Detailed Project Report on radial tyre manufacturing unit

RADIAL TYRE MANUFACTURING UNIT
[CODE NO. 2059]


Tyres and tubes, the strategic rubber products and basic supplements to the automotive vehicles are of most importance  to the  country's  economy. The tyre industry  sector  is  providing direct  empolyment to over 40,000 people and indirect empolyment to lakhs of people. This industry sector is now being  considered as a core industry sector.

The manufacturing of automobile tyres  as  an  essential ancillary for  the development of automobile sector  came into being in India during 1930's when the Dunlop India Ltd, the first tyre manufacturing transnational company  started   its operation in 1935 at Sahaganj in West Bengal.

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.

Most steel belted radial passenger and light truck tires are composed of an inner liner, two polyester reinforced body plies, two steel beads, two bead reinforcing strips, two anti-chafing strips, two steel belts, with belt edge wedges or wrap around gum strips, the sidewalls, and the tread. Many tires also include one or two layers of nylon or polyester constricting belts or strips over the steel belts (safety belts or cap plies).

The most common failure mode of steel belted radial passenger and light truck tires is separation between the steel belt components. This area is subject to the highest amount of stress during normal use and is also the area of weakest potential adhesion because of the difficulty of bonding rubber to metal and the mechanical stress at the belt edges. The adhesion can be adversely affected by various manufacturing practices including, but not limited to, under-curing, contamination, and improper storage and handling of tire components. For example, if any moisture is allowed to accumulate on steel belt wire or between the steel belts, degradation of the steel wire components or pockets of separation may occur. Similarly, small pockets of air between the steel belts may result in a breakdown of adhesion. Less common, but sometimes present, are foreign materials cured within the tire such as small pieces of metal, wood, or other contaminants. Contamination found in cured tires has varied widely, including perspiration, chicken bones, a live shotgun shell, a wrench, a glove, timecards, screws, etc.

COST ESTIMATION (ALL FIGURE IN LACS)

Plant Capacity                                               10000.00 Tyres/day       
Land & Building (10 Acres)                          Rs. 1.980  
Plant & Machinery                                          Rs.17,000
W.C. for 3 Months                                          Rs. 14.392
Total Capital Investment                              Rs. 33.712
Rate of Return                                               27%
Break Even Point                                          60%


INTRODUCTION    
BUREAU OF INDIAN STANDARDS    
LABORATORY TESTING OF TIRE COMPOUND    
COMPONENTS OF TYRES    
PROPERTIES AND CHARACTERISTICS OF RADIAL TYRES    
RAW MATERIALS    
DETAILS OF COMPONENTS IN TYRE BUILDING    
MARKET SURVEY    
OVERVIEW OF TYRE INDUSTRY IN SRI LANKA    
PRESENT MANUFACTURERS/EXPORTERS OF RADIAL TYRE    
TECHNICAL KNOW - HOW    
FOREIGN COLLABORATIONS    
MANUFACTURING PROCESS OF RADIAL TYRES    
PROCESS FLOW DIAGRAM OF RADIAL TYRE    
PROCESS IN DETAILS    
DIFFERENT OPERATION IN RADIAL TYRE MANUFACTURING    
PASSENGER CAR TYRE FORMULATION (RADIALS)    
TRUCK TYRE FORMULATION (STEEL RADIAL)    
FORMULATION OF TYRES COMPOUNDS    
RECIEPES FOR AUTOMOBILE BEAD WIRE    
POST MANUFACTURING METHOD FOR RADIAL TYRES    
SUPPLIERS OF PLANT AND EQUIPMENTS (GLOBAL)    
SUPPLIERS OF PLANT AND EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    82
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
DETAILS OF MACHINERY    
COMPOSITION OF PASSENGER TYRE      
RAW MATERIALS CALCULATION     


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