Presentation on Department

training
Technical(SSU-4)

Presented by: Jayanth.k

 Mixing Process Objective
1. Rubber as such is a soft semi-solid material, which does
not have any properties required for a tyre component
such as elasticity, strength, hardness, tear and flex
resistance etc.So to achieving those all properties we need
of compounding to secure certain properties in the tyres to
satisfy the service requirements.

2. To attain processing characteristics necessary for efficient

utilization of available equipment.

3. To achieve desirable properties and processibility at the

lowest possible cost.
 Mixing process flow diagram
RM
Storage
RM Issue

Chemica
Classifica Polymer Carbon Silica Oil
l
tion transfer Loading Loading Loading
Loading

semi
Stacking ,
Tagging auto
Polymer
& chemical
Put up
Sampling Preparat
ion
Not
OK

Polymer Chemical
Mixing
Charging Charging

Cooling
Manual
Chemica
O
K

l
Preparat
Batch off ion
Mill /
Dump
Conveyor
mill

Lab
Testing
Sl. No. Parameters # BB- # BB # BB-3 # BB-& 5
MIXER :
1 Manufacturer
2
3 Chamber total volume
4 Net volume for mixing
5 Rotor Vol.
6 Motor KW + No. + AC/DC
7 Gear box manufacturer
8 Rotor design
a Rotor design 6 wings 4 wings 4 wings 4 wings
b Friction ratio 1:1.10 1:1.10 1:1.10 1:1.10
c Rotor type Tangantial Tangantial Tangantial Tangantial
d Rotor RPM
9 Fill Factor 0.8 0.77
10 Cooling water
a Rotor 400 lit/min 300 lit/min 300 lit/min 300 lit/min
b chamber 500 lit/min 400 lit/min 400 lit/min 400 lit/min
c discharge door 50 lit/min 50 lit/min 50 lit/min 50 lit/min
d Hydraulic unit 150 lit/min 50 lit/min 50 lit/min 50 lit/min
11 TCU temp.
a Body (°C) 35 35 35 35
b Rotor (°C) 35 35 35 35
c discharge door (°C) 30-35 30-35 30-35 30-35
12 MIll
1 Manufacturer

2 size

3 Friction ratio N/A N/A 330 ltr

 MIXING OPERATING VARIABLES

1. Compound formulation
2. Compound batch weight / fill factor
3. Mixing steps and procedures mixing
4. Mixer applied batch pressure
5. Mixer RPM
6. Mixer temperature
7. Environmental effects
 Raw Materials For Mixing

• RSS 4
Natural Rubber • ISNR20
• SMR20

• SBR

Synthetic Rubber • PBR

Process Oil • Aeromatic Oil

• N220

Carbon •
•
N330
N660
• N326

• Stearic Acid , Zinc Oxide

Chemicals •
•
Peptizer, PVI
Anti Oxidants ,Wax
• Accelarator ,Sulphur
 Dipping Process
Raw Fabric Vaccu Dryer Pull Flexure
Rolls m Box Zone Roll 3 Unit

Squeeze Norma
Let Off Pull Wind Up
Roll lizing
Stand Roll 1 Accumulator
Pressure Zone

Let off Heat

Dipping Pull
Accum Set
Solution Roll 2
ulator Zone
• Sewing Machine
• L/Off and W/up Accumulator
• Vaccum Box
Components
• Dryer Zone
• HSZ
Dip Unit
• NZ
• Pull Roll
Solution
• Resourcinoid Formaldehyde latex (RFL) Dipping
• Denier 840/2
• Denier 1680/2
• Denier 1890/2

Fabric
Dipping
 EXTRUSION

•Extrusion is the process of forcing a

material through the opening (die) to
get a definite continuous shaped
material.

•The machine used for extruding the

material is known as extruder
 Cracker
Cap To
Feed Mill Compoun
Mill Tyre
d
Extruder Buildin
g
Base
Warmer Compoun
Feed Mill
Mill d

Stamping
Code Inspec
Identificatio Polythen tion
n e App.

Cushion Polythene
Applicatio and Colour Cooling Sponge
Skiving Weighing
n code Line Unit
application

Dual Extruder
Sohal
Mill
Cushion
Compound Process
 150 MM 200 MM 250 MM
SCREW DIAMETER

L / D RATIO 16 : 01 16 : 01 8 : 01

SCREW SPEED (RPM) 45 RPM 33 RPM 55RPM

DRIVE MOTOR RATING ( KW ) 205 KW 316 KW 252 KW

NUMBER OF PIN ROWS 12 12 00

NUMBER OF PINS / ROW 8 10 00

MAX O/p ( Kg/hr ) 1800 1800 3800

ACTIVE O/P AT 70 % SPEED 1300 1300 3000

 Weighing
TA Conveyor Sidewall Cooling
Extruder (Filler/sidewal
Belt Conveyor
l)

