Production
Tyre Manufacturing & Process
A tyre is an assembly of numerous components that are
built up on a drum and then cured in a press under heat
and pressure. Heat facilitates a polymerization reaction
that cross-links rubber monomers to create long elastic
molecules. These polymers create the elastic quality
that permits the tyre to be compressed in the area where
the tyre contacts the road surface and spring back to
its original shape under high frequency cycles.
Our manufacturing facility is divided into five main
departments that perform the following respective
functions -
- Compounding & Mixing
- Component preparation
- Tyre building
- Curing
- Final finish
State-of-the-art Manufacturing Machinery
Mixing Mill (Used in Process of Compounding
& Mixing)
Our modern mixing mill consists of twin counter-rotating
rolls, one serrated, that provide additional mechanical
working to the rubber, and produce a thick rubber sheet.
This mill is used to mix a batch of rubber compound in
the manufacturing process of 'Compounding & Mixing'
after all the required ingredients are brought together
through the operation of compounding.
Extruder Machine (Used in Process of
Component Preparation)
The extruder machine consists of a screw and barrel,
screw drive, heaters and a die. The extruder applies two
conditions to the compound - heat and pressure.
Extrusion is also used for sidewall profiles and inner
liners.
Calendar (Used in Process of Component
Preparation)
The calender is a set of multiple large-diameter rolls
that squeeze rubber compound into a thin sheet.
Calenders are used to produce body plies and belts.
Tyre Building Machine (Used in Process of
Tyre Building)
Typical TBM operations include the first stage
operation, where inner liner, body plies, and sidewalls
are wrapped around the drum, the beads are placed, and
the assembly turned-up over the bead. In the second
stage operation the belt package and tread are applied
and the green tyre is inflated and shaped. The final
product of the TBM process is called a green tyre.
Manual & Hydraulic Press (Used in
Process of Curing)
Mechanical presses hold the mold closed via toggle
linkages, while hydraulic presses use hydraulic oil as
the prime mover for machine motion, and locks the mold
with a breech-lock mechanism. Hydraulic presses have
emerged as more cost effective.
During and post manufacturing, there are several
sophisticated tests conducted by our Quality Assurance
& Quality Control departments such as tyre balance
& uniformity measurements as well as endurance,
plunger and X-ray tests, to ensure high quality tyres to
our esteemed customers.
|
