Jk tyre plant ppt

About Jk tyre plant, kankroli unit. Works, Process, Inspection, Machinery, Departments

1. JK TYRE & INDUSTRIES, K ANKROLI 1

2. ABOUT JK TYRE JK Tyre & Industries is the flagship company of JK Organization Group. In the last 10 years the sales turnover of the company has increased two-fold and it’s expected to touch Rs . 6550 crore by 2013-14. The company is headed by Dr. Raghupati Singhania , Vice Chairman & Managing Director. In 1977 the company set us a modern Automotive Tyres & Tubes Plant at Jaykaygram , Kankroli in technical collaboration with General Tire Co., USA and another plant in 1991 at Banmore near Gwalior in M.P. In 1997 the company has acquired two plants of Vikrant Tyres Ltd. at Mysore. 2

3. COMPANY VISION J.K . Tyre has installed sophisticated Plant & Machinery and used state of the Art Technology to constantly deliver products of high standard to its customers. It has continuously upgraded Plant & Machinery in order to stay ahead of its competitors and has many technological firsts to its credit viz : 3

4. TYRE: A precisely engineered assembly of rubber, chemicals, fabric and material designed to provide traction, cushions road shock and carry a load under the varying conditions. Geometrically: a tyre is torous Mechanically : it is a flexible membrane pressure container. Structurally : it is a high performance composite. Chemically : it is a material of long chain molecular. 4

5. Basic requirement of tyre : Load carrying capacity Transmit driving/breaking torque. It should provide flotation In addition tyre must process: High durability strength Good appearance Low rolling resistance Heat resistance Riding comfortment Low noise level 5

6. Components of tyre : 6

7. TREAD : That portion of tyre that comes into contact with the road.it is distinguished by the design of grooves and ribs.it provide traction BREAKER : a rubber coated layer of cords that is located between the plies and the tread it helps bonding between tread and ply and protect road shock. CARCASS : Two to at cross plied nylon fabric reinforced rubber sheet structure forming the skeleton of the tyre . PLY : A rubber coated layer fabric usually nylon connecting cods that runs at opposite angle of each other. SIDE WALL : That portion of a tyre between a tread and the bead which flexes in service all the tyre related information is written of this part of tyre rotate the plies from getting damaged from external cut. 7

8. BEAD ASSEMBLY : It consist of three parts- bead wire , filler & flipper. BEAD WIRE – A round hoop of steel wire , wrapped or reinforced by ply cords , that is shaped to fit the rim. FILLER – A solid rubber placed over bead in the absence of filler air entrapped and causes bead separation. FLIPPER – It covers the bead and filler assembly without any air gap , it also provide stiffness and modules gradation to the bead area. CHAFER : Rubber coated nylon cross woven fabric. It protects bead from chafing action of rim. 8

9. BUSINEES UNITS : BUSINEES UNIT-I BUSINESS UNIT-II BUSINESS UNIT-III 9

10. BUSINESS UNIT – I : Raw material of rubber is mixed in a banbury mixer like mixing with polymers , oil , carbon . 10

11. The banbury mixer is an internal, intensive, batch mixer capable of mixing viscous materials in very short time. The following definitions will enhance understanding of this product . BATCH indicates that machines mix a fixed volume of material during each mixing cycle.   There are 4 banburies in the whole plant. Banbury 1: Situated in BU1. It is mostly used for final batch mixing. Banbury 2: Situated in BU1. It is mostly used for master batch mixing. Banbury 3: Situated in BU1. It is mostly used for butyl tube and bladder compound mixing. Banbury 4&5: Situated in plant 3. It is mostly used for master as well as final batch mixing of NR/SR and butyl rubber based compound.   11

12. FUNCTION : Mixing of raw material to form homogenous rubber compound in sheet form. Input material: Rubber, carbon black, oil & chemicals. Output material: Mixed compound in sheet form.   12

13. MAIN PARTS OF THE BANBURRY MIXER:   HOPPER ASSEMBLY Hopper consists of two sub assemblies . Hopper itself, for loading the raw stock and the compounding ingredients MIXER BODY A mixing chamber Rotor: The place where the actual mixing is taking place. Hydraulically operated discharge door: it forms the bottom of the chamber and allows batch discharging.   Dust stops: There are four dust stops on each mixer Their function is to prevent material leaking out of the mixing chamber around the rotor shafts. Proper lubrication is necessary for satisfactory operation of dust stops. 13

