SOLID RUBBER TYRE MANUFACTURING
[EIRI/EDPR/4600] J.C. 2817XL
A solid tyre or an airless tyre. It is not filled with air but is manufactured using layers of rubber that are constructed around a metal frame or a wheel structure that can be mounted to a specific vehicle. They can also be made to fit on rims that are manufactured to support pneumatic tires.
Solid tyres are manufactured using a different rubber compound and process. They are rolled in thin layers of rubber onto a metal frame mount and pressed through a hydraulic pressure system. This process hardens the form and makes the rubber hold. The thickness of the rubber layers varies depending on the application of the tire.
Although solid tyres predate pneumatic tyres, they still play an important role in agriculture, industrial and logistic sectors. Solid tyres are extremely stable, economical, puncture-resistant, and maintenance-free and have a high load-bearing capacity in extreme service condition.
They are best suitable for forklift trucks, airport vehicles, heavy-duty transport vehicles, platform trucks, and other industrial vehicles
Solid tyres are often used in industrial applications such as scrap yards and glass works, which have the purpose to collect and convert waste metals into scrap that can be reused. These industrial environments play a vital role in the proper use of natural resources.
Tyres in these situations must be extremely stable, puncture-resistant and maintenance-free, giving them a long service life. Machines in industrial applications operate in environments where there is a high risk of impact and damage.
The reliable solid tyres are suitable for light- and heavy industrial equipment. Solid tyres operate on sites where any kind of liquid tends to spill on the floor. Even exposure to water will subject a tyre to more wear than a dry site. Scrap metal and debris also form a risk. These materials can puncture and tear the tread and sidewalls.
COST ESTIMATION
Plant Capacity 106.6667 Tyres/Day
Land & Building (2 Acres) Rs. 2.24 Cr
Plant & Machinery Rs. 2.89 Cr
Working Capital for 2 Months Rs. 5.32 Cr
Total Capital Investment Rs. 10.99 Cr
Rate of Return 15%
Break Even Point 70%
CONTENTS
INTRODUCTION
SOLID TIRE MARKET
SOLID TYRES
RESILIENT TYRE
PRESS-ON TYRES
CURED-ON TYRES
SOLID TYRES APPLICATIONS
FEATURES
COMPARSION OF SOLID TYRE VS PNEUMATIC TYRE (OR) FOAM FILLING TYRE
SOLID RESILIENT TYRES
INDUSTRIAL SOLID TYRE RIMS
AIRLESS TIRES
CONSTRUCTION
FIG: (A) TWEEL (B) NPT
WORKING
BENEFITS
THE FUTURE OF AIRLESS TIRES
END-USER INDUSTRIES & APPLICATIONS
THE GLOBAL MARKET PLAYERS
BIS SPECIFICATIONS
BIS STANDARD (TYRE)
MARKET POSITION
FINANCIAL PERFORMANCE OF TYRE PLAYERS
INDIAN TYRES MARKET OVERVIEW
AN OVERVIEW
KEY FIGURES:
POLICY ENVIRONMENT:
LOCATION MAP-TYRE PLANTS IN INDIA
PRODUCTION TREND
TOTAL TYRE PRODUCTION IN INDIA
TRUCK & BUS TYRE PRODUCTION
LCV TYRE PRODUCTION
PASSENGER CAR (INCL. JEEP) TYRE PRODUCTION
FARM/TRACTOR (INCL. FRONT, REAR AND TRAILER) TYRE PRODUCTION
OTR TYRE PRODUCTION
OTHER (ADV AND INDUSTRIAL) TYRE PRODUCTION
TOTAL TYRE EXPORT
TRUCK & BUS TYRE EXPORT
FARM/TRACTOR (INCL. FRONT, REAR AND TRAILER) TYRE EXPORT
OTR TYRE EXPORT
TYRE MANUFACTURERS IN INDIA
TYRE COMPONENTS DEFINITION
SOLID TYRES
ADVANTAGES OF RADIAL TYRES:
BETTER VEHICLE HANDLING DUE TO:
SELECTING THE RIGHT TYRE
COMMERCIAL TYRES
TRUCK & BUS BIAS TYRE CROSS SECTION
TRUCK & BUS BIAS TYRE SIDEWALL MARKING
TREAD WEAR INDICATOR (TWI)
TYRES WITH NON SKID DEPTH (N.S.D.)
