Detailed Project Report on MOTORCYCLE TYRE MANUFACTURING

 
MOTORCYCLE TYRE MANUFACTURING
 [CODE NO. 2011]

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                                            3333.33 Tyres/day                                
Land & Building (14000 Sq.Mtr)                 Rs.7.55      Cr
Plant & Machinery                                      Rs.100.00  Cr
W.C. for 3 Months                                      Rs. 26.00   Cr
Total Capital Investment                             Rs. 135.00 Cr
Rate of Return                                           20%
Break Even Point                                       68%

INTRODUCTION    
BUREAU OF INDIAN STANDARDS    
LABORATORY TESTING OF TIRE COMPOUND    
COMPONENTS OF TYRES    
DETAILS OF INGREDIENT USED IN TYRE MANUFACTURE    
RAW MATERIALS    
RAW MATERIALS AND COMPONENTS FOR THREE WHEELER TYRES    
RAW MATERIALS TEST FOR THREE WHEELER TYRES    
DETAILS OF COMPONENTS IN TYRE BUILDING    
OVERVIEW OF TYRE INDUSTRY IN INDIA    
MARKET SURVEY    
OVERVIEW OF TYRE INDUSTRY IN SRI LANKA    
GLOBAL MARKET POSITION OF PNEUMATIC TYRES    
TECHNICAL KNOW - HOW    
FOREIGN COLLABORATIONS    
TYRE SIZES FOR THREE WHEELERS    
FORMULATION OF THREE WHEELER TYRE    
MANUFACTURING PROCESS OF THREE WHEELER TYRES    
PROCESS IN DETAILS    
PROCESS FLOW DIAGRAM    
MACHINERY DESCRIPTION AND PROCESS FOR THREE WHEELER TYRES    
WATER CONSUMPTION, WASTE WATER GENERATION AND      CHARACTERIZATION IN TYRE MANUFACTURING    
FORMULATION OF TYRES COMPOUNDS    
RECIPIES FOR AUTOMOBILE BEAD WIRE    
SUPPLIERS OF PLANT AND EQUIPMENTS (GLOBAL)    
SUPPLIERS OF PLANT AND EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS    
TECHNOLOGY SUPPLIERS OF TYRE MAKING    
SPECIFICATION OF TYRE MANUFACTURING MACHINERIES    
DETAILS OF MACHINERY    
                
APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET