Manufacturing process of Rubber products

1.16 Tyre Manufacturing Process

Figure 26: Basic Tyre manufacturing process

Compounding Material Preparation Building Curing Testing and

Dispatch

Calendering

Raw Material Final batch

Incoming and compound Ply making Ply cutting
weighing warming

Extrusion for
Tread
Final batch
Master batch compound Extrusion Testing Tyre Building Curing Finishing
preparation warming

Beading
Inspection
Final batch and QA
Final batch Bead Bead Bead Testing
compound
preparation
Winding fillering flipping
preparation

Dispatch

I. Material Preparation:
1. Compounding Mixing:

Figure 27: Compound mixing Process flow chart

Quality tested Quality tested Quality tested
chemicals rubbers Carbon Black

Chemical Weighing machine Carbon weighing

Inside Tyre lube
weighing at mixer and feeding system
application

Quality certified
MIXER process oils & liquid
ingredients
Mixer output
- compound

Master batch Dump mill

Sheet mill

Stacking station Cool rack

Final batches to
processing stations

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Manufacturing process of Rubber products

Step 1: Rubber Material Incoming and Weighing

Input Raw Materials for compounding includes natural rubber, synthetic rubber, carbon
black, antioxidants, antiozonants, retarders, pigments, plasticizers, reinforcing agents,
etc.

Process  The raw material are stored in a desired place for each chemicals
description  The quality of raw material is ensured by internal testing procedures. Various
testing is done for different raw material. Visual test is done for natural rubber to
spot impurities. Ash and moisture test are conducted for carbon black.
 Quality of supplies is also ensured by the testing certificate offered by the supplier.
The tyre manufacturers usually procure from authorized suppliers who supplies
only quality product
 Various ingredients are then weighed according to formulation and are placed as a
batch for mixing

Output Ingredients in desired proportion as per formulation

Job role Compounding Expert, Chemists, Mixing Mill Supervisor, Mixing Mill Operator, Helpers
involved

Step 2: Master batch preparation

Input Ingredients for compounding in desired proportion as per Equipments used

formulation

Process  The mixing is done usually in a Banbury mixer ®(mixing Banbury Mixer
description machine) where the raw material feeding can be done in two
layers and the output is collected at the bottom
 Carbon black is loaded in the top storey (separate floor) to avoid
the dust generated from carbon black in mixing with other
chemicals
 In the middle layer, other materials such as rubber and other
chemicals are loaded and passed into the mixer through a
conveyor system
 Process parameters like temperature, pressure and time are set
by the operator based on pre determined specifications
 The mixing process combines rubber stock, carbon black and the
weighed chemicals to produce the master batch of rubber
compound
 The master batch is checked for quality through specific gravity
and viscosity test

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Manufacturing process of Rubber products

Output Rubber compound (Master batch)

Job role Compounding Expert, Supervisor, Mixing Operator (Compounder),

involved Helpers

Step 3: Final batch Preparation

Input Rubber compound (Master batch) Equipments used

Milling machine
Process  After the completion of the mixing cycle, the rubber compound
description is dropped onto a drop mill
 From the mill, the compound is sheeted out in the form of a
continuous strip of rubber compound
 It is then cooled immediately by passing through a slurry and
Banbury mixer
hanged in a place of a series of fans (for drying of slurry)
 These sheets are again sent to the second storey (Banbury
machine ®) for final batch preparation
 Sheets of various batches are mixed to have a good blending
and also to reduce the variations
 During final batch, vulcanising agents such as sulphur is added
and the temperature is less than that of master batch to ensure
that the compound does not gets cured in the process
 The final batch compound is also collected in a milling machine
where compounding sheets are formed
 The master batch is checked for quality through specific gravity
and rheology test

Output Sheets of rubber compound

Job role Mixing Operators (Compounders) and Helpers

involved
Note: The same process is followed to prepare rubber compound which goes as material for different
process such extrusion, calendaring and bead coating. The formulation of the compound differs for
each process.

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Manufacturing process of Rubber products

2. Calendering

Figure 28: Calendering Process flow chart

Compound
from mixing Dipped fabric Poly propylene
room interlayer fabric

Compound Calendered
Cooling zone Wind up
warm up Feed mill Calendering Storage
(Drums) station
(Cracker mill) fabric

Step 1: Raw Material incoming and Calendering

Input  Rubber compound formed in the mixing process Equipment used

 Latex coated fabric (procured from outside)
Calendaring machine
Process  Rubber compound is warmed up using a series of mills before
description taking into calendering section
-  The calendaring machine generally consists of four rollers and
calendaring three passages between them
 On the top and bottom nips, rubber compound is fed and in the
middle passage, fabric is admitted thus forming a sandwich of
fabric in between layers of rubber compound in a single pass
 The calendared rubber sheets are wound on drums with a fabric
to prevent the sticking of the calendared sheets
 Quality of the calendered fabric is checked through tests such as
adhesion test, moisture test, Part Load Elongation test, etc.

