tyres are checked on x-ray to ensure the structural
integrity.

Equipment:

Tyre x-ray inspection System

LumenX Company,USA

The Tyre X-Ray inspection system is completely automated for online

inspection of Tyres for all the construction parameters like Ply cord
spacing, turn ups, Belt step off and splice, and concentricity of Bead
Bundles.

The X-Ray system

The Gemini X-Ray system will provide X-ray energy .X-Rays are
emitted from panoramic tube head in a 270 degree vertical arc. The X-
rays penetrate the Tyre in different amounts depending on the tyre
density and material of construction

The Image System:

The linear diode array (LDA) image scanner head in C – shape will
provide the image on the screen.
Tyre engg:
Components used in Radial tyre building
1. Bead

2. Splice strip

3. Inner liner

4. Nylon chipper (750 -65mm)

5. Steel chipper

6. Body ply

7. Apex

8. Nylon chipper (450-90mm)

9. Flange

10. Sidewall

11. Crayon application

12. Carcass

13. Tread pack