Solid Rubber Tyre Manufacturing (Capacity: 106 Tyres/Day)

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