HOW TO CHECK IF REMAINING TREAD DEPTH IS LOWER THAN THE ABOVE LIMITS:
TYRE ROTATION
TYRE ROTATION:
1. TYRE ROTATION SCHEME FOR CAR TYRES
2. TYRE ROTATION SCHEME FOR COMMERCIAL TYRES
TYRE ROTATION SCHEME FOR DRIVE TYRES: PLAN1
DRIVE TYRES: ROTATE THE DRIVE TYRES IN EVERY 9000KM.
TYRE ROTATION SCHEME FOR DRIVE TYRES: PLAN II
INTRODUCTION
MARKET SIZE
INVESTMENTS
GOVERNMENT INITIATIVES
MANUFACTURING PROCESS FLOW DIAGRAM
BEAD WINDING
CALENDARING
EXTRUSION
INTERNAL MIXER
GREEN TIRE
CURING
QUALITY CONTROL TESTING
LABORATORY TIRE ANALYSIS
RAW MATERIALS
TIRE REINFORCEMENTS
RUBBER COMPONENT FORMULATIONS
TIRE CONSTRUCTION
ADHESIONS
LIST OF COMPLETE PLANT MANUFACTURERS & SUPPLIERS
SUPPLIERS OF PLANT & MACHINERY
RUBBER MIXING MILL
RUBBER COMPRESSION MOULD
RUBBER VULCANIZER
BOILER
RUBBER MACHINES (KNEADERS, EXTRUDERS AND HYDRAULIC PRESS)
CALENDERING MACHINERY
DOUBLE SHAFT PADDLE MIXER
WATER STORAGE TANKS
D.G. SET
SUPPLIERS OF RAW MATERIALS
PRECIPITATED SILICA
NATURAL RUBBER
SYNTHETIC RUBBER
ZINC OXIDE
STEARIC ACID
SYNTHETIC RUBBER MANUFACTURER
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
SUPPLIERS OF HYDRAULIC LIFT
SUPPLIERS OF HEAVY MOBILE CRANES
SUPPLIERS OF EXTRUDER
SUPPLIERS OF TANKS
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
UTILITIES
MACHINERY PHOTOGRTAPH
TYRE BUILDING MACHINES
TWIN SCREW SHEETER
RUBBER MIXING MILLS
HOT FEED EXTRUDER
TECHNICAL INFORMATION OF MACHINE
ABOUT RAW & FINAL PRODUCTS
2020 CONSUMPTION OF NATURAL RUBBER
NATURAL RUBBER AND ITS SUPPLY CHAIN:
FACTS AND SPECIFICITIES
THE PROCESS IS DYNAMIC:
END PRODUCT
ORGANIZATION CHART
PLANT LAYOUT
TYRE INSUSTRY CONSULTANT
TYRE INDUSTRY ASSOCIATION
PLANT LOCATION: ANAND, GUJRAT
ABOUT DISTRICT
LIST OF DOCUMENTS REQUIRED TO GET FOR LICENSES
OTHER LICENSES REQUIRED FOR THE SETUP:
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
IMPLEMENTATION SCHEDULE
THE KEY FACTORS THAT WOULD FACILITATE SUCCESSFUL AND TIMELY PROJECT IMPLEMENTATION ARE:
IMPLEMENTATION STRATEGY
IMPLEMENTATION SCHEDULE
PRE-PROJECT ACTIVITIES INCLUDE:
PROJECT IMPLEMENTATION SCHEDULE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE
16. DEPRECIATION CHART
17. PROFIT ANALYSIS
18. PROJECTED BALANCE SHEET