Output Calendered fabric

Job role  Calendaring Supervisors, Operators and Helpers

involved

Step 2: Ply cutting

Input  Rubberised fabric (or calendered fabric)

Process  After the calendaring process, the rubberised fabric sheet is then cut
description  The cutting is called a bias cutting which is a angled cut done by a machine fixed
at an angle as required
 The cut fabric is called a ply. The angled cut is a key characteristic and place a
critical role in building process
 The sheet is taken by the operator manually and is spliced correctly over the

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Manufacturing process of Rubber products

edges (width to length transformation)

 The spliced cut plies are rolled with a poly propylene inter layer fabric to prevent
sticking

Output Output of this process will be the cut ply rolls used in tyre building process

Job role  Calendaring Supervisors, Operators (Bias cutting operators, Splicer) and Helpers
involved
Note: The plies made from this process are used in tyre building and in beading (flipping) process.

3. Extrusion (for tread rubber)

Figure 29: Extrusion Process flow chart

Compound
from mixing Compound warm up Cushion
Feed mill
room (Cushion compound) Calender

Cushion Gum

Compound Extruded
from mixing Compound warm Cooling Length
Feed mill Extrusion
room up (Cracker mill) conveyor Skiving
Tread

Extruded
Side wall
Yes Not ‘OK’ Weighing
Slitting Suitable for rework station
Treads / sidewalls
Ok
No
Treads

Scrapped Booking
station

Step 1: Raw Material incoming and Extrusion

Input  Rubber compound formed in the mixing process Equipment used

Process  Rubber compound from the mixing is taken to the extrusion Extruder
description section
 The die is fixed appropriately in the extruder as per the size of the
tread required
 Rubber compound is fed into the extrusion machine
 Temperature in the extrusion machine needs to be set as per the
specification and needs to be monitored
 Tread rubber comes out of the extruder as per the shape of the

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Manufacturing process of Rubber products

die and colour lines are marked in the tread for identification
purpose
 Tread rubber passes through water for cooling

Output Extruded treads

Job role  Extrusion Operators and Helpers

involved

Step 2: Testing

Input  Extruded treads

Process  The tread rubber is cut as per the size of the tyre
description  Then the tread is checked automatically in the conveyor for
weight and length
 If there is a variation in length / weight / width, the tread is
rejected
 QC passed tread is taken for the next process

Output Treads meeting requirements of dimension and weight

Job role  Extrusion Supervisors, Extruding Operators and Helpers

involved
Note: Side wall, rubber compound (breakers) and bead fillering compound making is also made
similarly (through extrusion process).

4. Beading

Figure 30: Bead room Process flow chart

Compound
from mixing Compound warm up Mechanical Slitted
room (Cracker mill) knife slitter compound

Copper / Flipped bead

Bronze Bead winding Bead fillering Bead flipping for tyre
coated wire machine machine machine building
process
Flipper fabric
from ply cutting

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Manufacturing process of Rubber products

Step 1: Bead Winding

Input  Tempered steel wires with bronze / copper coating Equipment used
 Rubber compound formed in the mixing process in the extrusion
 Solution of rubber compound in a hydrocarbon solvent Bead winding
machine
Process  Rolls of tempered steel wire with copper coating are fixed in the
description winding machine. Bronze / Copper coating ensures the bonding
of the metal with rubber
 Bead winding is done and the beads are formed in a shape of
tape
 Coating is done using a cross head extruder where a bunch of
bead wire is coated with the rubber compound to form a bead
tape
 Then this rubberised beads pass through rubber compound
solution
 Enough length of the tape is concentrically wound (layer over
layer) on a circular former of desired diameter to form the wound
bead bundle

Output Wound beads

Job role  Bead winder operators and Helpers

involved

Step 2: Bead Fillering

Input  Wound beads

 Rubber compound strips

Process  A triangular extruded rubber compound is prepared in the extruder

description  This compound is placed on the bead bundle’s full periphery as an exterior strip

Output Fillered bead

Job role  Beading(fillering) operators and Helpers

involved

Step 3: Bead Flipping

Input  Fillered bead

 Rubberised fabric

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Manufacturing process of Rubber products

Process  The rubberised fabric is bought from the bias cutting process as rolls of fabric cut
description to the desired widths
 The flippering machine makes the flipper fabric to cover the full circumference of
the fillered bead
 The flipper fabric is cut to length when the full bead is covered and spliced
 The flipping machine consolidates the flipper with the fillered bead in the cover
process
 This process is done to provide additional strength to the tyre as the bead comes
to contact with the rim of the wheel