(Tensioner Filler
Unit)

Feed Mill

Filler to
Tyre Building Booking

Cracker
Mill

Sidewall to
Tyre Building

Sidewall or
Filler
Compound
MP Extruder Process
 L/Off
Dipped L/Off Splicing Pre Tension
Accumulato
Fabric Stand Unit Roll
r

Dryer

4-Roll Calendar process Pre

Calendar
Tension
roller

Rubber Cracker Warmer Feed mill Hot Rollers

compound Mill Mill

Post
W/up Pre w/up
Cooling Calendar
W/up stand Accumulato Centre Pricking
Cane Tension
r Guide
Roller
Flow diagram tyre curing
AGING
G.T. FOR
STORAGE JAMMING AWLING PAINTIN PAINTED
G TYRE

NOT OK POST
VISUAL FLASH CURE CURING
INSPECTION TRIMMING INFLATION PROCESS

OK

FINISH
OK GOOD
NOT OK OK
BALANCING 2ND LINE STOREAGE
INSPECTION

NOT OK NOT OK
NOT OK

OK OK

CLASSI- MAJOR MINOR REPAIR

SCRAP SCRAP FICATION
AREA
YARD
CURING PRESS
 TYRE CURING PROCESS
Typical cure cycle steps .

STEPS WHY IT SO GIVEN

1-HPS ON,CLOSE CIR DRAIN Faster pick up temperature & pressure to
start curing

2-OPEN CIR DRAIN Drain steam condensed & maintain

temperature
3-CLOSE CIR DRAIN

4-HPS OFF,CW IN,CIR COLD WATER Cold water to cool cured tyre, Cold water
OFF
CIR off for maintain pressure inside.
5-CW IN,CIR COLD WATER ON Continuous cooling.
6-COLD WATER OFF,OPEN MAIN Drain internal condensate.
DRAIN

7-OPEN ALL DRAIN,APPLY VACUUM vacuum is applied to separate the bladder

from the tyre.
Daily Process Audit.
PROCESS RESPONSIBILITIY

Acting as Trouble shooter for Problem arising in Process during

Shift.
Monitoring Bladder Life.
Interacting with Different Dept & Workman for Quality
Improvement.
Analysis of defect generation in Curing Process & giving
subsequent feedback to respective Dept.
Frequently visiting Quality Dept. to get feedback from Internal
customer.
Follow up of New product developed & providing Feedback.
Attending Bladder & Tyre Classification.
Process Responsibility
•Shift wise "process check" & on time feedback to relevant
sections.
• Disposition execution & follow up .
• Cause analysis for Non conforming batches & feedback
•Shift activities handling and execution.
• Reducing compound scrap & downgrade compound by
process check.
• Ensuring disposed materials as per given disposition.
• New material trials and follow-up as per plan.
 Calendered fabric storage

Calendered fabric let off

FLOW CHART OF BIAS

Dancer unit
CUTTER
Fabric Cutting
Liner Rewinding

Splicing

Rewound Liner Rolls Storage

Winding in Liners

Identificaiton

Cut Ply Storage

Tyre Building ,Slitter, 3 Roll Calender, Breaker Assembly

 BIAS CUTTERS

HIGH TABLE NEW HIGH TABLE NEW LOW TABLE OLD LOW TABLE
BIAS CUTTER BIAS CUTTER BIAS CUTTER BIAS CUTTER

BREAKER, OUTER PLY INNER PLY

FLIPPER, CHAFER 5800/SHIFT 7200/SHIFT
2300/SHIFT
 FILLERING
• FILLER IS APPLIED OVER THE BEAD TOP TO FILL THE VOIDS (GAPS) CREATED DURING THE
PLIES TURN-UPS. IT ALSO PROVIDE GRADUAL REDUCTION IN STIFFNESS FROM BEAD TO
PLIES.
• IT IS ALSO USED TO STIFFEN THE LOWER SIDEWALL OF THE TYRE.
• IT IS IN FORM OF RIGHT ANGLED TRIANGLE AND DIMENSIONS VARY ACC. TO TYRE SIZE AND
TYPE.
• THE COMPOUND SHOULD HAVE HIGH STIFFNESS.

