MOTORCYCLE TYRE MANUFACTURING [3616]
Motorcycle tyres are the only contact between the motorcycle vehicle and the ground. The contact surface of a motorcycle tyre is generally very small compared to a tyre used for larger vehicles such as cars, lorries and trucks. Hence, it is particularly vital for the motorcycle tyre to have good traction performance, good rolling and abrasion resistance and high wear resistance. It is impossible to have all the preceding ideal physical properties in a rubber compound. However, with the right combination of rubber components and suitable amounts of additives, a good compromise between each of the desired physical properties can be achieved. Conventional motorcycle tyres are generally manufactured from synthetic rubber such as styrene-butadiene rubber (SBR) and polybutadiene rubber (PBR), which are derived from fossil fuels such as crude oil. The rubber compound is usually reinforced with carbon black and further comprises fatty acid additives (cure aid) and vulcanization aids. Synthetic rubber produced in this manner exhibits high abrasion resistance, good wet grip and low rolling resistance. Motorcycle tires are critical to rider safety and bike performance. The casual rider probably cares little and thinks even less about how tire companies turn raw materials into high-performance tires. During a recent press introduction at Bridgestone’s Japanese home base, Motorcycle-USA got an eyewitness account of the tire-making process during a tour of the company’s Nasu Plant. The real beginning of the tire-making process is in the company’s engineering labs where designers use the latest technology to develop new compounds and tread patterns. After rigorous testing at the company’s nearby Bridgestone Proving Grounds, prototypes go into production at the Nasu facility. The 49-year-old plant, located in the Tochigi prefecture, is the sole motorcycle tire production plant for Bridgestone (with the company retaining 190 plants worldwide, 49 of them producing tires). Nasu gets raw materials in the front door and delivers finished tires out the back, with Bridgestone tire reps claiming 6300 motorcycle tires produced daily. Bridgestone keeps a tight rein on its process. Today, one cannot imagine a world without automobiles even though India has a large network of railway lines, considering the vastnes of the country and the thrust given for balanced development, road transport would have decisine role to play in the coming years. Vehicle would become more and more part of not only the commercial like but even the personal like. The Indian tyre and tube industry has been continuously in the process of up gradation of product quality to satisfy the requirements of Indian automotive manufactures, users of automobiles and the road conditions prevailing in the country. Various developments have taken place in design of tyres especially for passenger cars, light trucks, trucks and buses involving tyre construction, strength, sizes, tread design, rubber compounding etc. The pace of development of tyres in the country has also been hastened by the requirements of new passenger car and light truck manufactures and for export, which require higher accuracies, better uniformity longer life etc.
COST ESTIMATION
Plant Capacity 3334 Tyre/Day
Land & Building (3.5 Acre) Rs. 8.55 Cr
Plant & Machinery Rs. 110 Cr
Working Capital for 3 Months Rs. 28.61 Cr
Total Capital Investment Rs. 148.76 Cr
Rate of Return 19%
Break Even Point 70%
INTRODUCTION
TERM, DEFINITIONS
AND NOMENCLATURE IN PNEUMATIC TYRES
BUREAU OF INDIAN STANDARDS
LABORATORY TESTING OF TIRE COMPOUND
COMPONENTS OF TYRES
INNER LINER
BODY PLY
SIDEWALLS
BEADS
APEX
BELT PACKAGE
TREAD
CUSHION GUM
RAW MATERIALS
NATURAL RUBBER
SYNTHETIC RUBBER
CARBON BLACK
FUMED SILICA
VULCANIZATION
ANTIOXIDANT
ANTIOZONANT
DETAILS OF COMPONENTS IN TYRE BUILDING
INNER LINER
BODY PLY
SIDEWALL
BEADS
APEX
BELT PACKAGE
TREAD
CUSHION GUM
OTHER COMPONENTS
MATERIALS
MARKET SURVEY
MARKET DYNAMICS:
RAW MATERIAL:
EXPORTS:
CHALLENGES:
COMPANY FINANCIALS:
