Detailed Project Report on motorcycle tyre manufacturing
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MOTORCYCLE TYRE MANUFACTURING
[CODE NO.3801]
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.
COST ESTIMATION
Plant Capacity 667 Tyre/Day
Land & Building (1.50 Acre) Rs. 4 Cr
Plant & Machinery Rs. 20.35 Cr
Working Capital for 2 Months Rs. 2.94 Cr
Total Capital Investment Rs. 27.70 Cr
Rate of Return 22%
Break Even Point 63%
- 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
- GLOBAL MARKET POSITION OF TYRE INDUSTRY
- ASIA-PACIFIC LEADS THE AUTOMOTIVE TIRE MARKET
- TOP IMPACTING FACTORS
- INCREASE IN AUTOMOTIVE SALES ACROSS DIFFERENT SEGMENTS
- RISE IN COMPETITION AMONG THE TIRE MANUFACTURERS
- INTRODUCTION OF ADVANCED TECHNOLOGY IN THE MANUFACTURING PROCESS
- INCREASE IN THE OPERATING LIFE OF AUTOMOBILES
- GROWING MARKET OF RETREADING TIRES
- FLUCTUATING COSTS OF RAW MATERIAL
- GLOBAL MARKET SCENARIO OF MOTORCYCLE TYRE
- WORLD DEMAND TO RISE 4.1% ANNUALLY THROUGH
- MOTORCYCLE/OTHER TIRES TO OUTPACE MOTOR VEHICLE TIRES
- DOMINANT ASIA/PACIFIC MARKET TO ALSO LEAD GAINS
- GLOBAL DEMAND FOR CAR AND LIGHT COMMERCIAL VEHICLE TIRES FROM 2012 TO 2018 (IN MILLION UNITS)
- 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:-
- 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
- STEPS IN MOTOR CYCLE TYRE MANUFACTURING
- RAW MATERIAL MIXING
- EXTRUSION
- ASSEMBLY
- CURING
- QUALITY CHECK UP
- MOTORCYCLE TYRES PRODUCTION PROCESS & MIRS TECHNOLOGY
- MAIN SECTION
- TYRE SIZE DESIGNATION AND DIMENSION OF MOTOR CYCLE TYRE
- TABLE: MOTORCYCLE TYRES SIZE RIM DIAMETER CODES 12
- 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
- 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
- TEST SEQUENCE
- TABLE: RECOMMENDED INFLATION PRESSURE FOR TESTING LOAD/SPEED PERFORMANCE
- METHOD FOR DETERMINING THE DYNAMIC GROWTH OF TYRES
- DESCRIPTION OF TEST PROCEDURE
- CONTOUR-OUTLINE DEVICE
- EXECUTION OF TEST
- TABLE INFLATION PRESSURE FOR DIAGONAL OR BIAS PLY AND BELTED-BIAS TYRES)
- ASSESSMENT OF RESUTS
- TYRE STRENGTH TEST (PLUNGER TEST)
- APPARATUS
- PREPARATION OF TYRE FOR THE TEST
- TEST PROCEDURE
- CALCULATION
- REQUIREMENTS
- TABLE: REQUIREMENTS FOR PLUNGER TEST FOR DIAGONAL PLY TYRES
- TABLE: REQUIREMENTS FOR PLUNGER TEST 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 TYRE
- 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
- MOTORCYCLE TIRE BUILDING MACHINE
- MOTORCYCLE TIRE BUILDING MACHINE WITH TREAD ROLLS
- SYSTEM PARAMETERS:
- COLD FEEDING EXTRUDER
- MAIN SPECIFICATIONS:
- DUPLEX EXTRUDERS
- TRIPLEX EXTRUDERS
- TYRE BEAD RING WRAPPING MACHINE
- SUPPLIERS OF PLANT AND EQUIPMENTS (GLOBAL)
- SUPPLIERS OF PLANT AND EQUIPMENTS (INDIAN)
- 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)
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