14. Process: The polymer and master or remill compounds are Weighed on weighing conveyor for correct weighment and transferred to charging conveyor to charge into the mixer through hopper to maintain continuity in operation . The carbon blacks are stored in large silos. From the silos, they are they are transported in to daybins of blowing air. From daybins , carbon black is directly fed to the banbury by electronic weighing system. which is specified by the operator . PRE MASTER OR MASTER REMILL FINAL 14

15. Now further sidewalls and fillers are made from the mixed rubber in an extruder machine and also treads which is made in an MP-Extruder machine. Also nylon is inserted in between two rubber plies in 4-calendaring machine , called as three ply rubber. 15

16. BUSINESS UNIT-II: In this unit breaker , chafer , flipper are made in bias cutter machine. Also beads are made in bead winding machine. Now tyre building is done by overlapping the layer of 3-ply rubber, flipper, chafer, breaker one by one over a rotating collapsible drum. Now bead is attached from the either sides of drum. Further side wall and tread is again layered over the curved surface of the collapsible drum. By this tyre building process green tyre is obtained. 16

17. BEAD WINDING MACHINE TYRE BUILDING MACHINE GREEN TYRE 17

18. BUSINESS UNIT-III : JAMMING : Jamming is done at the tread splice area because there is a chance for spliced area of the tread to get separated either during curing or during service conditions. Jamming is done to prevent the separation. Jamming is a mechanical operation where a pressure is applied using knurled rolls rotating at constant speed. The applied pressure is 3-5 kg/cm 2 for truck tyres and 1-3 kg/ cm 2 for light truck and passenger tyres .   AWLING: Awling is the complete penetration of an awl through the carcass and inner liner Awling is designed to remove the air built in to the carcass that is not eliminated during stitching and building operation. Awling is done manually as well as by awling needle of the hardened steel on the awling machine. 18

19. PAINTING: Inner painting is mica and naphtha based paint. This prevents bladder sticking to the inner liner and ensures easy removal of bladder from tyre Outer painting is NR based paint along with lampblack with naphtha as solvent. It is applied on the side wall area alone. This ensures good flow of the compound. 19

20. CURING: Curing is a process where in a green tyre is molded in to a proper size, shape and vulcanized . This is done in a curing press under high temperature and pressure . TYPES OF TYRE CURING PRESSES: Bag-o- matic presses: These are most modern and are widely used. Bladder is open-ended cylindrical shaped. Tyre is ejected from bladder by applying vacuum. NRM presses: Bladder is pot shaped with its upper end closed. Bladder is sunk in bag well by ram and lifts the tyre from mould . 20

21. Bladder: Bladder is butyl rubber product, which is used for tyre curing. The requirements of a bladder are- Good air impermeability High steam, hot water resistance High heat resistance High flex resistance CURING PRESS(Before curing) CURING PRESS(After curing ) 21

22. post cure inflation (PCI ): Vacuum is applied at the end of the cycle to ensure that the pressure inside the bladder is drained so that the press does not open under pressure. Nylon tyre as soon as removed from the press, post cure inflation is done . Trimming: After receiving tyres from curing , it will go for trimming on vertical trimming machine. Venttrimming is done by nine-channel knife whereas the bead flash trimming is done by using a hexa blade knife. Post Cue inflation (PCI) Trimming 22

23. INSPECTION: The tyres after trimming are passed to inspection section where the visual abnormalities such as blisters, cracks, etc and if any are marked with a marking crayon and send to tyre rework area. OK tyre is accepted which is not having any abnormalities, the inspector would mark with yellow stamp near serial number and will send to ware house for lot re-inspection. R&D Department: A small piece of the rubber produced is checked by grinding such as checking of the distance between the threads in ply and cracks. Further point load is applied over the whole tyre so as to check the load bearing capacity of the tyre . 23

24. SERVICE SUPPORT UNITS To take care of the centralized activities service support units have been formed. There are 5 service support units taking care of the specialized activities.   SERVICE SUPPORT UNIT 1(SSU1) ENGEENERING SERVICES   SERVICE SUPPORT UNIT 2(SSU 2) COMMERCIAL SERVICES   SERVICE SUPPORT UNIT 3(SSU 3) PEOPLE SERVICES   SERVICE SUPPORT UNIT 4(SSU 4) KNOWLEDGE SERVICES   SERVICE SUPPORT UNIT 5(SSU 5) FACTORY MANAGEMENT 24

25. ANY QUERY…??? 25

26. 26 Thank you