OUTLOOK:
TWO WHEELERS: GROWTH LIKELY TO IMPROVE
REPLACEMENT DEMAND OUTLOOK
OBSERVATIONS AFTER ANALYZING THE SALES DATA ARE AS BELOW:
DOMESTIC SCOOTER MARKET
DOMESTIC MOTORCYCLE MARKET
DOMESTIC MOTORCYCLE, SCOOTER AND MOPED TREND
INSIGHTS FROM THE ABOVE DATA
OPERATING AND NET PROFIT TREND
CASH CONVERSION CYCLE (CCC)
PORTER’S FIVE FORCES
FUTURE DRIVERS FOR THE 2W INDUSTRY
TOP 10 GLOBAL TYRE COMPANIES
SWOT ANALYSIS OF MOTOR CYCLE TYRE
WEAKNESS
OPPORTUNITIES
THREAT
PRESENT MANUFACTURERS OF MOTORCYCLE TYRES
TECHNICAL KNOW - HOW
FOREIGN COLLABORATIONS
RESEARCH & TECHNOLOGY:-
SEQUENCES IN MOTORCYCLE TYRE MANUFACTURE
MANUFACTURING PROCESS OF MOTORCYCLE TYRE
FORMULATION OF MOTOR CYCLE TYRE
PROCESS FLOW DIAGRAM FOR MOTORCYCLE TYRE
PROCESS IN DETAILS
RAW MATERIALS
EXTRUSION
ASSEMBLY
CURING
INSPECTION
RUBBER COMPOUND FORMULATION
RUBBER COMPOUND MIXING
FABRIC/STEEL CORD PREPARATION
FABRIC CORD
STEEL CORD
BELT AND PLY CALENDERING
INNERLINER CALENDERING
BEAD COMPONENT PREPARATION
TIRE TREAD AND SIDEWALL EXTRUSION OPERATIONS
TIRE TREAD EXTRUSION
TIRE SIDEWALL EXTRUSION
TIRE BUILDING
TIRE CURING
MOTORCYCLE TYRES PRODUCTION PROCESS
& MIRS TECHNOLOGY
MAIN SECTION
TYRE SIZE DESIGNATION AND DIMENSION OF MOTOR CYCLE TYRE
TABLE MOPED TYRES NORMAL PROFILE
(WITH RIM DIAMETER CODE MORE THAN 12)
TABLE MOTORCYCLE TYRES NORMAL PROFILE
(WITH RIM DIAMETER CODE > 12)
TABLE – MOTOR CYCLE TYRES- ISO DESIGNATED TYRES
(WITH RIM DIAMETER CODE >-12)
TABLE: MOTOR CYCLE TYRES- ISO DESIGNATED TYRES
(WITH RIM DIAMETER CODE > 12)
SEQUENCES IN MOTOR CYCLE TYRE MANUFACTURE
METHOD OF PRODUCING MOTORCYCLE TYRE TREAD
TABLE: FORMULATIONS OF NATURAL RUBBER DERIVED POLYMERS
TEST REQUIREMENTS FOR PNEUMATIC TYRES
TYRE DIMENSIONS
SECTION WIDTH OF TYRE
DYNAMIC GROWTH OF TYRES
ENDURANCE TEST
TREAD WEAR INDICATORS
METHOD OF MEASURING TYRE DIMENSION
PRESSURE SHALL BE RESET AT THE VALUE .
TABLE : RECOMMENDED INFLATION PRESSURE FOR MEASURING
TYRE DIMENSIONS
TESTING METHOD FOR MOTOR CYCLE TYRES
PREPARATION OF TYRE FOR THE TEST
METHOD FOR DETERMINING THE DYNAMIC GROWTH OF TYRES
DESCRIPTION OF TEST PROCEDURE
EXECUTION OF TEST
TABLE INFLATION PRESSURE FOR DIAGONAL OR BIAS PLY
AND BELTED-BIAS TYRES)
ASSESSMENT OF RESULTS
FIG: ENVELOPING CURVE FOR DYNAMIC GROWTH TEST
TYRE STRENGTH TEST (PLUNGER TEST)
APPARATUS
TEST PROCEDURE
CALCULATION
REQUIREMENTS
TABLE : REQUIREMENTS FOR PLUNGER TEST FOR DIAGONAL PLY TYRES
TABLE: REQUIREMENTS FOR PLUNGER TEST FOR RADIAL PLY MILLIMETRIC
TABLE: REQUIREMENTS FOR PLUNGER TEST FOR RADIAL AND
DIAGONAL PLY FOR MILLIMETRIC (ISO DESIGNATED) TYRES
PROCEDURE FOR EN-DURANCE TEST
TEST APPARATUS
PREPARATION OF TYRE FOR THE TEST
TEST PROCEDURE
EXAMINATION OF TYRE AFTER TEST
TABLE: ENDURANCE TEST SCHEDULE
TABLE: EXAMPLES OF TYRE DESIGNATION FOR CODE DESIGNATED TYRES
TABLE: EXAMPLES OF TYRE DESIGNATION FOR ISO DESIGNATED TYRES
RECIEPES FOR AUTOMOBILE BEAD WIRE
DETAILS OF PLANT & MACHINERIES FOR MOTORCYCLE TYRE
MOTORIZATION DUAL WHEELS VEHICLE
TIRE BUILDING MACHINE
MOTORCYCLE TIRE BUILDING MACHINE MECHANICAL DESCRIPTION
MOTORCYCLE TIRE MAKING PROCESS EQUIPMENT
MOTORCYCLE TIRE BUILDING MACHINE RANGE
BICYCLE TIRE BUILDING MACHINE ( CENTER OVERLAP TYPE )
MOTORCYCLE TIRE BUILDING MACHINE
MOTORCYCLE TIRE BUILDING MACHINE WITH TREAD ROLL
DETAILS OF MACHINERIES
FUNCTIONS OF INTELLIGENT CONTROL SYSTEM FOR INTERNAL MIXER:
FUNCTIONS OF TREAD SECTION CONTOUR INSPECTION SYSTEM:
SYSTEM PARAMETERS:
PIN CYLINDER BARREL
COLD FEEDING EXTRUDER
MAIN SPECIFICATIONS:
CONICAL TWIN SCREW EXTRUDING SHEETER
CONICAL TWIN SCREW EXTRUDING SHEETING MILL
INTELLIGENT INTERNAL MIXER
UP-STREAM EQUIPMENTS FEEDING SYSTEM
TYRE TREAD TIRE SIDEWALL
DUPLEX EXTRUDING TRAIN LINE
RUBBER ROLLER CALENDER
RUBBER ROLLER CALENDER XYL250
CORD FABRIC AUTO CUTTING SPLICER
TYRE BEAD EXPANDING
ALL STEEL RADIAL TYRE COATED CORD FABRIC
SUPPLIERS OF PLANT AND EQUIPMENTS (GLOBAL)
SUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
TECHNOLOGY SUPPLIERS FOR TYRE MAKING
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 IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)