FLIPPING
• CORD WHICH WRAPS THE BEAD WIRE AND BEAD FILLER.
• IT IS USED TO ANCHOR THE BEAD INTO THE TYRE AND TO STIFFEN THE LOWER SIDE WALL.
• FILLER IS A CALANDERED FABRIC.
• THE FLIPPER COMPOUND IS PLACED ON THE FLIPPING M/C AND THE FILLED BEAD IS PLACED
OVER FLIPPER.
 TYRE BUILDING MACHINES

PLANT 1 PLANT 3

TRUCK[21] PASSENGER[6] TRACTOR[2] PASSENGER TRUCK

TBM-30[8] 146 ASM[2]

265 ASM[2] RB-3[10] RB-5[9]

RB-5[3] RB-3[4]

59J-[11]

1 FOR 16.9-28 SONA 1 FOR 12.4-28

TYRE (W) SONA TYRE(R)
 TREAD/ Flipped / Assembled
NAPTHA INNER PLIES / Band From 3
SW from Insulated BEADCut CHAFER breaker from PLIES / Band From
from LINER FromRoll Calender / Band Breaker 3 Roll Calender / BREAKER From
Extruder from Bead Roll from
Cement 3 Roll building m/c Band building m/c Bias Cutter
Section Slitter Doubbling
House Calender

Tread
TB 1 Preparation

ISURE CORRECT For

INDENTIFICATION & TB 2 TB 2 TB 2 TB 2 TB 2 TB 2 TB2 RB3
SUPPLY

TB 3 First Tyre Cord

GREEN TYRE BUILDING

TB 4

NOT OK

TYRE
Inspection TB 5 HOLD

OK Repair
BUILDING NOT OK
Disposition Reject

FLOWCHART
OK
OK

TB 6 Identify GT with Date, Shift

TYRE CURING
 SPECIFICATION OF BEAD
WINDING MACHINE
• LENGTH OF MACHINE---- 55.75 INCH.
• HEIGHT OF MACHINE----- 56.75 INCH.
• PRODUCTION TARGET-----2 X 3250 BEADS PER SHIFT.
• MACHINE PRODUCES 13 BEADS PER MIN.
• KNIFE WHICH CUTS THE BEADS AT END IN MADE UP OF TOOL TACTIC 6 HSS.
• IT HAS A BAWL TO GRIP BEAD WIRE.
• IT HAS A FESTOONER MOTOR TO PULL WIRES FROM WIRE SPOOL.
• AGEING TIME FOR BEAD INSULATION COMPOUND IS MIN 8Hrs AND MAX. 15 DAYS.
• AGEING TIME FOR COVERED BEAD IS 2 HRS min. AND 7 DAYS max.
• AGEING TIME FOR UNCOVERED BEAD 2 HRS min. AND 4 DAYS max.
 BEAD WINDING
BEAD-
• IT IS A BAND OF HIGH TENSILE STRENGTH STEEL WIRE AND CASED IN A
RUBBER COMPOUND. BEAD WIRE IS SPECIALLY COATED WITH SPECIAL
ALLOYS OF BRONZE OR BRASS.
• BEAD IS USED TO PROVIDE CLAMPING STRENGTH AT THE RIM FLANGE.
• IT IS THE AREA OF THE MOUNTED TYRE WHICH SEATS AGAINST THE WHEEL.
• THIS IS DONE TO GIVE HIGH MECHNICAL STRENGTH AND TO PROVIDE
ADHESIVE PROPERTIES TO RUBBER.
• BEAD WINDING USES A MACHINE HAVING A NO. OF CREELS OF COPPER
COATED STEEL WIRES AND PASSING THROUGH A CROSS HEAD EXTRUDER.
• THEN A COATING OF RUBBER IS DONE ON EACH GROUP OF STEEL WIRE
STRANDS AND THEN DURING WINDING A NO. OF TURNS ARE MADE.
 BREAKER ASSEMBLY
Receipt of cut breaker rolls from slitter

Breaker rolls let off

Pass through centering guides

Liner rewinding
Top and bottom
breaker assembly

Cut to length Storage

Winding in liner

Identification and storage

 General Description
A calender consists of two or more oppositely moving rolls or bowls
generally carried horizontally one above other fitted in a pair of vertical
frames standing on a base plate and connected by a bridge piece above
the top roll. The housing and associated structure is made as rigid as
possible.

Function of a Calender
The main function of a calender is to prepare compounded rubbers a
uniform smooth sheet of definite thickness and width. The two allied
functions of the calender where fabric or cloth is involved are
frictioning, skim coating and topping. In frictioning a thin sheet of
rubber is forced into the intertices of the fabric by means of frictioning
thus leading to the term frictioning. The objective of skim coating is to
apply a thin coating of rubber on the fabric.
 TYRE BUILDING MACHINES

PLANT 1 PLANT 3

TRUCK[21] PASSENGER[6] TRACTOR[2] PASSENGER TRUCK

TBM-30[8] 146 ASM[2]

265 ASM[2] RB-3[10] RB-5[9]

RB-5[3] RB-3[4]

59J-[11]

1 FOR 16.9-28 SONA 1 FOR 12.4-28

TYRE (W) SONA TYRE(R)