Output Output of this process will be the bead used in the tyre building process

Job role  Beading operators and Helpers

involved

II. Building

Figure 31: Building Process flow chart

Extruded treads Cut plies and Bead (fillered &
and Sidewalls chafer flipped)

TYRE
BUILDING

Green tyre
Green Tyre
repair

Scrap green Inspection

tyres station Not ‘OK’ green tyre
For rework

OK Green tyres for

preparation &
Curing

Input Ply, breaker, Side wall, flipped bead and Tread

Process  Tyre building can be a highly automated process or a series of manual processes
description  In case of the automated tyre assembly, the first stage is to begin with an
unsupported rubber sheet called inner liner, the beads, body plies, treads and
sidewalls being placed on the building drum. The correctly-positioned beads rings are
then attached, which results in the automatic wrapping of the ply edges around the

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Manufacturing process of Rubber products

bead core, and the simultaneously movement of the sidewalls into position
 After this, the tyre is shaped by inflating the rubber and applying side tread rubber,
and plies
 In the case of manual building, the building operator manually, sequentially builds
the tyre with ply, breakers, beads and then the tread
 During manual building, the building operator needs to ensure the alignment of the
tyre (centering)
 Tyre building is the most critical process and it needs to be built as per specification
without any wrinkles and air pockets
 The number of plies and breaker (and side walls) varies according to the tyre category
and it needs to be built accordingly
 All the materials need to be intact and after building it is called a green tyre

Output Green tyre

Job role Building Operator and Helper

involved

Figure 32: Curing and Finishing Process flow chart

Quality tested Quality tested
inner tube outer tube

OK Green Cured tyre

Tyres from Inside Tyre lube Outside Tyre Tyre Curing
Tyre Finishing
Tyre Building application lube application Press

Finished tyre

Scrapped Not OK Repaired Tyre

Rework Area Tyre Inspection
tyre Inspection
OK tyre

OK tyre
Warehouse

III. Curing

Input Green tyre Equipment used

Process  The tyre is applied with a lubricant inside the tyre to facilitate
Curing Machine
description easy laying and removal of bladder inside the tyre during curing
process
 Then the green tyre is taken to the curing press and is placed

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Manufacturing process of Rubber products

inside the curing machine

 Temperature, pressure and time parameters are set in the
machine by the operator and the tyre is cured based on
predetermined specifications
 After the curing time period, the tyre is removed from the
machine
 It is then placed in a machine called post cure inflation machine
depending on the tyre design and construction
 The tyre gets the physical properties and shape as required

Output Cured tyre

Job role Curing Operator and Helper

involved

IV. Testing and Dispatch

Step 1: Finishing

Input Vulcanized tyre

Process  Post Curing Inflation process is done to retain the shape of the tyre and to add
description strength of the tyre. This is an optional process
 Excess rubber remains on the tyre from vents in the curing mould. The finishing
operation trims flash or excess rubber from the tyre
 Additionally, excess layers of rubber may need to be ground from the side walls or
raised lettering on the tyre (only for radial tyres having balancing specifications)

Output De-flashed tyre

Job role Finishing Operator and Helper

involved

Step 2: QC and inspection

Type of testing Testing parameters

(Except a few, tyre test are destructive in nature. Destructive testes are carried out
on sampling basis)

Tensile test A specimen cut from the tyre is clamped in a tensile testing apparatus under a
defined pre-tension and subjected to constant rate of extensions until rupture. It is a
test of the mechanical properties of the rubber compound.

Abrasion test This is for determination of the resistance of tyre for wear and tear. The finished
product is rubbed, ground and scraped against material to test the point of it

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Manufacturing process of Rubber products

rupturing (destructive test)

Elongation test The extent to which the tyre compound elongates when it ruptures is tested

Breaking load The tyre is loaded gradually with the weights to find a point (load / weight) at which
test the tread breaks

Rheological test The rheological test determines the characteristics of the compound. Analysis of the
characteristics will help QA and compounding experts take action on the
compounded rubber

Viscometer test The viscometer test will map the change in rubber properties from the initial state to
the cured state, thereby offering the QA and compounding experts analysis of the
properties change

Dispersion test This test evaluates the extent to which the carbon black is dispersed. The dispersion
pattern is studied to glean the impact on the properties

Job role involved Quality Check Supervisor, Quality Inspector

Step 3: Dispatch

Input Inspected tyre

Process  If there is a problem in the tyre and if it can be fixed, it is sent to the repair section,
description else they are rejected
 The inspected and QC passed tyres are moved to godown for storage
 Tyres are dispatched as per order

Output Tyres ready for dispatch

Job role Helper

involved

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