Detailed Project Report on motorcycle tyre manufacturing

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)